Efforts to reduce the energy consumption, CO2 emissions, and production costs associated with lithium-ion battery manufacturing have prompted researchers to find alternatives to energy-intensive conventional oven drying. Towards this goal, we developed a method based on flashlight drying as a rapid, efficient approach, and succeeded in reducing the drying time and energy consumption to produce graphite composite anodes by 90

Dry electrode fabrication offers significant advantages over conventional slurry-based methods by eliminating solvent usage and significantly reducing energy consumption during manufacturing. However, the fibrillation of polytetrafluoroethylene (PTFE), commonly used as a binder in dry processing, often leads to particle agglomeration. This results in poor thickness control, compromised adhesion, and limited scalability. We present a sieve-assisted deposition strategy to suppress particle agglomeration during the fabrication of LiNi0.Co-6(0).Mn-2(0).O-2(2) (NCM622) dry electrodes. This simple yet effective method enabled the formation of electrodes with uniform thickness in the range of 70 similar to 80 mu m, which is critical for achieving high-energy and high-power densities. We further investigated the influence of thermal compression conditions on; interfacial adhesion and electrochemical performance. Applying a compaction load of 200 kg at temperature above 150 degrees C significantly enhanced adhesion between the PTFE binder and the aluminum current collector, surpassing the internal cohesion of the electrode layer. This led to improved structural stability, reduced internal resistance, and enhanced capacity retention at high C-rates. Our finding provide practical insights into the fabrication of solvent-free dry electrodes, offering clear process guideline for mitigating agglomeration, controlling electrode thickness, and optimizing interfacial bonding. This work contributes to the advancement of environmentally sustainable and high-performance lithium-ion battery manufacturing.

Carbon-based nanomaterials have received attention owing to their exceptional properties, including high electrical conductivity, chemical stability, and large surface area, rendering them ideal for multifarious energy and electrochemical applications. However, their production typically requires high-temperature and timeconsuming processes under controlled atmospheres, hindering their large-scale commercialization. This study proposes a facile and efficient method to rapidly (in milliseconds) and stably produce mechanically robust, porous graphitic carbon sheets with large surface areas from polyimide (PI) films by combining flashlight irradiation with a micro-perforation strategy. Conventional laser-based carbonization strategies rely on localized scanning, whereas the flashlight approach enables efficient large-area processing. To address limitations related to unstable carbonization, micro-perforations were introduced into the PI films using micro-needles to ensure uniform heat distribution, facilitate gas release, and alleviate drastic volume changes. This strategy effectively prevented delamination, wrinkling, and cracking, enabling stable carbonization with a high yield. The graphitic carbon sheets derived from the micro-perforated PI films exhibited superior electrical conductivity, mechanical robustness, and structural uniformity compared to those obtained from the non-perforated PI films. For practical validation, the carbonized sheets were employed as electrodes in supercapacitors. The perforated-PI-derived electrodes exhibited superior performance, delivering an areal capacitance, energy density, and power density of 96.1 mF cm- 2, 10.8 mu Wh cm- 2, and 157.3 mu W cm- 2, respectively. These values surpassed those of their nonperforated counterparts and conventional laser-carbonized electrodes. This study demonstrates a promising pathway for the scalable production of high-quality graphitic carbon sheets to meet the demands of nextgeneration electrochemical energy storage applications.

Solvent-free dry-electrode processing has emerged as a promising method for electrode fabrication as it eliminates solvent handling and suppresses binder redistribution during drying, enabling high-loading electrode fabrication with reduced energy demand and carbon footprint. However, dry-processed thick electrodes typically suffer from limited electrolyte infiltration and sluggish through-thickness ion transport, which severely compromise rate capability and cycling stability. In this study, we fabricate high-loading electrodes via a solvent-free dry process and introduce a microneedle-assisted perforation strategy to overcome these transport limitations. A custom-engineered microneedle tool enables the non-destructive formation of vertically aligned microchannels with precisely controllable depths and pore densities, without inducing active-material ablation or thermal damage. By systematically tuning the contact conditions between the microneedle master and the electrode surface, we elucidate the deformation mechanisms governing perforation and achieve burr-free, well-defined channels with flat surface profiles. The resulting microchannels significantly reduce electrode tortuosity and promote rapid electrolyte infiltration, leading to markedly improved rate performance and long-term cycling stability compared with non-perforated dry thick electrodes. Furthermore, replication of the microneedle array onto a flexible sheet and its integration onto a cylindrical roll demonstrate compatibility with roll-to-roll processing, highlighting the scalability of this approach. Overall, this microneedle-assisted structural engineering strategy provides a scalable and production-ready pathway toward high-energy-density lithium-ion batteries.

