{"title":"Quantifying single-cell biomechanics: a comparative analysis of experimental methods and theoretical models","authors":"Dipta Saha, Raisa Akhtaruzzaman, Sumaya Sharmin, Hyejin Moon, Ashfaq Adnan","doi":"10.1186/s40486-026-00272-6","DOIUrl":"10.1186/s40486-026-00272-6","url":null,"abstract":"<div><p>This review presents a comprehensive overview of methodologies employed to measure and quantify the biomechanical properties of single cells, focusing on techniques that provide insights into cellular deformation and force response. Understanding cell mechanics is crucial for advancing our knowledge of cellular behavior, disease progression, and therapeutic innovation in contexts such as cancer metastasis, tissue engineering, and regenerative medicine. We critically examine five primary experimental platforms: atomic force microscopy (AFM), dielectrophoresis (DEP), optical tweezers, micropipette aspiration, and hydrodynamic-induced deformation. For each method, we detail the underlying theoretical frameworks, experimental configurations, advantages, limitations, and application scope. Contact-based techniques (AFM, micropipette aspiration) provide high-resolution measurements of localized stiffness and viscoelasticity, while non-contact approaches (DEP, hydrodynamic stretching, optical tweezers) enable high-throughput analysis with minimal physical disruption. Furthermore, we evaluate the mechanical models used to extract biomechanical parameters and highlight modern data extraction processes, including automated image analysis. Crucially, this review addresses the significant discrepancies in measured properties that arise across different methods due to varying loading rates, boundary conditions, and model assumptions. By synthesizing these experimental and theoretical considerations, this review aims to guide the standardization and refinement of single-cell biomechanics for both fundamental research and translational biomedical applications.</p></div>","PeriodicalId":704,"journal":{"name":"Micro and Nano Systems Letters","volume":"14 1","pages":""},"PeriodicalIF":8.0,"publicationDate":"2026-10-17","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40486-026-00272-6.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149189597","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Hyeokjun Kwon, Chanseok Lee, Jihwan Park, Hyunki Son, Eunhwan Jo
{"title":"A self-powered wind speed and humidity sensor based on paired flap-type triboelectric nanogenerators with differential humidity responses","authors":"Hyeokjun Kwon, Chanseok Lee, Jihwan Park, Hyunki Son, Eunhwan Jo","doi":"10.1186/s40486-026-00268-2","DOIUrl":"10.1186/s40486-026-00268-2","url":null,"abstract":"<div><p>This study reports a self-powered sensor that simultaneously measures wind speed and relative humidity using two triboelectric nanogenerators. The output of conventional triboelectric nanogenerators decreases with increasing ambient humidity. In previous wind sensors, this dependence has been treated as an error to be eliminated. Herein, we used the humidity dependence as a measurement signal. One device used a spin-coated polyvinyl alcohol–lithium chloride film, whose output proved far less sensitive to humidity; this behavior is consistent with reported spectroscopic evidence that lithium chloride retains the absorbed water within the film matrix rather than as a free surface layer. The other used a commercial nylon film, whose output steadily decreases with increasing humidity. Each film forms the fixed bottom layer of a device, with an identical polyethylene terephthalate film fluttering above it in the wind, making the bottom material the only material difference between the two devices. Therefore, both outputs vary with wind speed but exhibit markedly different responses to humidity, enabling wind speed and relative humidity to be determined from the paired signals over 3–5 m/s and 40–70% RH. A separately powered readout system based on a commercial microcontroller output both quantities in real time, and the values agreed with those from a commercial anemometer and hygrometer placed at the wind-tunnel outlet.</p></div>","PeriodicalId":704,"journal":{"name":"Micro and Nano Systems Letters","volume":"14 1","pages":""},"PeriodicalIF":8.0,"publicationDate":"2026-10-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40486-026-00268-2.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149189044","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
HyungDal Park, Byeungleul Lee, Wonsuk Choi, Seonho Seok, Seonghwan Oh, Jinseok Kim
