Tong, Yuxin2022-09-152022-09-152021-03-23vt_gsexam:29365http://hdl.handle.net/10919/111831Non-planar additive manufacturing (AM) technologies, such as microextrusion 3D printing processes, offer the ability to fabricate conformal electronics with impressive structure and function on curvilinear substrates. Although various available methods offer conformal 3D printing capability on objects with limited geometric complexity, a number of challenges remain to improve feature resolution, throughput, materials compatibility, resultant function and properties of printed components, and application to substrates of varying topography. Hence, the overall objective of this dissertation was to create new non-planar AM processes that are compatible with personalized and anatomical computer-aided design workflows for the fabrication of conformal electronics and form-fitting wearables. After reviewing the current state of knowledge and state of the art, significant challenges in non-planar AM have been identified as: 1) limited non-planar AM path planning capability that synergizes with personalized or anatomical object surface modification, 2) limited approaches for printed and non-printed component integration on non-planar substrates. To address these challenges, a template-based reverse engineering workflow is proposed for conformal 3D printing electronics and form-fitting wearable devices on anatomical structures. This work was organized into three complementary tasks that enhance non-planar AM capabilities: 1） To achieve anatomical tissue-sensor integration, 3D scanning-based point cloud data acquisition and customized 3D printable conductive ink are proposed for capturing the topographical information of patient-specific malformations and integrating conformal sensing electronics across anatomical tissue-device interface. 2） To fabricate conformal antennas on flexible thin-film polymer substrates, a versatile method for microextrusion 3D printing of conformal antennas on thin film-based structures of random topography is proposed to control the ink deposition process across the curvilinear surfaces of freeform Kapton-based origami. 3） To simplify the fabrication process of form-fitting wearable devices with fiber-based form factors and self-powered capability, an innovative 3D printing process is proposed to achieve coaxial multi-material extrusion of metal-elastomer triboelectric fibers. By developing new advanced non-planar printing processes and conformal toolpath programming strategies, the utility of non-planar AM could be further expanded for fabricating various personalized implantable and wearable multi-functional systems, including novel 3D electronics. In summary, this work advances capability in additive manufacturing processes by providing new advances in multi-material extrusion processes and personalized device design and manufacturing workflows.ETDIn Copyright3D printingconformal printinghybrid 3D printingbionicswearable systemsflexible electronicsDissertation