Opportunities and Challenges of 3D Printing for Directional Liquid Transportation

LIU Yanming, CHEN Yang, MA Yali, LIU Weiwei, CHEN Qiang, LEI Baimao

Surface Technology ›› 2025, Vol. 54 ›› Issue (21) : 1-22.

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Surface Technology ›› 2025, Vol. 54 ›› Issue (21) : 1-22. DOI: 10.16490/j.cnki.issn.1001-3660.2025.21.001
Special Topic—Design and Applications of Hierarchical Surface Structure Exhibiting Superwettability

Opportunities and Challenges of 3D Printing for Directional Liquid Transportation

  • LIU Yanming1,2, CHEN Yang3, MA Yali1,2, LIU Weiwei1,2,*, CHEN Qiang4,5, LEI Baimao4,5
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Abstract

Directional liquid transport has become a vibrant and strategically relevant research area owing to its broad impact on precision drug delivery, high-efficiency fog harvesting, thermal management and energy conversion, microfluidic manipulation, and environmental remediation. The central objective is to steer liquids in a deterministic fashion by encoding spatial gradients of surface energy and curvature into engineered chemistries and multiscale textures, thereby harnessing capillarity, Laplace-pressure differentials, and controlled wetting hysteresis. Within this landscape, three-dimensional (3D) printing, i.e., additive manufacturing, has emerged as an enabling platform for constructing biomimetic structures and surfaces that support directional liquid motion. Its distinguishing advantages include materials versatility, architectural freedom, seamless multi-material integration, and low structural mass, collectively allowing the realization of liquid-handling architectures that are difficult, if not impossible, to obtain via conventional fabrication. This review first delineates the mechanistic foundations that govern directional transport, encompassing classical Young-Wenzel-Cassie-Baxter descriptions of wetting, capillary pumping in graded channels, chemical and geometric wettability gradients, Janus and asymmetric ridge/groove designs, ratcheted topographies, and bioinspired motifs (e.g., cactus spines, Nepenthes peristomes). Guided by these principles, it analyzes four mainstream 3D-printing modalities, namely material jetting, extrusion-based printing, powder-bed fusion, and photopolymerization, through the lens of directional liquid transport. For each modality, it summarizes the accessible material sets (polymers, elastomers, hydrogels, particle-reinforced composites, metals, and ceramics); attainable resolution, surface finish, and hierarchical fidelity; throughput and scalability; and the capability to encode multi-material or spatially graded properties that strengthen capillary anisotropy. Post-processing routes, such as plasma activation, laser texturing, surface grafting, and vapor-phase functionalization, are also highlighted for refining surface energy and roughness while preserving structural integrity. Despite rapid advances, key bottlenecks remain. Resolution-throughput trade-offs limit routine patterning of sub-micrometer features needed to maximize curvature-driven pressure gradients. The palette of printable chemistries can constrain wetting tunability and chemical durability. In addition, long-term robustness is challenged by fouling, abrasion, and environmental aging. Equally important, performance assessment lacks standardization. Beyond static or advancing/receding contact angles, it argues for a metrics suite that includes initiation threshold, steady-state transport velocity, run-out distance under tilt, flux under humidity or temperature gradients, and cycling stability under contaminants or mechanical insult. These benchmarks can improve comparability across studies and accelerate translation from proof-of-concept demonstrations to robust devices. Looking forward, several directions appear especially promising: (i) multi-material and gradient printing to co-design chemistry and geometry; (ii) architected lattices and capillary metamaterials that amplify Laplace-pressure gradients while maintaining mechanical integrity; (iii) stimuli-responsive and reconfigurable surfaces for on-demand routing and spatiotemporal control; (iv) inverse design and topology optimization informed by phase-field or volume-of-fluid simulations; (v) data-driven surrogates and machine-learning frameworks for rapid exploration of large design spaces; and (vi) hybrid manufacturing that couples additive processes with sub-micron lithography or ultrafast laser texturing. Overall, this review underscores the "material-structure-function" integration paradigm enabled by 3D printing and offers a coherent roadmap for the intelligent, durable, and high-performance fabrication of directional liquid-transport structures and surfaces. The synthesis presented in this work is intended to guide the selection of printing modalities and design strategies for application-specific requirements, and to catalyze cross-disciplinary progress at the interface of surface science, bioinspired design, and advanced manufacturing.

Key words

3D printing / directional liquid transport / bionic functional structures/surfaces / customizability / gradient design

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LIU Yanming, CHEN Yang, MA Yali, LIU Weiwei, CHEN Qiang, LEI Baimao. Opportunities and Challenges of 3D Printing for Directional Liquid Transportation[J]. Surface Technology. 2025, 54(21): 1-22 https://doi.org/10.16490/j.cnki.issn.1001-3660.2025.21.001

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Funding

National Natural Science Foundation of China (52175455); Liaoning Natural Science Foundation (2023-MSBA-006); Central Universities' Fundamental Research Funds for Disciplines (DUT24MS006)
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