Additive Manufacturing of Multiscale, Multifunctional Structures

Additive manufacturing (3D printing) has emerged as a transformative approach to design and fabricate materials and structures with unprecedented complexity, functionality, and scalability. In this talk, I will present our recent efforts in advancing multi-scale and multi-functional additive manufacturing by integrating novel materials, innovative printing strategies, and cross-scale structural design. First, I will introduce our freeze nano printing platform, which combines inkjet printing with freeze casting to enable the fabrication of materials with both complex macro-architectures and engineered porous microstructures. This hybrid approach leverages freeze-drying to achieve tailored porosity while addressing fundamental challenges such as thermal management and jetting dynamics in high-resolution printing. Next, I will discuss our work on biomass-based 3D printing for sustainable construction applications. Using a direct ink writing (DIW) approach, we transform agricultural byproducts such as wheat straw fibers into lightweight, thermally insulating wall panels, offering a sustainable alternative to conventional building materials. Finally, I will highlight our progress in bioprinting vascularized hydrogel structures using fast stereolithography 3D printing. This approach enables the creation of hierarchical, multi-scale architectures that mimic biological tissue environments, paving the way for advanced biomedical applications. Together, these advances highlight how additive manufacturing can unite functions across scales and drive the next generation of material innovation.