Ceramic components are widely used in biomedical, electronic, aerospace, and energy applications owing to their excellent mechanical, thermal, and chemical stability. Although digital light processing (DLP) enables the fabrication of complex ceramic geometries with high precision, conventional furnace sintering remains a major bottleneck due to long thermal cycles and high energy consumption. In this study, ultrafast high-temperature sintering (UHS) of alumina-silica ceramic specimens 3D-printed by digital light processing (DLP) was demonstrated. A UHS system utilizing Joule heating by carbon felt was fabricated in-house, and it was confirmed that heating rates of 104-105 degrees C/min can be achieved, allowing the temperature to exceed 1600 degrees C within just a few seconds. Observation of the thermal behavior of 3D-printed alumina-silica specimens showed that major binder decomposition occurred between 350 degrees C and 450 degrees C, with complete removal achieved at 650 degrees C. Accordingly, a three-step thermal treatment sequence was established, consisting of a two-step preheating at 450 degrees C and 650 degrees C-with the holding time at 650 degrees C varying from 30 to 270 s-followed by a final sintering at 1100 degrees C. The sintering behavior under this sequence was comparatively analyzed. The optimal profile under the tested conditions achieved complete debinding and sintering of the 3D-printed ceramic samples within minutes, while delivering microstructural quality comparable to that heat-treated for 30 h in a conventional furnace and showing no signs of carbon contamination. X-ray diffraction and Fourier transform infrared spectroscopy confirmed phase and chemical stability equivalent to conventional sintering, and mechanical tests showed comparable strength. The successful fabrication of a dental ceramic restoration using the UHS technique ultimately proved its industrial applicability as a quick and energy-efficient sintering process for the production of next-generation ceramic components.

The interest in microneedles is currently increasing due to their user-friendliness. However, the resource-intensive nature of conventional fabrication methodologies, such as photolithography and layer-by-layer 3D printing, restrain their application in high-dose drug delivery systems. This paper presents a novel one-step fabrication method for high-aspect-ratio microneedle arrays. The methodology integrates self-focusing photo polymerisation with digital light processing. In this approach, changes in the refractive index before and after photo polymerisation was leveraged to enable the single-exposure fabrication of microneedles with sharp tips and controllable geometries. Grayscale image projection was used to enable localised control over structural height and spacing, facilitating capillary-driven aggregation of microneedles and the formation of microcavities capable of accommodating high drug loads. Mechanical testing and in vitro experiments conducted using porcine skin confirmed both the penetration strength and the delivery of vitamin B12 without structural damage. Furthermore, internal light-guiding properties embedded in the microneedles enable localised optical delivery for potential phototherapeutic applications. Thus, the proposed technique allows rapid, maskless manufacturing with flexible customisation of microneedle designs tailored to specific drug doses or skin conditions. This fabrication strategy holds promise for applications in transdermal drug delivery, personalised therapy, and dermatological light treatment.

The primary challenge in creating controllable liquid-based materials lies in managing the structural complexities and multiscale interfaces that govern solid, liquid, and gas phase interactions. Current fabrication methods for liquid-infused surfaces lack topological flexibility, limiting them to planar and simple-patterned structures. Conversely, digitally fabricating slippery architectural materials marks a significant shift towards scalable microprinting of complex, topologically slippery designs. This paper introduces a method for digitally fabricating slippery objects with solid-liquid composite interfaces and geometric design freedom. The slippery architecture has been demonstrated through digital printing of photopolymerization-induced multiphase materials and photoinduced grafting, enabling precise control over structural topologies and slippery properties of infused liquids. This versatile platform facilitates the fabrication of structures at multiple scales, enhancing liquid manipulation, droplet evaporation, and biomedical microfluidic chip design. These methods advance beyond conventional techniques, showcasing the potential of architected slippery surfaces with controlled structural scales.

Three-dimensional (3D) porous hosts decorated with uniformly distributed lithiophilic nanoseeds are an effective route to fabricate highly stable Li metal anodes, yet most nanoseeding methods require high temperatures or complex chemistries that impede manufacturing scalability. Here, we report a facile, industry-compatible strategy that generates conformal Ag nanoseeds (approximate to 20-50 nm) on electrospun carbon nanofiber (CNF) scaffolds by thermally decomposing a commercial organo-silver ink at only 150-180 degrees C. This low-temperature treatment preserves the CNF architecture while providing an ultrahigh density of metallic Ag0 nuclei that lower the Li nucleation barrier. Relative to bare CNF, the Ag-decorated host (CNF@Ag) reduces the initial nucleation overpotential from 22 mV to 7 mV (approximate to 66 % decrease) and doubles the exchange current density (0.58 -> 1.2 mA cm-2). Consequently, CNF@Ag exhibits significantly higher long-term stability than the bare CNF, as confirmed by galvanostatic cycling in both symmetric and half-cell configurations. In practical full-cell tests, CNF@Ag anodes deliver over 300 stable cycles at 0.5 C and exhibit substantially lower polarization up to 10 C when coupled with LiFePO4 cathodes. Spectroscopic (XPS, Raman) and microscopic (SEM/TEM) analyses confirm that the process is chemically benign, yields uniformly anchored seeds without damaging the carbon framework, and effectively stabilizes the Li plating/stripping morphology. This organo-metallic ink-based approach thus offers a generalizable, low-temperature pathway to integrate lithiophilic nanoseeds into 3D electrodes, advancing the development of high-energy, fast-charging lithium-metal batteries.

