Among the several flexible thermoelectric modules in existence, sintered Bi-Te-based modules represent a viable option because of their high output power density and flexibility, which enables the use of arbitrary heat sources. We have fabricated Bi-Te-based modules with a large-scalable fabrication process and improved their output performance. The reduction in the interconnection resistance, using thick electrodes of the flexible printed circuit, significantly improves the module's output power to 87 mW/cm$^{2}$ at $ΔT$ = 70 K, which is 1.3-fold higher than a previous prototype module. Furthermore, the establishment of the fabrication for the top electrodes by using the surface mount technology makes it possible to realize a high-throughput manufacturing of the module. Our durability tests reveal that there is no significant change in the internal resistance of the module during 10000 cycles of mechanical bending test and 1000 cycles of thermal stress test.
A large-area thermoelectric generator (TEG) utilizing a folded thin-film concept is implemented and the performance evaluated for near room temperature applications having modest temperature gradients (< 50 K). The TEGs with the area of ~0.33 m^2 are shown capable of powering a wireless sensor node of multiple sensors suitable e.g. for monitoring environmental variables in buildings. The TEGs are based on a transparent, non-toxic and abundant thermoelectric material, i.e. aluminium-doped zinc oxide (AZO), deposited on flexible substrates. After folding, both the electrical current and heat flu…
This paper reviews the use of relatively new manufacturing method called as additive manufacturing, most often mentioned as 3D printing in fabrication of high performance superalloys. The overview of the article describes the structure, property, processing, performance relationship of the fabrication process and the superalloys. The manufacturing methods such as Electron Beam Melting, Laser Beam Melting and Direct Energy Deposition used to fabricate commercially available alloys are explained. The microstructure / grain structure resulting from directional building, complex thermal cycles is …
The tremendous amount of wasted heat from solar radiation and industry dissipation has motivated the development of thermoelectric concepts that directly convert heat into electricity. The main challenge in practical applications for thermoelectrics is the high cost from both materials and manufacturing. Recently, breakthrough progresses in ionic thermoelectrics open up new possibilities to charge energy storage devices when submitted to a temperature gradient. The charging voltage is internally from the ionic Seebeck effect of the electrolyte between two electrodes. Hence electrolytes with hi…
Constructing precise micro-nano metal patterns on complex three-dimensional (3D) plastic parts allows the fabrication of functional devices for advanced applications. However, this patterning is currently expensive and requires complex processes with long manufacturing lead time. The present work demonstrates a process for the fabrication of micro-nano 3D metal-plastic composite structures with arbitrarily complex shapes. In this approach, a light-cured resin is modified to prepare an active precursor capable of allowing subsequent electroless plating (ELP). A multi-material digital light proc…
Modeling the Thermal Behavior of Photopolymers for In-Space Fabrication
Technion - Israel Institute of Technology（以色列理工学院）；The Rakia Mission（Rakia任务）；Rice University（莱斯大学）；NASA Ames Research Center（美国国家航空航天局艾姆斯研究中心）；ETH Zürich（苏黎世联邦理工学院）
Metamaterials are artificially engineered devices that go beyond the properties of conventional materials in nature. Metamaterials allow the creation of negative refractive indexes, light trapping with epsilon-near-zero compounds, bandgap selection, superconductivity phenomena, non-Hermitian responses and, more generally, to manipulate the propagation of electromagnetic and acoustic waves. In the past, low computational resources and the lack of proper manufacturing techniques have limited the attention to 1-D and 2-D metamaterials. However, the true potential of metamaterials will be ultimate…
Additive manufacturing techniques enable the fabrication of functional microstructures with mechanical and chemical properties tailored to their intended use. One common technique is stereolithography, which has recently been augmented in response to modern demands to support smaller features, larger build areas, and/or faster speeds. However, a limitation is that such systems typically utilize a single-aperture imaging configuration, which restricts their ability to produce microstructures at large volumes due to the tradeoff between the image resolution and image field area. In this paper, w…