{"title":"Enhanced mechanical and electrical performance of Ti/Au microelectrode arrays using a pre-cured polyimide substrate","authors":"HyungDal Park, Byeungleul Lee, Wonsuk Choi, Seonho Seok, Seonghwan Oh, Jinseok Kim","doi":"10.1186/s40486-026-00266-4","DOIUrl":"10.1186/s40486-026-00266-4","url":null,"abstract":"<div><p>This paper presents an approach for fabricating flexible neural electrodes with improved adhesion and low impedance through optimization of the PSPI curing process. The fabrication involves a two-step process in which thin-film metallization is performed on a partially cured photosensitive polyimide (PSPI) substrate, followed by a final curing process after metal electrode patterning. The effects of the PSPI curing condition on the adhesion and electrical characteristics of the Ti/Au thin-film electrodes were systematically investigated. The enhanced metal adhesion was quantitatively evaluated using a tape test, while the electrical characteristics were characterized through electrochemical impedance and phase measurements after complete curing of the polymer substrate. The flexible neural electrodes fabricated using the proposed process exhibited an impedance of 9.96 kΩ at 1 kHz, compared with 36.24 kΩ for electrodes fabricated using the conventional fully cured PSPI process. These results demonstrate that controlling the PSPI curing condition during electrode fabrication can improve metal–polymer adhesion while maintaining favorable electrical characteristics.</p></div>","PeriodicalId":704,"journal":{"name":"Micro and Nano Systems Letters","volume":"14 1","pages":""},"PeriodicalIF":8.0,"publicationDate":"2026-10-03","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40486-026-00266-4.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149132129","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Girish Shankar Mishra, N. Mohankumar, Amit Bhattacharyya, Himadri Sekhar Das, R. Meenakshi, Sanivarapu Prasanth Vaidya, Nitin Rakesh
{"title":"Effect of sensitivity on the performance of dielectric–modulated asymmetrical AlGaN/GaN/InGaN/GaN MOSHEMTs for precise biosensing applications","authors":"Girish Shankar Mishra, N. Mohankumar, Amit Bhattacharyya, Himadri Sekhar Das, R. Meenakshi, Sanivarapu Prasanth Vaidya, Nitin Rakesh","doi":"10.1186/s40486-026-00264-6","DOIUrl":"10.1186/s40486-026-00264-6","url":null,"abstract":"<div><p>This paper investigates a simulation based AlGaN/GaN/InGaN/GaN asymmetrical Metal Oxide Semiconductor High Electron Mobility Transistor (MOSHEMT) architecture that detects neutral biomolecules, including Zein, APTES, ChOx, Protein, Glucose, and Uricase. The device uses high-k (Al<sub>2</sub>O<sub>3</sub>) dielectric material for simulation, offering superior electrical insulation, stable chemical properties, high surface site density (8 × 10<sup>14</sup> /cm²), and reduced Fermi pinning. The influence of the source-to-gate (L<sub>SG</sub>) and gate-to-drain (L<sub>GD</sub>) lengths on the performance of the proposed architecture is systematically evaluated in the presence of different biomolecules. Additionally, the reduction of short-channel effects, such as punch through and threshold voltage roll-off, improves scalability in advanced technologies. A 3-nm-thick In<sub>0.1</sub>Ga<sub>0.9</sub>N notch layer is incorporated into the proposed device, forming an additional potential barrier between the primary AlGaN/GaN 2DEG channel and the GaN buffer. The polarization-induced conduction-band discontinuity further results in the formation of a shallow secondary potential well at the InGaN/GaN interface, where limited carrier accumulation gives rise to a secondary conduction channel. In conjunction with the primary 2DEG, this dual-channel carrier confinement enhances electron mobility, reduces buffer leakage, and consequently improves the overall biosensing performance. The simulation analysis demonstrates an increase in drain current (I<sub>DS</sub>) to 5.026 A/mm and a threshold voltage (V<sub>th</sub>) of − 4.466 V for the neutral biomolecule Uricase (<i>k</i> = 1.5) when L<sub>GD</sub> = 0.75 μm, compared with L<sub>GD</sub> = 0.5 μm and L<sub>GD</sub> = 0.25 μm at V<sub>GS</sub> = 2 V and V<sub>DS</sub> = 1 V. Similarly, the transconductance (g<sub>m</sub>) and output conductance (g<sub>d</sub>) when <i>k</i> = 1.5 in the cavity are 2.4 S/mm and 27mS/mm for L<sub>GD</sub> = 0.75 μm compared with the different L<sub>GD</sub> counterparts. The AlGaN/GaN/InGaN/GaN dielectric-modulated MOSHEMTs show excellent sensitivity, making them suitable for advanced biological applications.</p></div>","PeriodicalId":704,"journal":{"name":"Micro and Nano Systems Letters","volume":"14 1","pages":""},"PeriodicalIF":8.0,"publicationDate":"2026-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40486-026-00264-6.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149133238","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Mahsa Rastegar Pour, Dongjoon Lee, Raneen Qasim, Nadezhda Korostyleva, Donghoon Yoon, Albert Kim, Jungkwun Kim
