3D Printing of Aerogels

Aerogels exhibit unique properties such as ultra-low density, high and tunable porosity, large surface area, low thermal conductivity, refractive index, and low dielectric constant, which make them suitable for many applications including energy storage and conversion, catalysis, sensors, and bioengineering. The vision of tailoring the macrostructure of aerogels for broader applications has stimulated the research on the 3D printing of aerogels. Here, Dr. Lin and his collaborators propose a novel printing methodology, namely 3D freeze printing (3DFP), that combines multi-nozzle inkjet/extrusion printing with freeze casting for 3D printing of aerogels with several key qualities, including continuous, boundary-free, controlled alignment of porosity, and truly 3D structures (e.g., 3D objects with overhang features). A high-speed X-ray imaging technique has been applied to reveal the process dynamics in the 3DFP process. To date, the 3D printed aerogels have been successfully applied for Radomes for hypersonic vehicles, high-temperature ceramics, acoustic absorption, bone repair, energy storage, thermal insulation, chemical sensor, and chemical absorption.