US DOE earmarks $179M for microelectronics science research centers

The U.S. Department of Energy (DOE) announced $179 million in funding over four years for three Microelectronics Science Research Centers (MSRCs), authorized by the Micro Act in the CHIPS and Science Act of 2022. These centers will conduct basic research in microelectronics materials, device and system design, and manufacturing science to transform future microelectronics technologies. The MSRCs, formed as networks of 16 projects led by 10 national laboratories, complement activities under the CHIPS and Science Act at the Department of Commerce, the Department of Defense, and other agencies.

The Microelectronics Energy Efficiency Research Center for Advanced Technologies (MEERCAT) will advance integrated innovations across materials, devices, information-carrying modalities, and systems’ architectures. Focusing on intelligent sensing, data bandwidth, multiplexing, and advanced computing, the center will explore transformative solutions that seamlessly bridge sensing, edge processing, artificial intelligence, and high-performance computing.

The Co-design and Heterogeneous Integration in Microelectronics for Extreme Environments (CHIME) Center will develop extreme environment electronics through heterogeneous integration and a seamless fusion of diverse materials, processes, and technologies to enable next-generation systems. The center will create robust, high-performance solutions capable of excelling in the most challenging conditions, including extreme thermal and radiation environments.

The Extreme Lithography & Materials Innovation Center (ELMIC) aims to advance the fundamental science driving the integration of new materials and processes into future microelectronic systems, focusing on key areas such as plasma-based nanofabrication, extreme UV photon sources, 2D-material systems, and extreme-scale memory. The center’s scientific investigations will be informed strongly by a systems-to-physics motivation aimed at long term impact.

For more information: U.S. Department of Energy

Image: (From left) Lawrence Livermore National Laboratory researchers Drew Willard, Brendan Reagan, and Issa Tamer work on the Big Aperture Thulium laser system, one of the projects designated under the Extreme Lithography & Materials Innovation Center.

From roots to rugged circuits: Tree-inspired printing tech for flexible electronics

Researchers at Xi’an Jiaotong University, China, have developed a new Template-Constrained Additive printing technology inspired by tree root systems that enhances the mechanical robustness and precision of flexible electronic circuits, allowing them to withstand extreme conditions like high temperatures and mechanical wear, expanding their applications in smart robotics and advanced sensing systems.

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Reducing TOPCon solar cell degradation via copper plating

Researchers at the University of New South Wales, Australia, have created a protective barrier on the front silver grid of a TOPCon solar cell using a 1 µm copper plating layer, which reduces corrosion susceptibility and significantly lowers contaminant-induced degradation compared to unprotected reference devices.

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Innovative apatite nanoparticles for advancing the biocompatibility of implanted biodevices

Medical implants have revolutionized healthcare with advanced materials and technologies, but many face challenges like poor cell adhesion, leading to inflammatory responses. Apatite coatings, especially hydroxyapatite (HA) found in bones, can enhance integration with tissues, but artificially synthesized apatite nanoparticles often lack effective binding with biological tissues. Researchers at Nagaoka University of Technology, Japan, have developed surface-modified apatite nanoparticles that improve cell adhesion, paving the way for the next generation of biocompatible medical implants.

Led by Dr. Motohiro Tagaya, Associate Professor at the Department of Materials Science and Bioengineering at Nagaoka University of Technology, Japan, this research aims to enhance the performance of apatite coatings and advance the field of biocompatible materials for medical devices.  Along with Dr. Tagaya, Mr. Kazuto Sugimoto from Nagaoka University of Technology, Dr. Tania Guadalupe Peñaflor Galindo from Sophia University, and Mr. Ryota Akutsu from Nagaoka University of Technology were also a part of this research team.

Apatites are a class of calcium-phosphorus-based inorganic compounds, with hydroxyapatite—a naturally occurring form found in bones. These compounds are known for their high biocompatibility. Recent studies have found that coating artificial joints and implants with apatite nanoparticles is a plausible solution for improving the biocompatibility of these biodevices. However, the artificially synthesized nanoparticles often show reduced binding affinity to biological tissues in vitro. According to Dr. Tagaya and his team, this difference could be linked to the nanoscale surface layer of the apatite nanoparticles.

Dr. Tagaya’s research was driven by a desire to unravel the complexities of biocompatible materials, leading his team to develop an interdisciplinary framework that controls the intricate interactions between apatite and biological systems.