{"title":"Self-actuated, pH-responsive hydrogel-driven microneedle actuator (pH-MA) patch for smart depth-controlled wound interface","authors":"Mahsa Rastegar Pour, Dongjoon Lee, Raneen Qasim, Nadezhda Korostyleva, Donghoon Yoon, Albert Kim, Jungkwun Kim","doi":"10.1186/s40486-026-00265-5","DOIUrl":"10.1186/s40486-026-00265-5","url":null,"abstract":"<div><p>Chronic wounds are frequently associated with bacterial infection, elevated alkalinity, and persistent inflammation that collectively impair the normal healing process. Yet current wound care devices are passive and cannot actively respond to critical biochemical cues in real time. To address this limitation, we present a self-actuated, pH-responsive, hydrogel-driven microneedle actuator (pH-MA) that adaptively modulates its insertion depth in response to the local wound environment, enabling autonomous and site-specific control of microneedle–tissue engagement. The pH-MA system consists of a microneedle array supported by a pH-sensitive chemomechanical acrylamide-based hydrogel layer underneath. In an alkaline environment, the hydrogel swells and mechanically advances the microneedles to achieve deeper penetration into the wound bed, whereas in acidic conditions, i.e., in an acute wound, the hydrogel shrinks and retracts the microneedles. Experimental results show that the pH-MA produces microneedle expansion of up to 148 μm and contraction of up to 191 μm from the baseline during multi-cycle actuation. The force during insertion reaches up to 260 mN, exceeding the reported skin insertion threshold by more than threefold. In vivo testing using an LAC-infected murine wound model further demonstrated the feasibility of patch application and microneedle–tissue engagement. This pH-MA platform demonstrates compelling potential as a smart wound interface capable of adaptive, depth-controlled microneedle actuation.</p></div>","PeriodicalId":704,"journal":{"name":"Micro and Nano Systems Letters","volume":"14 1","pages":""},"PeriodicalIF":8.0,"publicationDate":"2026-09-28","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40486-026-00265-5.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"149133239","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Chan Hwa Hong, Sae Rom Seo, Min-Seok Kim, Young Kyu Hong, Min Hyung Kang, Hye Jin Kim
{"title":"Highly stretchable multimodal sensor with split-line structural design for adaptive robotic grippers","authors":"Chan Hwa Hong, Sae Rom Seo, Min-Seok Kim, Young Kyu Hong, Min Hyung Kang, Hye Jin Kim","doi":"10.1186/s40486-026-00263-7","DOIUrl":"10.1186/s40486-026-00263-7","url":null,"abstract":"<div><p>A large-area multimodal sensor device integrating pressure, temperature, humidity, proximity, and bending sensors was developed on a stretchable and flexible substrate. The substrate combines rigid polyimide with a soft elastomer to enhance stretchability, achieving up to 127% elongation through split-line structural designs that effectively relieve stress concentration. After 1,000 stretch-release cycles at 30% strain, resistance variation remained below 0.48%, confirming excellent mechanical durability. The pressure sensors exhibited high sensitivities of 27.5 kPa⁻¹ (8-channel array) and 9.2 kPa⁻¹ (18-channel array) across a wide pressure range, demonstrating suitability for robotic gripper applications. The central sensing units accurately measured bending (R² = 0.998), environmental parameters, and object distance with verified functionality. Overall, the device exhibits robust, reliable, and highly stretchable multimodal sensing performance, offering strong potential for advanced robotic manipulation and environmental monitoring applications.</p><h3>Graphical Abstract</h3><div><figure><div><div><picture><source><img></source></picture></div></div></figure></div></div>","PeriodicalId":704,"journal":{"name":"Micro and Nano Systems Letters","volume":"14 1","pages":""},"PeriodicalIF":8.0,"publicationDate":"2026-07-27","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40486-026-00263-7.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148614130","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Geonho Choi, Donghyun Lee, Minyoung Kim, Jungwook Choi
