Materials & DesignPub Date : 2026-03-01Epub Date: 2026-01-28DOI: 10.1016/j.matdes.2026.115577
Zhongyuan Li , Won-Il Lee , Nikhil Tiwale , Kyle P. Wade , Mark Aindow , Chang-Yong Nam , Seok-Woo Lee
{"title":"Achieving ultrahigh modulus of resilience and enhanced thermal stability in ZnOx/SU-8 interpenetrating network polymer nanocomposite nanopillars","authors":"Zhongyuan Li , Won-Il Lee , Nikhil Tiwale , Kyle P. Wade , Mark Aindow , Chang-Yong Nam , Seok-Woo Lee","doi":"10.1016/j.matdes.2026.115577","DOIUrl":"10.1016/j.matdes.2026.115577","url":null,"abstract":"<div><div>The modulus of resilience, a mechanical property that quantifies the maximum strain energy density a material can store during elastic deformation, is a crucial parameter for materials used in flexible displays, micro/nano-electro-mechanical system (M/NEMS) actuators, and ultra-sensitive pressure sensors. In this study, ZnO<sub>x</sub>/SU-8 nanocomposite nanopillars with a diameter of 300 nm, fully infiltrated with a uniformly distributed, interpenetrating amorphous ZnO<sub>x</sub> filler network, were synthesized via vapor-phase infiltration (VPI). In-situ uniaxial nano-compression tests revealed that the modulus of resilience of ZnO<sub>x</sub>/SU-8 reaches ∼ 12 MJ/m<sup>3</sup>, which is an ultrahigh value among all engineering materials with comparable strength. In addition, the synthesis fidelity, inorganic infiltration depth, and mechanical performance were all significantly improved compared to VPI-synthesized AlO<sub>x</sub> nanocomposites. Thermal stability, another key requirement for M/NEMS device materials operating under extreme environments, was also notably enhanced. Furthermore, partial crystallization of the amorphous ZnO<sub>x</sub> fillers during annealing contributed to an additional increase in modulus of resilience, reaching up to ∼ 13.9 MJ/m<sup>3</sup>. This work presents an effective fabrication strategy for producing nanostructured organic–inorganic hybrid nanocomposites with ultrahigh modulus of resilience and superior thermal stability, paving the way for their integration into next-generation flexible displays and high-performance M/NEMS devices working under harsh environments.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115577"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185984","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"The effect of Si accumulation in a 7108 Al–Zn–Mg alloy in the context of recycling","authors":"Calin D. Marioara , Constantinos Hatzoglou , Yngve Langsrud , Grethe Waterloo","doi":"10.1016/j.matdes.2026.115578","DOIUrl":"10.1016/j.matdes.2026.115578","url":null,"abstract":"<div><div>Recycled 7108 alloys were simulated by additions of 0.2–0.3 wt% Si, alone or in combination with Mn or Cu. Si had a negative impact on mechanical properties by slowing precipitation kinetics and reducing the overall hardness due to the formation of L-phase needle/laths of the Al–Mg–Si-Cu alloy system co-existing with typical metastable η precipitates of the Al–Zn–Mg(–Cu) alloys, which led to a coarsening of the later. Annular dark field scanning transmission electron microscopy confirmed the presence of a new type of metastable η consisting of overlapping and laterally intertwined ORR<sup>−1</sup> and OR<sup>−1</sup>R sequences of stacked R and O units across the platelet thickness. Most L-phase precipitates contained C sub-units with Zn replacing Cu positions, associated with a local Zn enrichment of adjacent {1 0 0}Al planes at the interface. Adding 0.29 wt% Mn to a 7108 alloy with 0.20 wt% Si led to partial removal of Si from solid solution into α-AlSi(Fe + Mn) dispersoids. This increased the hardness, although at levels below the standard alloy with no Si added. The addition of 0.17 wt% Cu to the same alloy enhanced the precipitation of L-phase leading to the highest peak hardness and a shift of the hardening curve to longer aging times.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115578"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185995","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials & DesignPub Date : 2026-03-01Epub Date: 2026-01-30DOI: 10.1016/j.matdes.2026.115540
Qianning Dai , Bijun Xie , Bin Xu , Yujie Song , Honglin Zhang , Zhengwang Zhu , Mingyue Sun , Dianzhong Li
