Laser-induced in-situ electrohydrodynamic jet printing of micro/nanoscale hierarchical structure

With the rapid advancement of micro/nanoscale devices, there is a growing demand for hierarchical micro/nano porous-structure, particularly in fields of high-performance sensors, electrochemical energy storage, and photocatalysis. The fabrication methods for hierarchical micro/nano-porous structures have been limited by complex processes and high costs, making further development and application difficult. In this paper, a novel strategy of laser-induced in-situ electrohydrodynamic jet (E-Jet) printing of hierarchical micro/nano-porous structures was proposed. Based on the mechanism of high-energy laser beam induction on the jet, it successfully fabricated hierarchical porous ZnO structures from nanoscale to dozens of microns. The jet size focusing and solidification behavior were analyzed by combining experimental and simulative exploration. The resultant effects of the thermal field, flow field, and laser field on the spatial temperature distribution and the jetting morphology were examined. Furthermore, the laser-induced influence on the morphology of the printed micro/nano-porous ZnO structures was explored. Meanwhile, the performance of micro/nano-porous ZnO photoelectric sensors printed by E-Jet under different laser powers was investigated. The laser-induced in-situ E-Jet printing method provided an innovative pattern for the high-resolution additive manufacturing of hierarchical porous structures, demonstrating its potential for applications in advanced material and high-performance devices.