Additive Manufacturing of Functional Emulsions

THE CHALLENGE

The core challenge in advancing additive manufacturing for soft composite materials lies in the inability to precisely control the internal microstructure during production—a critical factor that directly impacts a material’s thermal, electrical, and mechanical performance. This limits the scalability and reliability of manufacturing next-generation products like flexible electronics, wearable devices, and advanced thermal management systems. Current technologies often rely on rigid fillers and lack the fine-tuned control over droplet shape, orientation, and distribution needed for consistent performance. This leads to unpredictable outcomes, wasted materials, and increased production costs. Furthermore, the absence of integrated, real-time control systems for shaping and stabilizing liquid inclusions means manufacturers cannot fully customize materials to meet specific functional needs. Solving this challenge opens the door to new markets by enabling mass production of multifunctional, high-performance composites tailored for dynamic and high-demand applications.

OUR SOLUTION

Our solution offers a breakthrough additive manufacturing technique that enables real-time control over the internal structure of soft composite materials by precisely manipulating liquid metal droplets during the printing process. Using a specially formulated emulsion ink and direct ink writing, we control key parameters like nozzle speed, height, and diameter to stretch spherical droplets into elongated shapes with tunable aspect ratios. These microstructural changes, stabilized by a naturally forming oxide layer, directly influence the material’s thermal, electrical, and mechanical properties. This allows manufacturers to produce highly customizable, high-performance materials in a scalable and cost-effective way—reducing waste, enhancing functionality, and enabling applications in fast-growing sectors like wearable electronics, soft robotics, and advanced thermal management. Unlike traditional methods, our technology empowers companies to tailor each component to meet specific performance demands, unlocking new levels of product differentiation and market competitiveness.

Figure: Manufacturing strategy for controlling the spatial inclusion morphology and composition of functional emulsions.

Advantages:

• Programmable microstructure for tunable thermal, electrical, and mechanical properties
• Scalable direct ink writing with in-situ control over droplet morphology
• Multifunctional soft composites combining flexibility with metal-like conductivity
• Cost-effective fabrication compatible with various material systems

Potential Application:

• Conformable thermal interface materials
• Flexible and stretchable electronics
• Soft robotics components
• Wearable sensors and devices