The team synthesized hydroxyapatite nanoparticles by mixing aqueous solutions of calcium and phosphate ions. The pH of the solution was controlled using three different bases, which included tetramethylammonium hydroxide (TMAOH), sodium hydroxide (NaOH), and potassium hydroxide (KOH). The precipitated nanoparticles were then evaluated for their surface layer characteristics and were further used for coating via electrophoretic deposition.

The results revealed that pH was a key factor during synthesis, since it affected the crystalline phases, surface properties, and electrophoretic deposition. On analyzing the crystalline phases of the nanoparticles, it was observed that the choice of pH influenced the formation of different calcium phosphate phases like calcium-deficient hydroxyapatite (CDHA) and carbonate-containing hydroxyapatite (CHA). Higher pH favored the formation of CHA, leading to better crystallinity, and a higher calcium to phosphorus (Ca/P) molar ratio.

The surface of the apatite nanoparticles shows three different layers. The inner apatite layer/core is characterized by the presence of the crystalline structure of the apatite. Above the apatite layer is the non-apatitic layer, which is rich in ions like phosphate ions and carbonate ions. This layer reacts with water molecules and forms the hydration layer. Analyzing the surface characteristics of these layers revealed that pH adjustments facilitated the formation of the non-apatitic layer rich in reactive ions, enhancing hydration properties, which was confirmed.

Importantly, the study revealed that while higher pH facilitates the formation of the non-apatitic layer, the presence of Na+ ions reduces the concentration of phosphate ions, leading to decreased reactivity of the layer. The introduction of substantial ions by NaOH also affected the uniformity of electrophoretic deposition, as observed in scanning probe microscope studies. This effect was not observed with KOH, indicating that KOH was more suitable than NaOH for forming the non-apatitic layer and ensuring uniform coating.

These findings can be potentially useful for surface coating of a wide range of biodevices that are implanted in the human body, including artificial joints and implants.

For more information: ACS Applied Materials & Interfaces

Image: Researchers from Nagaoka University of Technology, Japan develop highly biocompatible apatite nanoparticles by manipulating surface properties through pH changes.

Behold the world’s thinnest pasta

The world record for thinnest pasta has just been shattered.

A team of researchers has created starchy nanofibers from white flour, with an average thickness of about 370 nanometers, or roughly two-hundredths the thickness of a human hair. These nanofibers, produced by mixing flour with formic acid to uncoil the starch molecules, are being explored for use in biodegradable bandages rather than as food.

“Normally, if you want to cook starch, then you use water and heat to break up the tight packing of starch,” notes Adam Clancy. “We do that chemically with formic acid. So we effectively pickle it instead of cooking it.”

Clancy is a chemist at University College London in England. He was part of a team that warmed this dough to give it the right consistency. To stretch the dough into tiny noodles, they used a technique called electrospinning.

In this process, an electrical charge pulled the dough through a needle and onto a plate several centimeters away. The starch molecules tangled with each other as they left the needle, forming a jet. As the jet flew through the air, the formic acid evaporated. This left behind a thin fiber. After about 30 minutes, the fiber formed a thin mat on the plate.

This isn’t the first time someone has made a mat of starchy nanofibers. Such mats typically have tiny holes called pores. These pores are large enough to let water molecules through, but too small for bacteria to enter. That makes them good options for bandages and wound dressings.

But past research has electrospun mats using pure starch, as opposed to a starch-containing flour. The process of extracting pure starch from plant matter takes a lot of energy and water. The new study shows such costly extraction isn’t always needed.

Since the fibers are made of dried flour, they count as pasta, the authors say. That makes them the thinnest pasta on record.

Each noodle is roughly a thousandth the width of su filindeu. That’s a type of pasta about half the width of angel hair noodles, which are about 1 millimeter (0.04 inch) thick when cooked.

So is Clancy’s nanopasta edible? “I certainly hope so,” he says.

For more information: Nanoscale Advances

Image: These nanofibers (seen under a scanning electron microscope) can be called pasta because they are made from dried flour. That makes them the thinnest noodles ever.

Scientists use quantum computers to simulate elusive particles

Researchers from Harvard University, MIT, and QuEra Computing Inc. have developed a new digital quantum simulation architecture based on reconfigurable atom arrays to simulate fermionic systems on quantum computers. This approach aims to advance materials science, chemistry, and high-energy physics by improving simulations of complex quantum materials and exotic phases of matter, which are challenging to study with classical computational methods. Fermions, such as electrons, protons, and neutrons, obey the Pauli exclusion principle, making their simulation difficult due to non-local interactions where changes in one part of the system can affect distant parts.