{"title":"Machine learning-assisted design acceleration framework for energy absorbing re-entrant honeycomb auxetic structures","authors":"Geonho Choi, Donghyun Lee, Minyoung Kim, Jungwook Choi","doi":"10.1186/s40486-026-00262-8","DOIUrl":"10.1186/s40486-026-00262-8","url":null,"abstract":"<div><p>The demand for lightweight energy-absorbing structures has rapidly increased. Auxetic structures, such as re-entrant honeycombs, exhibit negative Poisson’s ratio behavior and high impact stability; however, their compressive response is highly nonlinear and sensitive to geometric parameters, making them computationally expensive and design inefficient. In this study, we present an end-to-end machine learning design acceleration framework for a quasi-2D re-entrant honeycomb that integrates PyAnsys Geometry and PyMechanical. The proposed framework employs automated geometry generation and finite element analysis (FEA) to build a dataset (<i>n</i> = 40) for interpretable surrogate modeling and covariance matrix adaptation evolution strategy optimization. Experimental validation was conducted using printed digital light processing specimens. An ensemble surrogate model (combining polynomial regression and gradient boosting regression) achieved the best 5-fold cross-validated performance (R² = 0.729). Surrogate-based optimization yielded an optimal design that increased energy absorption density (EAD) in refined-mesh FEA by 63.6% relative to a baseline design (EAD: 90.015 to 147.304 kJ/m³). Also, compression tests confirm enhance in pre-fracture energy absorption. Evaluated under a strain limit of ε = 0.15 (due to premature fracture of the optimized specimen), EAD increased by 83.96% relative to a baseline design (EAD: 37.96 to 69.83 kJ/m³). The proposed framework provides a validated method for accelerating the optimization of porous structures under nonlinear responses.</p></div>","PeriodicalId":704,"journal":{"name":"Micro and Nano Systems Letters","volume":"14 1","pages":""},"PeriodicalIF":8.0,"publicationDate":"2026-07-14","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40486-026-00262-8.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148465808","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
Trong Dang Huu, Truong Thi Kim Tuoi, Ravi Pratap Singh, Ngoc Dang Khoa Tran, Vien Quoc Nguyen, Thach Hong Pham, Julfekar Arab, Gaurav Kumar, Khairul Fadzli Samat, Jun Hieng Kiat, Nguyen Van Toan, Takahito Ono
{"title":"Microengineering glass substrates: techniques and applications","authors":"Trong Dang Huu, Truong Thi Kim Tuoi, Ravi Pratap Singh, Ngoc Dang Khoa Tran, Vien Quoc Nguyen, Thach Hong Pham, Julfekar Arab, Gaurav Kumar, Khairul Fadzli Samat, Jun Hieng Kiat, Nguyen Van Toan, Takahito Ono","doi":"10.1186/s40486-026-00261-9","DOIUrl":"10.1186/s40486-026-00261-9","url":null,"abstract":"<div><p>The rapid advancement of Micro-Electro-Mechanical Systems (MEMS) and microfluidic technologies has established glass as an indispensable substrate material, effectively overcoming the limitations of traditional silicon in applications requiring high optical transparency, chemical inertness, and superior electrical insulation. However, the amorphous network structure and inherent brittleness of glass pose significant barriers to the high-precision fabrication of deep microstructures. This review provides a systematic and rigorous overview of contemporary subtractive microengineering techniques. Fabrication methods are systematically categorized into five primary groups: mechanical (micro-grinding, sandblasting, and ultrasonic machining), thermal (reflow, microwave, and laser ablation), chemical/electrochemical (wet etching and electrochemical discharge machining), plasma-based (Reactive Ion Etching), and hybrid strategies such as Laser and Ultrasonic Assisted Electrochemical Discharge Machining. We analyze the critical relationships between material properties and removal mechanisms, emphasizing the brittle-to-ductile transition in mechanical machining and the pivotal role of gas film stabilization in discharge-based processes. Through representative demonstrations of chip-level hermetic packaging, through-glass via (TGV) arrays, and high-resolution bio-analytical platforms, this paper highlights the transformative role of microengineered glass in enhancing device performance and reliability. Finally, the core challenges regarding precision-throughput-cost trade-offs and emerging trends are discussed to provide a foundational roadmap for next-generation glass-based microsystems. This review offers a comprehensive framework for navigating the selection and innovation of glass materials and fabrication strategies, ensuring application-oriented precision and throughput for advanced MEMS and microfluidic platforms.