{"title":"Tailoring interfacial reactive layer for high-strength maraging steel/high-entropy alloy dissimilar joints","authors":"Qianning Dai , Bijun Xie , Bin Xu , Yujie Song , Honglin Zhang , Zhengwang Zhu , Mingyue Sun , Dianzhong Li","doi":"10.1016/j.matdes.2026.115540","DOIUrl":"10.1016/j.matdes.2026.115540","url":null,"abstract":"<div><div>Joining ultra-high-strength maraging steels and high-entropy alloys (HEAs) is crucial for advanced applications. However, the formation of brittle intermetallics often limits interfacial performance. Here, we demonstrate a rapid hot-compression bonding strategy that uses a niobium (Nb) interlayer to control interfacial reactions and produce a high-strength joint between 18Ni350 maraging steel and AlNbTi<sub>3</sub>Zr<sub>1.5</sub> HEA. The effects of bonding temperatures on the interfacial microstructures, mechanical properties, and fracture mechanisms were systematically investigated. An exceptional joint tensile strength exceeding 1 GPa was achieved at an optimal bonding temperature of 850 °C. This is attributed to the formation of a continuous, ultra-thin nanocrystalline Fe<sub>2</sub>Nb reactive layer (RL) at the 18Ni350/Nb interface, coupled with a well-bonded, intermetallic-free HEA/Nb interface. However, increasing the temperature to 1000 °C thickens the Fe<sub>2</sub>Nb RL to over 300 nm and promotes grain coarsening, reducing the joint strength to 747 MPa. Correspondingly, the fracture mode transitions from a complex path involving both interfaces and the interlayer at low temperatures to preferential fracture along the thickened Fe<sub>2</sub>Nb RL at 1000 °C. These findings reveal the central role of intermetallic design in governing interfacial performance, demonstrating that controlling interfacial nanostructures is a critical strategy for fabricating high-strength dissimilar joints.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115540"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185997","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials & DesignPub Date : 2026-03-01Epub Date: 2026-02-05DOI: 10.1016/j.matdes.2026.115622
Zhehong Lu , Fuyao Chen , Baoying Liu , Yuanqing Xu , Xiaomin Fang , Wei Zhao , Tao Ding , Jiantong Li , Yubing Hu , Yiqing Xue , Wei Jiang
{"title":"Enhanced anti-plasticizer migration in GO/EPDM insulation for composite solid propellants: Experimental study and molecular dynamics simulation","authors":"Zhehong Lu , Fuyao Chen , Baoying Liu , Yuanqing Xu , Xiaomin Fang , Wei Zhao , Tao Ding , Jiantong Li , Yubing Hu , Yiqing Xue , Wei Jiang","doi":"10.1016/j.matdes.2026.115622","DOIUrl":"10.1016/j.matdes.2026.115622","url":null,"abstract":"<div><div>Ethylene–propylene–diene monomer (EPDM) is widely used as an insulation in composite solid propellants. However, the migration of plasticizers from the propellant into the insulation seriously affects the long-term reliability. In this study, graphene oxide (GO)/EPDM insulation were prepared and their anti-migration behavior against typical plasticizers, including dioctyl sebacate (DOS), N-butyl-N-(2-nitroxyethyl) nitramine (Bu-NENA), and nitroethyl nitrate (En), was systematically investigated. The incorporation of GO significantly reduced the migration of plasticizers through nanobarrier mechanism. Migration experiments showed that the overall performance was optimized at a GO content of 3 phr. Compared with pure EPDM, the equilibrium migration amount of DOS decreased to 37.17%, Bu-NENA to 24.69%, and En to 41.86%. Dynamic mechanical analysis confirmed higher storage modulus and lower tan δ, while contact angle tests revealed reduced wettability to plasticizers, both evidencing stronger interfacial interactions and weaker thermodynamic compatibility. SEM and XRD demonstrated that GO nanosheets were well dispersed, constructing tortuous diffusion pathways. Molecular dynamics simulations (MD simulations) further verified the mechanism, showing that the diffusion coefficient of DOS decreased by ∼ 32% in GO/EPDM, and binding energy analysis indicated reduced compatibility between plasticizers and the GO/EPDM. This research provide a practical route for designing high-performance anti-migration insulation.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115622"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146186065","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials & DesignPub Date : 2026-03-01Epub Date: 2026-02-12DOI: 10.1016/j.matdes.2026.115659