The research team used a quantum computing method that maps fermionic behavior onto qubits by leveraging a model known as Kitaev’s honeycomb lattice. This mathematical framework describes how particles interact in a two-dimensional honeycomb-shaped grid. The Kitaev model is particularly useful because it allows researchers to study exotic phases of matter, including spin liquids — materials where magnetic moments remain disordered even at very low temperatures. The approach encodes fermionic statistics using long-range entangled states to allow for more efficient quantum simulations of strongly interacting systems.

The study confirms the existence of a non-Abelian spin liquid phase by measuring an odd Chern number, a key mathematical indicator of topological order. Non-Abelian states are special because the way particles interact depends on the order in which they are exchanged. Unlike conventional particles, which either return to their original state or flip when swapped, non-Abelian particles retain a memory of the sequence of swaps, making them useful for robust quantum computing.

Although it’s not exact, to grasp some idea of the concept, you could think of non-Abelian states like a combination lock — if you enter the numbers in a different order, it will give you a different result. On the other hand, conventional particles are like light switches, which only have two states regardless of how many times you flip them.

The odd Chern number serves as a topological signature that identifies different quantum phases, much like how a fingerprint identifies an individual.

The work demonstrates how quantum simulations can efficiently capture the essential physics of strongly correlated fermions, according the researchers.

By encoding fermionic interactions in a topologically ordered state, the system enables precise control over the quantum evolution of fermions. Topological states are quantum states of matter that depend on their overall structure rather than specific local details. These states are particularly important because they provide robust ways to store and manipulate quantum information, making them valuable for fault-tolerant quantum computing.

Quantum simulations of fermionic systems are particularly challenging due to the non-local nature of fermion interactions. Traditional quantum computing methods require complex encodings that can introduce significant computational overhead. The researchers overcame these challenges using measurement-based state preparation, tunable Floquet circuits, and error detection techniques. Floquet engineering, which is a method that uses periodic driving to control quantum interactions, played a crucial role in simulating fermionic behavior in a controllable manner.

In the experiment, the team used a reconfigurable array of 104 atomic qubits on a neutral-atom quantum computing platform to represent the honeycomb lattice. They employed Floquet engineering to simulate fermionic behavior. Through this method, they successfully prepared and verified various low-energy states, including those corresponding to topological spin liquids. These spin liquids are phases of matter that, unlike conventional magnets, do not exhibit long-range magnetic order but instead host highly entangled quantum states with exotic properties such as fractionalized excitations.

One of the study’s major findings is the ability to simulate strong interactions within a fermionic system, particularly in the context of the Fermi-Hubbard model. This model is widely used in condensed matter physics to describe electron interactions in materials and has implications for understanding high-temperature superconductivity. By engineering interactions among fermions on a square lattice, the researchers were able to explore dynamics relevant to real-world materials, potentially providing insights into novel electronic properties that could be harnessed in future technologies.

Despite these advances, the study acknowledges several limitations that will likely be the focus of future work, as we’ll see later. Quantum errors remain a significant challenge, limiting the depth of circuits that can be executed before decoherence affects results. To mitigate these errors, the researchers implemented built-in error detection methods and post-selection techniques, improving the accuracy of their results. However, fully error-corrected simulations will require further advancements in quantum hardware and fault-tolerant encoding schemes. Scaling up these simulations to more complex and larger systems will also require improving quantum hardware stability and reducing noise.

Future directions for this research include expanding the scale of quantum simulations and integrating more sophisticated error correction techniques. The researchers also suggest that their approach could be applied to other complex quantum systems, including lattice gauge theories and quantum gravity models. Lattice gauge theories are mathematical frameworks used to describe fundamental interactions in particle physics, and their simulation could provide new insights into quantum chromodynamics, the theory governing the strong force that binds atomic nuclei.

Simulating aspects of quantum gravity could shed light on how quantum mechanics and general relativity interact at small scales, an area that remains largely unexplored due to the limitations of classical computation.

For more information: arXiv

Detecting additive manufacturing defects in real time

A research team led by Associate Professor Tao Sun has made significant advancements in additive manufacturing, particularly for aerospace and other industries requiring strong metal parts. They have successfully tackled the challenge of detecting keyhole pores, a major defect in the laser powder bed fusion (LPBF) technique.

Introduced in the 1990s, LPBF uses metal powder and lasers to 3D print metal parts. But porosity defects remain a challenge for fatigue-sensitive applications like aircraft wings. Some porosity is associated with deep and narrow vapor depressions which are the keyholes.