</p></div>","PeriodicalId":704,"journal":{"name":"Micro and Nano Systems Letters","volume":"14 1","pages":""},"PeriodicalIF":8.0,"publicationDate":"2026-07-07","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40486-026-00261-9.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148465551","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Immobilized microalgae-driven triboelectric nanogenerators for sustainable bioelectricity production","authors":"Kushal Ruthvik Kaja, Chalampol Janpum, Tanakit Komkhum, Sugato Hajra, Venkateswaran Vivekananthan, Naratip Vittayakorn, Kamon Thinsurat, Chawalit Ngamcharussrivichai, Hoe Joon Kim, Pichaya In-na","doi":"10.1186/s40486-026-00259-3","DOIUrl":"10.1186/s40486-026-00259-3","url":null,"abstract":"<div><p>Triboelectric nanogenerators (TENG) are emerging as promising solutions for decentralised energy generation due to the growing need for sustainable power sources. These devices convert wasted mechanical energy into electricity under ambient conditions, offering advantages such as eco-friendly operation, material versatility, and effective energy scavenging. Despite these benefits, their relatively low electrical output compared to conventional sources like batteries and fuel cells remains a limitation. Microalgae have attracted attention for their ability to produce bioelectricity through photosynthesis and respiration while simultaneously capturing carbon dioxide. Immobilising microalgal cells on conductive substrates improves electron transfer and metabolic activity. In this context, living <i>Chlorella vulgaris</i> TISTR 8580 with varied cell densities was immobilised on aluminium electrodes and incorporated into a TENG platform to explore energy harvesting from solid-solid and solid-liquid interactions. The highest output of 110 V and 330 nA was generated, confirming the microalgae as a promising tribolayer and extending the conventional triboelectric series. However, sustaining cell viability over extended periods remains a challenge, highlighting the need for optimised light and nutrient conditions in future developments.</p></div>","PeriodicalId":704,"journal":{"name":"Micro and Nano Systems Letters","volume":"14 1","pages":""},"PeriodicalIF":8.0,"publicationDate":"2026-07-02","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40486-026-00259-3.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148380236","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
{"title":"Homogeneous solidification strategy for freeze-casting-assisted direct ink writing investigated by computational fluid dynamics modeling","authors":"Younghoon Son, Gyeongwan Lee, Jungwook Choi","doi":"10.1186/s40486-026-00260-w","DOIUrl":"10.1186/s40486-026-00260-w","url":null,"abstract":"<div><p>Freeze-casting-assisted direct ink writing (DIW) enables the fabrication of three-dimensional (3D) aerogel architectures with improved geometric versatility. However, multilayer deposition often produces inter-layer microstructural nonuniformity because the pre-frozen underlying layers introduce additional thermal resistance. To address this challenge, we investigated a homogeneous solidification strategy using a computational fluid dynamics (CFD) model. The framework incorporates a moving substrate boundary condition, constant-temperature thermal boundary, and interface tracking, while the nanocomposite ink properties are explicitly modeled as functions of temperature and shear rate. Using the CFD results and a custom digital image-processing algorithm, the freezing time required for the extruded filaments to fully solidify on a cold substrate is quantified. Based on the extracted freezing-time data, we determined the substrate-temperature pairs that yield identical freezing times across sequential layers. The resulting process map provides practical guidelines for mitigating layer-to-layer thermal variations and enables the reliable printing of aerogels with uniform inter-layer microstructures.</p></div>","PeriodicalId":704,"journal":{"name":"Micro and Nano Systems Letters","volume":"14 1","pages":""},"PeriodicalIF":4.0,"publicationDate":"2026-06-12","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"https://link.springer.com/content/pdf/10.1186/s40486-026-00260-w.pdf","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"148237121","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"OA","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}