Multi-scale hybrid fabrication of digitally designed non-woven prototypes
A multi-scale hybrid fabrication approach that decouples non-woven structures into independently controlled scales using 3D printing for macro-scale molds and fiber slurry coating for micro-scale control. This method enables rapid prototype development with improved mechanical properties and fluid handling.
Overview
The multi-scale hybrid fabrication method offers an innovative solution to the limitations of current non-woven structure production. By decoupling the structure into macro and micro scales, this approach allows for precise control over the pore topology and fiber architecture. Using 3D-printed molds, the process defines void architecture while maintaining stochastic fiber arrangements. This technique leverages available commercial fibers and 3D printing technology to produce functional prototypes efficiently.
Technical specifications
Key features:
- Macro-scale control: 3D-printed molds define the architecture of voids, enabling precise fluid pathways and mechanical gradients.
- Micro-scale fiber control: Slurry-coated fibers, bonded via resin infusion or thermal bonding, maintain randomness while adhering to the mold.
- Validation methods: Micro-CT scans and mechanical testing ensure the integrity of pore volume, while electrochemical impedance spectroscopy (EIS) provides rapid transport characterization.
- Scalable production: The process scales from small samples to larger sheets, with a manufacturing roadmap for roll-to-roll deposition and continuous bonding.
Technology readiness level
The technology is at TRL 4, indicating that it has been validated in a lab environment. The next phases will focus on scaling and further validating its mechanical properties, fluid handling capabilities, and production processes.
About Washington University in St. Louis
Washington University in St. Louis is a private research university with a large graduate and professional footprint and a major clinical enterprise. Its medical campus is integrated with a leading hospital system, enabling joint clinical research, secure data access, and large-scale trial recruitment. An adjacent innovation district and partner incubators provide flexible lab space, prototyping resources, and corporate co-location, while shared core facilities welcome external users under service agreements. Research is supported by NIH, NSF, DOE, and other competitive federal funding alongside industry sponsorship. A dedicated technology transfer office manages IP, licensing, startup formation, and streamlined sponsored research and clinical trial agreements.
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