The formation and size of the keyhole is a function of laser power and scanning velocity, as well as the materials’ capacity to absorb laser energy. If the keyhole walls are stable, it enhances the surrounding material’s laser absorption and improves laser manufacturing efficiency. If, however, the walls are wobbly or collapse, the material solidifies around the keyhole, trapping the air pocket inside the newly formed layer of material. This makes the material more brittle and more likely to crack under environmental stress.

Sun and his team, including Professor Anthony Rollett from Carnegie Mellon University and Mechanical Engineering Professor Lianyi Chen from the University of Wisconsin-Madison, developed an approach to detect the exact moment when a keyhole pore forms during the printing process.

“By integrating operando synchrotron x-ray imaging, near-infrared imaging, and machine learning, our approach can capture the unique thermal signature associated with keyhole pore generation with sub-millisecond temporal resolution and 100 percent prediction rate,” Sun said.

In developing their real-time keyhole detection method, the researchers also advanced the way a state-of-the-art tool — operando synchrotron x-ray imaging — can be used. Utilizing machine learning, they additionally discovered two modes of keyhole oscillation.

“Our findings not only advance additive manufacturing research, but they can also practically serve to expand the commercial use of LPBF for metal parts manufacturing,” said Rollett.

“Porosity in metal parts remains a major hurdle for wider adoption of LPBF technique in some industries. Keyhole porosity is the most challenging defect type when it comes to real-time detection using lab-scale sensors because it occurs stochastically beneath the surface,” Sun said. “Our approach provides a viable solution for high-fidelity, high-resolution detection of keyhole pore generation that can be readily applied in many additive manufacturing scenarios.”

For more information: Science Magazine

Image: UVA materials science and engineering postdoctoral fellow Zhongshu Ren (left) and Tao Sun display the results of their research.

One Minute Mentor: Phase Transformations using finite-element-method (FEM) model.

Heat treatment of tool steels means several phase transformations. Every phase transformation must be described by start amount, end amount, and kinetics (change of phases depending on temperature and time). Start and end amount can be calculated with different thermodynamic software. For example, Thermocalc is well validated for tool steels. All of the aforementioned data are used as input data for a finite-element-method (FEM) model. In any case the first step of simulation models is validation, which means the comparison of experiments and mathematical simulation. The better the input data and the better the model formulation, the better are the results and the fewer loops have to be made for an appropriate model (reference model). This reference model is then used for process optimization. All these steps of model development are illustrated in the figure. 

For more information, click on the link below (subscription required). Then scroll to Figure 15. R Schneider; R. Mesquita; W Schützenhöfer, Distortion in Tool Steels, ASM International, 2014  https://doi.org/10.31399/asm.hb.v04d.a0005980

 

Constellium and renault group complete r&d project advancing lightweight aluminium solutions

Constellium, Paris, announced the successful completion of the “ISA3” R&D project, an initiative launched in 2021 to advance lightweight aluminium solutions for automotive applications. Conducted in collaboration with Renault Group, ESI Group, the Institut de Soudure, and the University of Lorraine, the project was supported by a grant from the France Relance investment program. The research focused on developing cost-efficient, recyclable aluminium components to enhance vehicle performance and sustainability.

A key achievement of the project was the development of a lightweight aluminium door in partnership with Renault. Utilizing Constellium’s proprietary uni-alloy 6xxx rolled and extrusion-based solutions, the door design achieved a 14% weight reduction compared to existing aluminium doors used in compact battery electric vehicles. By employing a single alloy series, the project streamlined closed-loop recycling, reducing the door’s overall carbon footprint. This innovation resulted in a 33% reduction in Global Warming Potential (GWP), reinforcing the project’s emphasis on sustainability.

Beyond material advancements, the project also explored more efficient and flexible production processes to enhance performance while optimizing costs. Ludovic Piquier, senior vice president, manufacturing excellence and chief technical officer at Constellium, emphasized that the results highlight the company’s commitment to providing sustainable, high-performance aluminium solutions for the automotive sector.

Patrice Belliard, expert in flat products at Renault Group, noted that the project demonstrated how aluminium can support both weight reduction and cost efficiency in automotive manufacturing. Mathilde Chabin, manufacturing product director at ESI Group, added that the use of advanced pre-certification and validation technologies eliminated the need for physical prototypes, accelerating innovation while reducing costs and environmental impact.

The completion of Project ISA3 underscores the potential of aluminium to contribute to the automotive industry’s decarbonization efforts while delivering economic and environmental benefits.

Read further here. 