Siying Xiang , Yi Luo , Jiebin Wen , Minzhe Peng , Guangxian Li , Yajiang Huang
{"title":"Bio-based polyamide 1012 powder with strengthened hydrogen bonding interactions for sustainable laser additive manufacturing","authors":"Siying Xiang , Yi Luo , Jiebin Wen , Minzhe Peng , Guangxian Li , Yajiang Huang","doi":"10.1016/j.matdes.2026.115659","DOIUrl":"10.1016/j.matdes.2026.115659","url":null,"abstract":"<div><div>Bio-based polyamide powders, such as polyamide 1012 (PA1012), are promising materials for sustainable laser additive manufacturing (AM) technologies. However, they generally exhibit poor processability and high moisture sensitivity. Herein, we demonstrate that the AM behavior and water resistance of PA1012 could be enhanced by regulating intermolecular hydrogen bonding interactions. Stronger hydrogen bonds formed in PA1012 powders upon incorporating a thermoplastic phenolic resin (PF), leading to broader processing windows and lower melt viscosities, allowing the fabrication of parts with fewer defects and superior mechanical performance. Incorporating 5–15 wt% PF reduced the water absorption of PA1012 parts by 54–57 %, thereby largely improving their mechanical and dimensional stabilities in humid conditions. Moreover, PF suppressed the post-condensation and deterioration of unfused powders. Therefore, strengthening the hydrogen bonding interactions in polyamide powder offers a simple strategy to enhance the part performance in humid conditions and promote the sustainability of laser additive manufacturing.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115659"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185814","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials & DesignPub Date : 2026-03-01Epub Date: 2026-01-28DOI: 10.1016/j.matdes.2026.115550
Yang Yang , Rui Ma , Chen Peng , Haoning Dong , Jingyi Zhao , Hualong Fu , Meiying Su , Qidong Wang , Liqiang Cao
{"title":"Temperature and humidity effects on moisture diffusion in epoxy molding compound based on Fickian, dual-stage and Langmuir models","authors":"Yang Yang , Rui Ma , Chen Peng , Haoning Dong , Jingyi Zhao , Hualong Fu , Meiying Su , Qidong Wang , Liqiang Cao","doi":"10.1016/j.matdes.2026.115550","DOIUrl":"10.1016/j.matdes.2026.115550","url":null,"abstract":"<div><div>Epoxy molding compound (EMC) is a critical material in advanced packaging, as its moisture diffusion behavior significantly impacts the long-term reliability of packaged devices. The moisture diffusion behavior of EMC was investigated under varying temperature and humidity conditions through moisture absorption experiments, and the corresponding diffusion mechanisms were analyzed using the Fickian, dual-stage, and Langmuir models. The results showed that the Fickian model was only applicable under low humidity and temperature conditions. Although the dual-stage model fit well, its assumption of “independent diffusion of bound water” contradicted experimental observations. The Langmuir model also achieved high fitting accuracy. This study also established temperature–humidity-dependent functions for EMC moisture-related parameters. As the temperature increased, the bound water content increased exponentially, along with the transformation probability of free-bound water and the diffusion coefficient. Under medium humidity, the moisture content increased linearly with humidity, while the transformation probability and diffusion coefficient decreased linearly. At high humidity, capillary condensation became the dominant process, leading to a sharp increase in saturated moisture content, diffusion coefficient, and conversion probability. Low-temperature liquid-nitrogen adsorption experiments confirmed the occurrence of capillary condensation.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115550"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185889","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials & DesignPub Date : 2026-03-01Epub Date: 2026-02-03DOI: 10.1016/j.matdes.2026.115606
Xue Zhang , Shengbin Cao , Xiaosong Liu , Tianchan Jia , Kai Dong