Recently, the development of environmentally friendly etch‐free micro‐printed circuit boards with fine‐line traces has garnered significant attention. A novel photonic‐assisted fabrication method is introduced that utilizes ultraviolet (UV) light and intense pulsed light (IPL) to produce highly conductive silver films on flexible substrates. Although silver organometallics can be reduced by the heating effect from localized surface plasmons (LSPs), this process alone is inefficient. Introducing zinc oxide nanoparticles (ZnO NPs) under UV illumination leverages their photocatalytic activity to accelerate Ag+ reduction, enabling faster film formation than silver‐only samples However, the resulting films initially exhibit relatively high resistivity (377.77 µΩ cm) due to insufficient light intensity. To address this, IPL is utilized to facilitate the reduction and sintering process. Optimizing IPL power and ZnO NP thermal uniformity produced ZnO/Ag films with low resistivity (6.3 µΩ cm) and fine lines (37.46 µm) in seconds, while suppressing defects typical of Ag‐only films. The resulting films demonstrate excellent mechanical and oxidative stability. Its conductivity arises from the synergistic interaction between the plasmonic resonance of silver and the photocatalytic activity of ZnO NPs, with the former also amplifying the latter. This tunable, energy‐efficient, and environmentally friendly method is promising for photonic‐integrated flexible systems and organic light‐emitting diodes.

Surface texturing is carried out to realize a robust liquid-repellent surface, that is, a surface with a high contact angle for various liquids. Surfaces with an array of micropillars, microcavities, or a hierarchical structure composed of micropillars and microcavities were fabricated, and their wetting behaviors were evaluated. The microstructural arrays were fabricated on a flexible polymer substrate using ultraviolet nanoimprint lithography and contact angles of liquids with different surface tensions were measured and compared. Furthermore, the long-term liquid repellency of the developed surfaces was evaluated by measuring static and dynamic contact angles. The results revealed that the microcavity structure is suitable for preventing the wetting of the surface with low-surface-tension liquids, such as hexane and silicone oil. Unlike the pillar array, the microcavity structure prevented the wetting of the surface with such liquids.

This research addresses challenges with silver nanowires (Ag NWs) as transparent conductive electrodes (TCEs) and heaters in commercial devices. Here, zinc oxide nanoparticles (ZnO NPs) are first reported as a protective layer for Ag NWs. Multi-physics simulations confirm enhanced thermal stability due to improved heat dissipation, temperature distribution, and thermal conductivity from ZnO. When Ag NWs are surrounded by air, heat transfers mainly through convection and radiation because of air's low conduction coefficient. Encasing Ag NWs in ZnO enhances heat transfer to the ZnO surface, accelerating cooling and dissipating more heat into the atmosphere via convection. The results show composite's efficiency in the Joule effect, maintaining a consistent temperature of 78 °C for 700 s after 500 bending cycles, a significant improvement over Ag NWs operating for only 5 s at 80 °C. Additionally, the composite film exhibited exceptional performance, including a sheet resistance of 9.8 Ω sq-1 and an optical transmittance of 96.96 %, outperforming Ag NWs, which have a sheet resistance of 12 Ω sq-1 and a transmittance of 94.11%. The combination of enhanced electrical, thermal, and mechanical stability, along with impressive optical properties, makes Ag NWs/ZnO NPs a promising candidate for transparent conductive electrode materials in various applications.

Three-dimensional porous nanoarchitectures on current collectors are effective for stabilizing Li metal anodes. However, developing these nanostructures in a simple and cost-effective manner is challenging. To address this, we propose a flashlight-based ultrafast and scalable method for manipulating nanoarchitectures on Cu foil. Cu(OH)(2) nanorods directly grown on Cu foil that are exposed to a flashlight can be photothermally activated to undergo ultrafast phase conversion to a mixed phase of Cu and CuxO while minimizing their structural collapse. The transformed hybrid nanorods have a sufficient pore volume, a large lithiophilic surface, and efficient electrical conduction to stabilize the lithium anode, thereby improving the long-term cycling stability and rate performance of the Li metal battery. Notably, capacity retention is observed to be similar to 96% after 200 cycles at 0.5 C and similar to 70% of its maximum capacity under a high-rate condition (5 C). Our simple approach enables ultrafast, large-area fabrication of nanoarchitectures that can stabilize the Li metal anode. We believe that further development in conjunction with a roll-to-roll process will accelerate the commercialization of Li metal batteries.