Automaker modernizes heat-treatment operations with Nitrex technology

Automaker modernizes heat-treatment operations with Nitrex technology

Nitrex, Quebec, announced that a major automotive manufacturer has selected its EndoFlex L generators to upgrade heat-treatment operations. This initiative supports the automaker’s commitment to improving production efficiency while advancing sustainability and cost management efforts.

The facility specializes in manufacturing engine components that require carburizing, a heat-treatment process that enhances surface durability by introducing carbon into the material. Previously, the site relied on aging, gas-heated generators to produce endothermic gas for this process. However, these generators had become inefficient, consuming excessive natural gas and increasing CO₂ emissions. To address these challenges, the manufacturer has chosen Nitrex’s electrically heated EndoFlex L endothermic gas generators to optimize efficiency and reduce environmental impact.

Designed specifically for carburizing applications, the EndoFlex L features a multi-retort design and precise temperature control, ensuring a consistent and stable supply of high-quality endothermic gas. The system operates on demand, significantly reducing gas consumption and emissions, making it a more sustainable and cost-effective solution.

Daniel Panny, head of sales Europe at Nitrex, emphasized the company’s long-standing relationship with the automaker, noting that previous projects included upgrading legacy generators with the EndoInjector gas injection system. He stated that this latest investment demonstrates how sustained partnerships can drive meaningful advancements in industrial manufacturing.

Read further here.

Harper international commissions two carbon fiber production lines in China

Harper International, Buffalo, NY, announced the successful installation and commissioning of two carbon fiber production lines for Shandong Yongcheng New Materials Co. Ltd. (SYNM) in the Shandong province of China. The newly commissioned systems incorporate Harper’s advanced thermal processing technology, including oxidation ovens, low-temperature (LT) and high-temperature (HT) carbonization furnaces, and integrated energy recovery and waste gas abatement systems.

The two 3-meter-wide production lines at SYNM’s facility will allow for an annual production capacity of 3,000 metric tons of carbon fiber. The site has been designed with future expansion in mind, with the potential to scale up to 12,000 metric tons per year. Harper’s expertise ensured efficient system performance and uniform carbon fiber product quality.

Paul Elwell, vice president of Harper International, emphasized the strong collaboration between Harper and SYNM, which contributed to a smooth installation and commissioning process. He also noted that Harper looks forward to supporting SYNM’s continued growth and expansion in carbon fiber manufacturing.

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Wisconsin Oven delivers two-zone belt conveyor oven for steel tempering

Wisconsin Oven Corporation, East Troy, WI, announced the shipment of a two-zone belt conveyor oven designed for tempering steel parts following induction hardening. The system is engineered for precise temperature control and enhanced energy efficiency, meeting industry specifications for uniform heating.

The oven has the capacity to heat 2,400 pounds of steel per hour from 70°F to 350°F, with a maximum temperature rating of 500°F. It features a top-down airflow recirculation system with a 32,000 CFM blower, evenly distributed between the two heating zones. Temperature control is managed by a Watlow F4T digital recorder/controller, which includes Ethernet communication capabilities and adaptive PID temperature control. A temperature uniformity survey verified uniformity within ±10°F at 350°F, ensuring compliance with AIAG specification CQI-9.

The conveyor system utilizes a continuous belt with a variable frequency drive for speed adjustments, and the work zone measures 4’0” W x 21’0” L x 14” H. To improve energy efficiency, the oven is equipped with the E-Pack™ Energy Efficiency Package, which includes additional insulation and variable frequency drives on the recirculation blowers. These features reduce energy consumption and operational costs, potentially providing substantial annual savings depending on utility rates and operating conditions.

The system’s design optimizes heat-up efficiency and uniformity, making it well-suited for high-volume steel tempering applications. The oven incorporates programmable temperature controls with auto-tuning functionality, ensuring consistent and repeatable performance for industrial heat treatment processes.

Read further here.

Evident’s new DSX2000 Digital Microscope simplifies inspection workflows

Evident (Waltham, Mass.) announces the launch of its DSX2000 fully motorized digital microscope designed to simplify operations and boost productivity in material analysis and inspection workflows. An automated and integrated system for imaging, measurement, analysis and reporting, the advanced microscope can be easily operated by users of all skill levels for fast, precise results and high-quality macro to micro imaging at resolutions beyond 4K.

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Novel x-ray technique of functional materials maps their architecture

Researchers at the Swiss Light Source (SLS) recently developed a pioneering x-ray technique to probe the 3D orientation of a material’s building blocks at the nanoscale. Applied to a polycrystalline catalyst, the technique allows the visualization of crystal grains, grain boundaries and defects—key factors dictating catalyst performance. Beyond catalysis, the innovation unlocks previously inaccessible details about the structure of diverse functional materials in numerous applications.