{"title":"Graphene/MXene modified polyurethane flexible nanomembrane for dual-functional pressure-temperature sensing","authors":"Xue Zhang , Shengbin Cao , Xiaosong Liu , Tianchan Jia , Kai Dong","doi":"10.1016/j.matdes.2026.115606","DOIUrl":"10.1016/j.matdes.2026.115606","url":null,"abstract":"<div><div>Flexible sensors have shown significant potential for applications in smart wearable devices, electronic skin, and health monitoring. However, developing high-performance sensors with a wide sensing range and high sensitivity using simple and cost-effective fabrication methods remains a challenge. Unlike traditional single-function sensors that can only detect strain, a flexible wearable pressure–temperature dual-functional sensor based on an electrospun nanofiber platform was developed in this study. A resistive pressure sensor was fabricated by spraying a graphene/MXene composite solution onto polyurethane (PU) nanofibers film. Additionally, a resistive temperature sensor was also coupled onto the pressure sensor by combining graphene/MXene with poly(3,4-ethylenedioxythiophene):poly (styrenesulfonate) (PEDOT:PSS), forming a dual-functional sensor. The fabricated sensors exhibit ultra-high sensitivity (GF ≈ 1200), fast response times (110 ms), high durability, and stable performance without degradation even after up to 5,000 cycles of motion. This dual-functional sensor can achieve precise temperature detection with a resolution of 1 °C. In practical applications, the sensor can be comfortably worn on the wrist, enabling real-time monitoring of subtle strain changes such as pulse beats and large strain variations like finger bending, as well as temperature fluctuations such as body temperature.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115606"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146186003","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials & DesignPub Date : 2026-03-01Epub Date: 2026-02-07DOI: 10.1016/j.matdes.2026.115629
Salvatore Del Basso , Pietro Squeri , Rishit Mohan Ahuja , Rishav Karki , Giuseppe De Giorgio , Vardan Galstyan , Raffaele Martucci Zecca , Enrico Dalcanale , Xiongchuan Huang , Davide Vurro , Saksham Sharma , Pasquale D’Angelo , Andrew Adamatzky , Giuseppe Tarabella
{"title":"On the origin of spontaneous electrical oscillations in a minimal peptide assembly","authors":"Salvatore Del Basso , Pietro Squeri , Rishit Mohan Ahuja , Rishav Karki , Giuseppe De Giorgio , Vardan Galstyan , Raffaele Martucci Zecca , Enrico Dalcanale , Xiongchuan Huang , Davide Vurro , Saksham Sharma , Pasquale D’Angelo , Andrew Adamatzky , Giuseppe Tarabella","doi":"10.1016/j.matdes.2026.115629","DOIUrl":"10.1016/j.matdes.2026.115629","url":null,"abstract":"<div><div>The design of functional materials involves understanding how complex functionalities can emerge from simple material building blocks. In this context, peptide-based systems represent a versatile materials platform due to their chemical diversity, tunability and compatibility with sustainable processing routes. However, the conditions under which electrical functionality can emerge in minimal, abiotic peptide assemblies remain poorly understood. Here, we report the design and characterization of a minimal peptide-based material obtained through abiotic thermal polymerization, exhibiting spontaneous and persistent electrical oscillations under constant environmental conditions. The material is formed by the thermal condensation of four amino acids (Asp, Glu, Arg, Leu), resulting in a chemically heterogeneous ensemble of short oligomeric peptides. A comprehensive materials characterization combining DOSY NMR, HPLC-MS, FTIR, DLS, SEM, and qualitative Biuret assays reveals a disordered, proteinoid-like assembly with dynamic aggregation–disaggregation behaviour and strong coupling to ionic transport in the surrounding medium. Electrical measurements demonstrate autonomous oscillatory signals arising under constant environmental conditions and in the absence of external stimulation. Simultaneous dynamic light scattering and electrical measurements reveal a direct correlation between electrical oscillations and aggregation–disaggregation dynamics, indicating that the electrical activity emerges as a collective property of chemically heterogeneous peptide ensembles rather than from individual molecular species. These results provide experimentally grounded insight relevant to the design of peptide-based functional materials, highlighting minimal peptide assemblies as a promising platform for adaptive sensing, bio-inspired interfaces, and unconventional computing applications.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115629"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146186082","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials & DesignPub Date : 2026-03-01Epub Date: 2026-02-03DOI: 10.1016/j.matdes.2026.115611