The utilization of thick electrodes represents a promising strategy for high energy density batteries, but practical application is hindered by the observed challenges of low cyclic stability and rate performance. To address these issues, we employed electrochemical impedance spectroscopy (EIS) as a non-destructive method to establish a diagnostic model capable of identifying the causes of the instability of thick electrodes. While EIS models for thick electrodes have previously been discussed, the connection between these models and the degradation mechanism has yet to be fully understood. Our investigation revealed that resistances of the current collector, solid electrolyte interphase, or electrolyte, increase with the increment of electrode thickness and further increases following the cycling test with a similar degree, indicating that the degradation of thick electrodes is not governed by those resistances. Rather, a new resistance component emerged in the thick electrode after the cycling test, indicating the emerged resistance plays as the predominant factor driving degradation. The new resistance component on the impedance spectra is linked to Li dendrite formation, due to impeded Li-ion transfer. The hindered Li-ion movement is probably due to the migration of low-weight molecules in the drying process and/or the extended distance Li-ions must transverse

Herein, a straightforward route for fabricating highly loaded graphite composite anodes with enhanced electrochemical performance via ultrafast, scalable flashlight irradiation is presented. When a flashlight irradiates the surface of a thick graphite anode, instantaneous and non-equilibrium photo-thermochemical interactions occur between the flashlight and the constituent materials of the anode. As a result, a porous structure (through which the electrolyte easily penetrates), a large reaction site, improved conductivity, as well as phase transformation of active graphite material can be developed on the anode surface, which can facilitate ion and electron transport at the interface with the electrolyte. By fabricating a half-cell using this flash-activated, highly loaded graphite anode, it is found that the electrochemical performance, such as increases in the charge density, rate capability, and stability can be improved. Finally, the roll-to-roll (R2R) compatibility of the high-performance thick-film electrode fabrication process consisting of coating-drying-flashlight surface activation (FLSA) is successfully demonstrated using a self-built R2R system integrated with a flashlight irradiation module.

A slippery interface, based on the synergistic relationship between structural topologies and functional liquids found in living organisms, exhibits controlled interactions with viscous fluids and solid materials owing to its low adhesion properties. However, creating a porous surface to be infilled with lubricants or using gelation methods typically requires long process times, and scaling up to large areas presents significant challenges. In this study, we developed a simple fabrication method, composed of two main steps, for creating a slippery interface. First, an organogel was fabricated by exposing a mixture of a photocurable polydimethylsiloxane resin and lubricant to ultraviolet (UV) light, following a roll-to-plate process. Subsequently, the organogel surface was coated with a lubricant and subjected to a UV-grafting process to enhance its slippery properties. The low sliding angles of the resulting slippery organogel for various viscous fluids and its performance in antifouling and anti-icing tests indicated its low adhesion to liquids, solids, and biological deposits. This approach is simpler than conventional methods and is suitable for scaling up of slippery organogels that can be used to develop large-area slippery surfaces using photo-induced processes.

AbstractThe sustained water repellency of interconnected micropatterned surfaces is explored over an extended duration, with a focus on their resilience during a 90‐day water‐immersion test. Initially, the microstructure surfaces exhibit high water repellency, a characteristic of the Cassie–Baxter state. However, subsequent detailed temporal analyses reveal varying responses depending on the structural topology. The interconnected micropatterned surfaces exhibit remarkable long‐term resistance to water; this is attributed to the formation of large and stable air pockets enabled by their unique microcavity structures. In comparison, hierarchical microcavity surfaces with micropillars exhibit a notable decrease in water repellency, as evidenced by reduced contact angles, suggesting a transition to a wetting state owing to the emergence of surface hydrophilicity during long‐term water exposure. This study demonstrates the importance of stable air‐pocket effects, particularly in applications where the long‐term stability of liquid repellency is critical, and suggests the role of interconnected structures in maintaining water repellency over time.

Owing to their unique structural robustness, interconnected reentrant structures offer multifunctionality for various applications. a scalable multistep roll-to-roll printing method is proposed for fabricating reentrant microcavity surfaces, coined as wetting-induced interconnected reentrant geometry (WING) process. The key to the proposed WING process is a highly reproducible reentrant structure formation controlled by the capillary action during contact between prefabricated microcavity structure and spray-coated ultraviolet-curable resins. It demonstrates the superior liquid repellency of the WING structures, which maintain large contact angles even with low-surface-tension liquids, and their robust capability to retain solid particles and liquids under external forces. In addition, the scalable and continuous fabrication approach addresses the limitations of existing methods, providing a cost-effective and high-throughput solution for creating multifunctional reentrant surfaces for anti-icing, biofouling prevention, and particle capture.