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Sustainable building components create a good indoor climate

Researchers from ETH Zurich have explored a new passive dehumidification approach for indoor spaces, where high humidity is absorbed by walls and ceilings and temporarily stored in a hygroscopic material. This method, which releases moisture when the room is ventilated, offers an energy-efficient alternative to mechanical dehumidification systems commonly used in high-traffic areas like offices, museums, and government buildings. According to Professor Guillaume Habert, this solution is ideal for spaces where existing ventilation systems are insufficient.

Habert and his research team followed the principle of the circular economy in their search for a suitable hygroscopic material. The starting point is finely ground waste from marble quarries. A binder is needed to turn this powder into moisture-binding wall and ceiling components. This task is performed by a geopolymer, a class of materials consisting of metakaolin (known from porcelain production) and an alkaline solution (potassium silicate and water). The alkaline solution activates the metakaolin and provides a geopolymer binder that binds the marble powder to form a solid building material. The geopolymer binder is comparable to cement but emits less CO2 during its production.

In the ETH project, the scientists succeeded in producing a prototype of a wall and ceiling component measuring 20 × 20 cm and 4 cm thick. Production was carried out using 3D printing in a group led by Benjamin Dillenburger, Professor for Digital Building Technologies. In this process, the marble powder is applied in layers and glued by the geopolymer binder (binder jet printing technology). “This process enables the efficient production of components in a wide variety of shapes,” says Benjamin Dillenburger.

Combining geopolymer and 3D printing to produce a moisture reservoir is an innovative approach to sustainable construction. Building physicist Magda Posani led the study of the material’s hygroscopic properties at ETH Zurich before recently taking on a professorship at Aalto University in Espoo, Finland. The project is based on the doctoral theses of materials scientist Vera Voney, supervised by Senior Research Associate Coralie Brumaud and architect Pietro Odaglia, who developed the material and the 3D printing machine at ETH.

“We were able to demonstrate with numerical simulations that the building components can significantly reduce humidity in heavily used indoor spaces,” says Posani, summarising the main result of the research project. For the simulation, it was assumed that the walls and ceiling of a reading room used by 15 people in a public library in Oporto, Portugal had been completely lined with hygroscopic components. Magda Posani calculated how often and to what extent the humidity exceeded the comfort zone, i.e. 40 to 60 percent relative humidity in this virtual reading room over the course of a year. From this, she calculated a discomfort index, a figure that expresses the loss of comfort caused by excessively high or low humidity. If the reading room were fitted with the moisture-binding components, the discomfort index could be reduced by 75 percent compared to a conventional painted wall. If components were used that were 5 cm thick instead of just 4 cm, the discomfort index fell by as much as 85 percent.

The hygroscopic wall and ceiling components are climate-friendly, i.e. they cause significantly lower greenhouse gas emissions over a 30-year life cycle than a ventilation system that dehumidifies air quality to the same extent. In the simulation calculations, the wall and ceiling components were also compared with a clay plaster that has been used since time immemorial and also passively regulates the air humidity in indoor spaces. This old technique proved to be even more climate-friendly than the hygroscopic components. However, the plaster has a lower storage capacity for water vapour.

The research at ETH has shown that the combination of geopolymer and 3D printing can be used to produce wall and ceiling components for efficient moisture buffering. After this proof of concept, the technology is, in principle, ready to be further developed and scaled for industrial manufacture. At the same time, research continues. In a project with Turin Polytechnic and Aalto University, ETH Zurich is working to produce wall and ceiling components with even lower greenhouse gas emissions. Because one thing is clear: if Switzerland wants to achieve its net zero target by 2050, it needs buildings that cause as little greenhouse gas emissions as possible during construction and use.

For more information: Nature Communications

Designing nano-architected materials using ML and 3D printing

Researchers at the University of Toronto’s Faculty of Applied Science & Engineering have used machine learning and 3D printing to create nano-architected materials that combine the strength of carbon steel with the lightness of Styrofoam. In a new paper, Professor Tobin Filleter’s team describes these nanomaterials, which offer exceptional strength, light weight, and customizability, potentially benefiting industries from automotive to aerospace.