Miaomiao Gou , Xuancheng Fu , Gang Song , Chang Liu , Yong Zhang , Fengting Lv , Guanghai Dai
{"title":"Conjugated polymer nanoparticles (CPNs)-based optogenetic platform reprogramming the tumor microenvironment of MSS colorectal cancer","authors":"Miaomiao Gou , Xuancheng Fu , Gang Song , Chang Liu , Yong Zhang , Fengting Lv , Guanghai Dai","doi":"10.1016/j.matdes.2026.115611","DOIUrl":"10.1016/j.matdes.2026.115611","url":null,"abstract":"<div><div>Microsatellite-stable (MSS) tumors, characterized by an immune-desert tumor microenvironment (TME), are notoriously resistant to systemic immunotherapies. Herein, near-infrared (NIR)-responsive nanoplatform based on donor–acceptor structured conjugated polymer nanoparticles (CPNs) coupled with a heat shock protein 70 (HSP70)-driven plasmid co-encoding IFN-γ, IL-2, and EGFP was developed to reprogramme the TME. CPN-mediated photothermal heating induces localized plasmid transcription, enabling paracrine release of IFN-γ and IL-2. These cytokines are predicted to drive macrophage repolarization toward an M1-like phenotype and enhance T cell proliferation via JAK–STAT signaling, thereby converting immunologically “cold” MSS tumors into “hot” lesions amenable to immune attack. This strategy offers a spatially controlled approach to bypass systemic toxicity while potentiating antitumor immunity.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115611"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185709","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Materials & DesignPub Date : 2026-03-01Epub Date: 2026-02-04DOI: 10.1016/j.matdes.2026.115607
Yongliu Yu , Jin Leng , Liang-Hui Du , Zhao-Hui Zhai , Peng Chen , Yuxi Liu , Liying Chen , Li-Guo Zhu , Qiwu Shi
{"title":"Pd-free activation for low-loss silver-coated polymer waveguides in millimeter-wave transmission","authors":"Yongliu Yu , Jin Leng , Liang-Hui Du , Zhao-Hui Zhai , Peng Chen , Yuxi Liu , Liying Chen , Li-Guo Zhu , Qiwu Shi","doi":"10.1016/j.matdes.2026.115607","DOIUrl":"10.1016/j.matdes.2026.115607","url":null,"abstract":"<div><div>Waveguides are crucial components for enabling stable signal links in rapidly developing millimeter-wave and terahertz applications. Among various configurations, metal-coated polymeric hollow waveguides offer a compelling combination of low transmission loss, lightweight flexibility, and cost-effectiveness, yet their reliable fabrication remains challenging. The conventional approaches, which typically rely on palladium-based activation to achieve metal-polymer adhesion, suffer from high cost, limited scalability, and environmental concerns. This work proposes a disruptive Pd-free surface modification strategy using a silane coupling agent to address the intrinsic adhesion issue between polycarbonate substrates and silver coatings. The introduced aminosilane layer forms chemical bonds onto the inner surface of a polymer hollow tube, enabling the further growth of silver layer. Through systematic parameter optimization, we fabricated polymer hollow-core waveguide with a silver-plated inner surface, achieving lengths of up to 4 m and a transmission loss as low as 0.73 dB/m at 220 GHz—a value approaching the theoretical limit. Furthermore, we demonstrated a prototype automotive millimeter-wave radar system incorporating the fabricated waveguide for ranging applications. This work establishes a scalable, low-cost, and efficient pathway to high-performance hollow waveguides, suitable for advanced millimeter-wave and terahertz systems in communications, data center interconnects, sensing, and beyond.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"263 ","pages":"Article 115607"},"PeriodicalIF":7.9,"publicationDate":"2026-03-01","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"146185730","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}