Current ceramic solid-state electrolyte (SSE) films have low ionic conductivities (10-8 to 10-5 S/cm ), attributed to the amorphous structure or volatile Li loss. Herein, we report a solution-based printing process followed by rapid (~3 s) high-temperature (~1500°C) reactive sintering for the fabrication of high-performance ceramic SSE films. The SSEs exhibit a dense, uniform structure and a superior ionic conductivity of up to 1 mS/cm. Furthermore, the fabrication time from precursor to final product is typically ~5 min, 10 to 100 times faster than conventional SSE syntheses. This printing and rapid sintering process also allows the layer-by-layer fabrication of multilayer structures without cross-contamination. As a proof of concept, we demonstrate a printed solid-state battery with conformal interfaces and excellent cycling stability. Our technique can be readily extended to other thin-film SSEs, which open previously unexplores opportunities in developing safe, high-performance solid-state batteries and other thin-film devices.

Nanoparticles (NPs) dispersed within a conductive host are essential for a range of applications including electrochemical energy storage, catalysis, and energetic devices. However, manufacturing high quality NPs in an efficient manner remains a challenge, especially due to agglomeration during assembly processes. Here we report a rapid thermal shock method to in situ synthesize well-dispersed NPs on a conductive fiber matrix using metal precursor salts. The temperature of the carbon nanofibers (CNFs) coated with metal salts was ramped from room temperature to ∼2000 K in 5 ms, which corresponds to a rate of 400,000 K/s. Metal salts decompose rapidly at such high temperatures and nucleate into metallic nanoparticles during the rapid cooling step (cooling rate of ∼100,000 K/s). The high temperature duration plays a critical role in the size and distribution of the nanoparticles: the faster the process is, the smaller the nanoparticles are, and the narrower the size distribution is. We also demonstrated that the peak temperature of thermal shock can reach ∼3000 K, much higher than the decomposition temperature of many salts, which ensures the possibility of synthesizing various types of nanoparticles. This universal, in situ, high temperature thermal shock method offers considerable potential for the bulk synthesis of unagglomerated nanoparticles stabilized within a matrix.

Nanoparticles hosted in conductive matrices are ubiquitous in electrochemical energy storage, catalysis and energetic devices. However, agglomeration and surface oxidation remain as two major challenges towards their ultimate utility, especially for highly reactive materials. Here we report uniformly distributed nanoparticles with diameters around 10 nm can be self-assembled within a reduced graphene oxide matrix in 10 ms. Microsized particles in reduced graphene oxide are Joule heated to high temperature (∼1,700 K) and rapidly quenched to preserve the resultant nano-architecture. A possible formation mechanism is that microsized particles melt under high temperature, are separated by defects in reduced graphene oxide and self-assemble into nanoparticles on cooling. The ultra-fast manufacturing approach can be applied to a wide range of materials, including aluminium, silicon, tin and so on. One unique application of this technique is the stabilization of aluminium nanoparticles in reduced graphene oxide film, which we demonstrate to have excellent performance as a switchable energetic material.

Bimetallics are emerging as important materials that often exhibit distinct chemical properties from monometallics. However, there is limited access to homogeneously alloyed bimetallics because of the thermodynamic immiscibility of the constituent elements. Overcoming the inherent immiscibility in bimetallic systems would create a bimetallic library with unique properties. Here, we present a nonequilibrium synthesis strategy to address the immiscibility challenge in bimetallics. As a proof of concept, we synthesize a broad range of homogeneously alloyed Cu-based bimetallic nanoparticles regardless of the thermodynamic immiscibility. The nonequilibrated bimetallic nanoparticles are further investigated as electrocatalysts for carbon monoxide reduction at commercially relevant current densities (>100 mA cm-2), in which Cu0.9Ni0.1 shows the highest multicarbon product Faradaic efficiency of ~76% with a current density of ~93 mA cm-2. The ability to overcome thermodynamic immiscibility in multimetallic synthesis offers freedom to design and synthesize new functional nanomaterials with desired chemical compositions and catalytic properties.

Reducing human reliance on energy-inefficient cooling methods such as air conditioning would have a large impact on the global energy landscape. By a process of complete delignification and densification of wood, we developed a structural material with a mechanical strength of 404.3 megapascals, more than eight times that of natural wood. The cellulose nanofibers in our engineered material backscatter solar radiation and emit strongly in mid-infrared wavelengths, resulting in continuous subambient cooling during both day and night. We model the potential impact of our cooling wood and find energy savings between 20 and 60%, which is most pronounced in hot and dry climates.

Ceramics are an important class of materials with widespread applications because of their high thermal, mechanical, and chemical stability. Computational predictions based on first principles methods can be a valuable tool in accelerating materials discovery to develop improved ceramics. It is essential to experimentally confirm the material properties of such predictions. However, materials screening rates are limited by the long processing times and the poor compositional control from volatile element loss in conventional ceramic sintering techniques. To overcome these limitations, we developed an ultrafast high-temperature sintering (UHS) process for the fabrication of ceramic materials by radiative heating under an inert atmosphere. We provide several examples of the UHS process to demonstrate its potential utility and applications, including advancements in solid-state electrolytes, multicomponent structures, and high-throughput materials screening.