The integration of 3D printed sensors into hosting structures has become a growing area of research due to simplified assembly procedures, reduced system complexity, and lower fabrication cost. Embedding 3D printed sensors into structures or bonding the sensors on surfaces are the two techniques for the integration of sensors. This review extensively discusses the fabrication of sensors through different additive manufacturing techniques. Various additive manufacturing techniques dedicated to manufacture sensors as well as their integration techniques during the manufacturing process will be discussed. This review will also discuss the basic sensing mechanisms of integrated sensors and their applications. It has been proven that integrating 3D printed sensors into infrastructures can open new possibilities for research and development in additive manufacturing and sensor materials for smart goods and the Internet of Things.

The growing demand for wearable devices, soft robotics, and tissue engineering in recent years has led to an increased effort in the field of soft materials. With the advent of personalized devices, the one-shape-fits-all manufacturing methods may soon no longer be the standard for the rapidly increasing market of soft devices. Recent findings have pushed technology and materials in the area of additive manufacturing (AM) as an alternative fabrication method for soft functional devices, taking geometrical designs and functionality to greater heights. For this reason, this review aims to highlights recent development and advances in AM processable soft materials with self-healing, shape memory, electronic, chromic or any combination of these functional properties. Furthermore, the influence of AM on the mechanical and physical properties on the functionality of these materials is expanded upon. Additionally, advances in soft devices in the fields of soft robotics, biomaterials, sensors, energy harvesters, and optoelectronics are discussed. Lastly, current challenges in AM for soft functional materials and future trends are discussed.

Thermoplastic materials such as PA12 and PA6 have been extensively employed in Selective Laser Sintering (SLS) 3D printing applications due to their printability, processability, and crystalline structure. However, thermoplastic-based materials lack polymer inter-chain bonding, resulting in inferior mechanical and thermal properties and relatively low fatigue behavior. Therefore, 3D printing of high-performance crosslinked thermosets using SLS technology is paramount to pursue as an alternative to thermoplastics. In this work, a thermoset resin was successfully 3D printed using SLS, and its thermal stability of printed parts after a multi-step post-curing process was investigated. Dimensionally stable and high glass transition temperature (T_g: ~300 °C) thermoset parts were fabricated using SLS. The polymer crosslinking mechanism during the printing and curing process was investigated through FTIR spectra, while the mechanical stability of the SLS 3D-printed thermoset was characterized through compression tests. It is found that 100% crosslinked thermoset can be 3D printed with 900% higher compressive strength than printed green parts.

This research presents a simple method to additively manufacture Cone 5 porcelain clay ceramics by using the direct ink-write (DIW) printing technique. DIW has allowed the application of extruding highly viscous ceramic materials with relatively high-quality and good mechanical properties, which additionally allows a freedom of design and the capability of manufacturing complex geometrical shapes. Clay particles were mixed with deionized (DI) water at different ratios, where the most suitable composition for 3D printing was observed at a 1:5 w/c ratio (16.2 wt.%. of DI water). Differential geometrical designs were printed to demonstrate the printing capabilities of the paste. In addition, a clay structure was fabricated with an embedded wireless temperature and relative humidity (RH) sensor during the 3D printing process. The embedded sensor read up to 65% RH and temperatures of up to 85 °F from a maximum distance of 141.7 m. The structural integrity of the selected 3D printed geometries was confirmed through the compressive strength of fired and non-fired clay samples, with strengths of 70 MPa and 90 MPa, respectively. This research demonstrates the feasibility of using the DIW printing of porcelain clay with embedded sensors, with fully functional temperature- and humidity-sensing capabilities.

The ability to detect impact waves and their propagation across materials is the key to structural health monitoring and defect detection of materials. To detect impact waves from a certain type of structures, it is important for a sensor to be highly flexible and complex in shape. Direct ink write (DIW) allows for the manufacturing of complex sensors. This article presents the fabrication of a flexible impact wave propagation sensor (IWPS) through the DIW technique. The dispersion of a ferroelectric ceramic material barium titanate (BaTiO _3, or BTO) in polydimethylsiloxane (PDMS), not only enhances the flexibility of the 3D (three-dimensional) printed sensor but also ensures the uniform piezoelectric response throughout the whole sensor. This research explored the impact load generated impact wave in the flexible sensor and sensing response. The capability of DIW for multi-material printing was utilized to print multi-walled carbon nanotube based electrodes on BTO/PDMS stretchable composites. A total of 50 wt% of BTO in the PDMS matrix resulted in a piezoelectric coefficient of 20 pC N ⁻¹ after contact poling of IWPS. Upon applying impact loading at the center of the sensor, an impact wave was generated which gradually diminished with the distance from the origin of the applied impact load. The impact wave propagation was quantitatively characterized by measuring output voltage from different nodes of IWPS. Additionally, from the voltage response time difference at different locations of the sensor, the particle-wave velocity of a certain material attached to IWPS was determined in this research. Using the custom-designed IWPS, it was found that the particle-wave velocity of stainless steel and low-density polyethylene were 5625 m s ⁻¹ and 2000 m s ⁻¹ respectively, which are consistent with their theoretical values.