Low-cost elastomer nanocomposite ink for 3D microprinting of porous fibrous structures
Solvent-free elastomer nanocomposite ink made by in situ exfoliation of 2D nanomaterials for extrusion-based 3D printing of porous membranes and scaffolds at micrometer resolution. Enables flexible desalination membranes, heat-spreading meshes, and other functional structures with enhanced mechanical, thermal, and electrical performance at low cost and reduced environmental impact.
Overview
This technology provides a low-cost, solvent-free elastomer nanocomposite ink designed for extrusion-based 3D microprinting of porous fibrous structures. By exfoliating two-dimensional nanomaterials such as graphene and hexagonal boron nitride directly within a silicone elastomer matrix, the process produces a printable ink capable of fabricating flexible porous membranes and scaffolds with micrometer-sized pores. The in situ shear exfoliation approach uses bulk starting materials, eliminating the need for expensive pre-processed nanofillers or additives and reducing both cost and environmental impact. Mild plasma treatment can be applied post-printing to tune wettability, enabling hydrophilic behavior where needed.
Technical specifications
Key features:
- In situ shear exfoliation of 2D nanomaterials (graphene, hexagonal boron nitride) directly within elastomer to form nanocomposite ink
- Solvent-free, low-cost process using bulk precursors such as graphite
- Nanofiller loadings of 15–40% with less than 1% impurity incorporation and strong filler-matrix bonding verified spectroscopically
- Nanofiller size reduced below 25 microns using a customized batch mixer with repetitive shear and elongation forces
- Refinement via three-roll mill and planetary mixer to remove bubbles and achieve suitable rheological properties
- Customized printhead with stainless steel nozzles of 50 microns or smaller, compatible with Hyrel EHR printers
- Achieves non-woven layers (1.5 cm x 1.5 cm x 0.5 cm) with 5 micron resolution and pore volume deviation of 5% or less
- 400–500% increase in strength and fracture toughness, 800% enhancement in thermal conductivity, and substantial gains in electrical conductivity
- Applicable to flexible desalination membranes, heat-spreading meshes, and other porous functional structures
Technology readiness level
The underlying nanocomposite approach has been validated in published work demonstrating mechanical, thermal, and electrical performance gains, and the technology is protected by a granted patent. Planned next-stage validation includes preparing and rheologically characterizing the nanocomposite ink, printing test structures using a customized micro-nozzle printhead, and evaluating microscopic, spectroscopic, mechanical, thermal, wettability, and optical properties of printed samples. The work targets micrometer-scale resolution printing of porous fibrous analogs suitable for membrane, thermal management, and scaffold applications.
About University of South Florida
A comprehensive public research university with multiple campuses across the Tampa Bay region, USF combines scale with an applied, partnership‑driven culture. A research and technology park anchors co‑located corporate R&D, startups, and shared facilities that enable prototyping and testing. USF Health’s connection to a major hospital system and nearby specialty clinics supports clinical studies, device validation, and translational collaborations. Research is supported by competitive federal funding from agencies such as NIH, NSF, and DoD. A dedicated technology transfer office and research foundation manage IP, licensing, industry agreements, and venture creation, with incubator and accelerator resources in the park.
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