Fused silica glass is the preferred material in all applications which require long-term chemical and mechanical stability as well as excellent optical properties. The manufacturing of complex hollow microstructures within transparent fused silica glass is of high interest for, among others, the miniaturization of chemical synthesis towards more versatile, configurable and environmentally friendly flow-through chemistry as well as high-quality optical waveguides or capillaries. However, microstructuring of such complex three-dimensional structures has proven evasive due to the high thermal and…
The foundry development of integrated photonics has revolutionized today's optical interconnect and datacenters. Over the last decade, we have witnessed the rising of silicon nitride (Si$_3$N$_4$) integrated photonics, which is currently transferring from laboratory research to foundry manufacturing. The development and transition are triggered by the ultimate need of low optical loss offered by Si$_3$N$_4$, which is beyond the reach of silicon and III-V semiconductors. Combined with modest Kerr nonlinearity, tight optical confinement and dispersion engineering, Si$_3$N$_4$ has today become th…
Miniature varifocal lenses are crucial for many applications requiring compact optical systems. Here, utilizing electro-mechanically actuated 0.5-mm aperture infrared Alvarez meta-optics, we demonstrate 3.1 mm (200 diopters) focal length tuning with an actuation voltage below 40 V. This constitutes the largest focal length tuning in any low-power electro-mechanically actuated meta-optic, enabled by the high energy density in comb-drive actuators producing large displacements at relatively low voltage. The demonstrated device is produced by a novel nanofabrication process that accommodates meta…
Improving lithium-ion batteries (LIBs) safety remains in a challenging task when compared with the tremendous progress made in their performance in recent years. Embedding thermo-responsive polymer switching materials (TRPS) into LIB cells has been proved to be a promising strategy to provide consistent thermal abuse protections at coin-cell level. However, it is unrealistic to achieve large-scale applications without further demonstration in high-capacity pouch cells. Here, we employed tungsten carbide (WC) as a novel conductive filler, and successfully overcame the intrinsic processing diffi…
Advanced manufacturing (AM) technologies, such as nanoscale additive manufacturing process, enable the fabrication of nanoscale architected materials which has received great attention due to their prominent properties. However, few studies delve into the functional gradient cellular architecture on nanoscale. This work studied the gradient nano-Gyroid architected material made of copper (Cu) by molecular dynamic (MD) simulations. The result reveals that, unlike homogeneous architecture, gradient Gyroid not only shows novel layer-by-layer deformation behavior, but also processes significantly …
Photolithography assisted chemo-mechanical etching (PLACE), a technique specifically developed for fabricating highquality large-scale photonic integrated circuits (PICs) on thin-film lithium niobate (TFLN), has enabled fabrication of a series of building blocks of PICs ranging from high-quality (high-Q) microresonators and low-loss waveguides to electrooptically (EO) tunable lasers and waveguide amplifiers. Aiming at high-throughput manufacturing of the PIC devices and systems, we have developed an ultra-high-speed high-resolution laser lithography fabrication system employing a high repetiti…
Silicon ring resonator-based devices, such as modulators, detectors, filters, and switches, play important roles in integrated photonic circuits for optical communication, high-performance computing, and sensing applications. However, the high sensitivity to fabrication variations has limited their volume manufacturability and commercial adoption. Here, we report a low-cost post-fabrication trimming method to tune the resonance wavelength of a silicon ring resonator and correct for fabrication variations at wafer-scale. We use a Ge implant to create an index trimmable section in the ring reson…
Pixelated Plastic Scintillator Array Manufacturing using Fast-, Photo-Curable Resin
Air Force Institute of Technology（空军理工学院）；Oak Ridge National Laboratory（橡树岭国家实验室）；Defense Threat Reduction Agency Nuclear Science and Engineering Research Center（国防威胁降低局核科学与工程研究中心）