“Nano-architected materials combine high-performance shapes, like making a bridge out of triangles, at nanoscale sizes, which takes advantage of the ‘smaller is stronger’ effect, to achieve some of the highest strength-to-weight and stiffness-to-weight ratios, of any material,” said Peter Serles, the first author of the new paper. “However, the standard lattice shapes and geometries used tend to have sharp intersections and corners, which leads to the problem of stress concentrations. This results in early local failure and breakage of the materials, limiting their overall potential. “As I thought about this challenge, I realized that it is a perfect problem for machine learning to tackle.”

Nano-architected materials are made of tiny building blocks or repeating units measuring a few hundred nanometres in size – it would take more than 100 of them patterned in a row to reach the thickness of a human hair. These building blocks, which in this case are composed of carbon, are arranged in complex 3D structures called nanolattices.

To design their improved materials, Serles and Filleter worked with Professor Seunghwa Ryu and PhD student Jinwook Yeo at the Korea Advanced Institute of Science & Technology (KAIST) in Daejeon, South Korea. This partnership was initiated through the University of Toronto’s International Doctoral Clusters program, which supports doctoral training through research engagement with international collaborators.

The KAIST team employed the multi-objective Bayesian optimization machine learning algorithm. This algorithm learned from simulated geometries to predict the best possible geometries for enhancing stress distribution and improving the strength-to-weight ratio of nano-architected designs.

Serles then used a two-photon polymerization 3D printer housed in the Centre for Research and Application in Fluidic Technologies (CRAFT) to create prototypes for experimental validation. This technology enables 3D printing at the micro and nanoscale – creating optimized carbon nanolattices.

These optimized nanolattices more than doubled the strength of existing designs – withstanding stress of 2.03 megapascals for every cubic meter per kilogram of its density, which is about five times higher than titanium.

“This is the first time machine learning has been applied to optimize nano-architected materials, and we were shocked by the improvements,” said Serles. “It didn’t just replicate successful geometries from the training data; it learned from what changes to the shapes worked and what didn’t, enabling it to predict entirely new lattice geometries. Machine learning is normally very data-intensive, and it’s difficult to generate a lot of data when you’re using high-quality data from finite element analysis. But the multi-objective Bayesian optimization algorithm only needed 400 data points, whereas other algorithms might need 20,000 or more. So, we were able to work with a much smaller but an extremely high-quality data set.”

“We hope that these new material designs will eventually lead to ultra-lightweight components in aerospace applications, such as planes, helicopters, and spacecraft that can reduce fuel demands during flight while maintaining safety and performance,” said Filleter.

“This can ultimately help reduce the high carbon footprint of flying. For example, if you were to replace components made of titanium on a plane with this material, you would be looking at fuel savings of 80 liters per year for every kilogram of material you replace,” said Serles.

“Our next steps will focus on further improving the scale-up of these material designs to enable cost-effective macroscale components,” said Filleter. “In addition, we will continue to explore new designs that push the material architectures to even lower density while maintaining high strength and stiffness.”

For more information: Advanced Materials

Materials that absorb carbon and combat climate change

Switching to building materials designed to store carbon dioxide could significantly advance net-zero greenhouse gas emission efforts. A new study estimates that using CO2-sequestering materials could capture up to 16.6 ± 2.8 gigatons of CO2 annually, nearly 50% of 2021’s global CO2 emissions. Reducing atmospheric CO2 and lowering emissions is crucial for slowing global warming. Construction materials, due to their widespread use and long lifespan, could serve as major carbon reservoirs. Van Roijen and her team suggest incorporating carbon aggregates into concrete and using bio-based components in bricks.

The study highlights that the carbon storage potential depends more on the volume of material used (e.g., cement, which stores less carbon per unit but is ubiquitous) than the amount of carbon stored per unit weight. However, challenges remain, including resistance from builders hesitant to adopt new materials due to liability concerns, limited availability of carbon-sequestering minerals, and the need for a carefully managed supply chain.

These challenges, underscore the importance of systemic changes to make these innovations viable.

For more information: Science

These nanoscale ‘soccer balls’ make leafhoppers antireflective and waterproof

A recent study may provide insights into the distinctive coating on leafhoppers’ skin, potentially inspiring the creation of innovative new materials. Leafhoppers, which encompass over 20,000 small insect species, are adorned with hollow, soccer ball–shaped nanoparticles composed of proteins and lipids. These nanoparticles, known as “brochosomes,” were first identified in the 1950s. They help the insects’ skin repel water and minimize light reflection. The exact shape and size of brochosomes vary among different species.

Elizabeth Bello, a graduate student in Marianne Alleyne’s entomology lab at the University of Illinois Urbana-Champaign, applied techniques developed by materials scientists to pick up brochosomes individually, compress them, and study their mechanical properties. The balls’ size, shape, and material properties determine how well they resist compression and cling to surfaces, Alleyne reported earlier this month at the annual meeting of the Society for Integrative and Comparative Biology. Further study of brochosomes could help the development of materials with a wide range of applications, including waterproofing, camouflage, self-cleaning surfaces, and even data encryption and anticounterfeiting devices.

For more information: Science Advances

Sandia partners with national labs to develop energy-efficient AI and computing tech

To address future energy needs, the Department of Energy Office of Science has announced the creation of three new Microelectronics Science Research Centers. One of these, the Microelectronics Energy Efficiency Research Center for Advanced Technologies (MEERCAT), will focus on energy efficiency by exploring solutions that integrate sensing, edge processing, artificial intelligence, and high-performance computing. Sandia National Laboratories will be a founding member of MEERCAT and will lead one of its eight energy efficiency-related research projects.

The other two centers will work on resilience in extreme environments, including high-radiation, cryogenic and high magnetic field environments.

“Our center will provide industry with new, higher performance options for energy-efficient computing,” said Nelson, the principal investigator for the Sandia-led project.

Sandia is also partnering on two projects led by other laboratories: one on energy efficiency with Lawrence Berkeley National Laboratory and another on extreme environments with Los Alamos National Laboratory.

AI is a major factor in rising energy demand because it uses more energy than conventional computer algorithms and has seen a surge in popularity within homes and workplaces. Along with the growth of other energy-intensive technologies like quantum computing and advanced sensors, this has created an urgent need for more efficient technologies.

The three new research centers will provide a total of $179 million for 16 multidisciplinary, fundamental research projects lasting up to four years. They are funded through DOE’s Office of Science and authorized by the Micro Act, passed in the CHIPS and Science Act of 2022. This legislation has invested billions of dollars through multiple agencies to help companies build new plants for advanced semiconductors in the U.S. It also funds fundamental research to advance the technologies these future factories will produce.

“We are working with companies to understand their problems and pulling experts together from across the DOE to solve these problems quickly,” Nelson said.

When the Energy Department announced its plan to form Microelectronics Science Research Centers in May 2024, Nelson reached out to a familiar team.

Two years earlier, a group of directors and experts from DOE’s five scientific user facilities, the Nanoscale Science Research Centers, had started holding regular, collaborative discussions.

“We met every two weeks for two years,” Nelson said. “We discussed our collective resources and how we can work together to achieve national priorities.”

Nelson is the director of one of these Office of Science user facilities, the Center for Integrated Nanotechnologies, which is jointly operated by Sandia and Los Alamos national laboratories. The other four user facilities: the Center for Nanoscale Materials, the Center for Functional Nanomaterials, The Molecular Foundry and the Center for Nanophase Materials Sciences are spread across the country, each co-located at a national lab.

The team agreed that by working together they could advance new materials to make computing more powerful and energy-efficient.

Researchers had already found that materials like molybdenum disulfide, gallium arsenide and even diamond may be better than silicon for certain aspects of computing. In theory, computer chips made from one of these alternative materials might be far more energy-efficient and could solve the looming energy crisis.

“They’re very promising,” Nelson said.

But the task of taking any of these materials, perfecting them in a lab, learning how to mass produce them and then building a factory to make chips from them while competing against an established silicon industry and supply chain, the team agreed, felt daunting at best.

Taking a different route, the group of lab leads and other collaborators proposed a project entitled “Nano-Scale Research Center for Heterogeneous Integration Platforms.” This project would aim to leverage the existing infrastructure and expertise of the DOE user facilities and partnering institutions and develop ways to insert new materials into standard silicon fabrication processes.

Now greenlit with DOE’s recent announcement, the project will bring together resources from all five Nanoscale Science Research Centers. It will also include researchers from Fermi National Accelerator Laboratory, the Massachusetts Institute of Technology and MIT Lincoln Laboratory.

They will build on previous research in what scientists call heterogeneous integration. This means using many kinds of materials to make computer chips, all monolithically integrated into a silicon backbone. The tricky part is to ensure electrons and information flow seamlessly between different materials.

Sandia and its collaborators are aiming for breakthroughs that could help industry create much more energy-efficient computer chips.

“By collaborating across multiple national laboratories and universities, our goal is really to accelerate the innovation discovery process and make a positive impact on economic and national security,” Nelson said.

For more information: Sandia National Laboratories

Image: The Center for Integrated Nanotechnologies, pictured here, is one of five Department of Energy Nanoscale Science Research Centers teaming up to help make computer chips more energy-efficient.