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At least 127 records · Page 7

All sources NASA NTRS DOE OSTI

DOE OSTI2023

Using mechanistic models and machine learning to design single-color multiplexed nascent chain tracking experiments

mRNA translation is the ubiquitous cellular process of reading messenger-RNA strands into functional proteins. Over the past decade, large strides in microscopy techniques have allowed observation of mRNA translation at a single-molecule resolution for self-consistent time-series measurements in live cells. Dubbed Nascent chain tracking (NCT), these methods have explored many temporal dynamics in mRNA translation uncaptured by other experimental methods such as ribosomal profiling, smFISH, pSILAC, BONCAT, or FUNCAT-PLA. However, NCT is currently restricted to the observation of one or two mRNA species at a time due to limits in the number of resolvable fluorescent tags. In this work, we propose a hybrid computational pipeline, where detailed mechanistic simulations produce realistic NCT videos, and machine learning is used to assess potential experimental designs for their ability to resolve multiple mRNA species using a single fluorescent color for all species. Our simulation results show that with careful application this hybrid design strategy could in principle be used to extend the number of mRNA species that could be watched simultaneously within the same cell. We present a simulated example NCT experiment with seven different mRNA species within the same simulated cell and use our ML labeling to identify these spots with 90% accuracy using only two distinct fluorescent tags. We conclude that the proposed extension to the NCT color palette should allow experimentalists to access a plethora of new experimental design possibilities, especially for cell Signaling applications requiring simultaneous study of multiple mRNAs.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2020

Process Development of the Vaporizing Foil Actuator Welding Technique

The industrial focus on continuous improvement for products is leading design engineers to consider multi-material design concepts more frequently. The design concepts use the advantages of each material while simultaneously minimizing the drawbacks. It also allows for the overall weight of the products to be reduced. Some traditional joining methods, though, struggle to join dissimilar material combinations. A technique known as vaporizing foil actuator welding, which was developed around ten years ago, is a solid-state joining method that has the potential to overcome the barriers to dissimilar material joining. The biggest drawbacks of vaporizing foil actuator welding are that it is still exclusively used in laboratory settings and early in the technology development process. As such, there is not enough confidence in the process for it to be transitioned to manufacturing environments yet. This work begins by analyzing the current state of the technology and identifying a roadmap to achieve a transition to manufacturing. The analysis found that increased confidence in the technology requires sample to sample repeatability to be improved. Beyond that, the process also needs to be fully automated before it can be considered as a viable technique for mass production. In order to further develop the technique, a fully automated work cell was constructed. By removing the human element from the process, this cell helped identify iii the aspects which contribute to process variability. The positioning of the vaporizing foil actuator was identified as the most important factor in process stability. A small set of samples were made in the automated cell with the addition of one component epoxy adhesive around the perimeter of the weld. These samples showed improved process repeatability compared with the samples made without adhesive. This indicates that small amounts of adhesive may be critical in using the process in industrial settings. Additionally, work was performed with manual positioning and adhesive dispensing. This work found that a hybrid joint behaves like traditional weld bonding, where the addition of adhesive makes the joint stronger than if either of the two joining methods were used on their own. To realize this performance with vaporizing foil actuator welding, though, the adhesive needs to be protected from burning during the rapid compression of air during the impact process.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Hybrid Nanostructured Ni(OH) 2 /NiO for High Capacity Lithium–ion Battery Anodes

A straightforward hydrothermal process followed by a controlled calcination technique is introduced for the synthesis of a Ni(OH) 2 modified NiO nanohybrid structure. Conversion materials as Li-ion battery anodes, NiO in this case, suffer from capacity fade and structural/morphological instability during lithiation and delithiation. The novelty of this work is in utilizing this hybrid configuration to increase the specific capacity and enable reversible electrochemistry. Here, we study the lithiation/delithiation process of NiO using a suite of spectroscopy and microscopy techniques from the atomic to electrode scale. We propose a mechanism for a reversible redox couple behavior of the NiO electrode by means of a hybrid Ni(OH)2/NiO structure. The ultimate objective of this work is to guide the development of anode with rationally-designed heterogeneity to create high capacity Li-ion batteries with excellent cycling and rate performance.

25 ENERGY STORAGE↗

DOE OSTI2020

Advanced Modular Sub-Atmospheric Hybrid Heat Engine (Phase 1 Final Report)

The Phase 1 Final Report describes the results of the work completed during the “Advanced Modular Sub-Atmospheric Hybrid Heat Engine” project. The objectives of Phase 1 work were to develop a conceptual design of the turbine-based modular hybrid heat engine (MHHE), including thermodynamic cycle analysis, define the nominal engine component boundary conditions, identify technology gaps, and develop a detailed test plan to address these gaps through bench scale testing in a potential subsequent Phase 2 project. To achieve the project objective, the following activities were performed in Phase 1 work: (1) Market analysis and primary fuel selection, (2) Conceptual design and integrated layout development, (3) Design support and key components characterization, (4) Planning to move technology to pre-commercial demonstration.

42 ENGINEERING↗

DOE OSTI2022

Stabilized photoemission from organic molecules in zero-dimensional hybrid Zn and Cd halides

This work explores the utilization of a photoactive organic cation for the preparation of R 2 MCl 4 (M = Zn, Cd; R = (E)-4-styrylpyridinium, C 13 H 12 N + ). Here, the zero-dimensional crystal structures of R 2 MCl 4 contain isolated tetrahedral anions [MCl 4 ] 2– separated by the organic cations R + , leading to flat bands around the optical band gap. In R 2 MCl 4 , the inorganic band gaps are sufficiently large to accommodate the organic molecular levels within, and therefore, the optical properties of R 2 MCl 4 are determined by the organic cation. Our combined optical spectroscopy and density functional theory (DFT) studies confirm the attribution of the bright green photoluminescence demonstrated by R 2 MCl 4 to the organic molecular emission. Importantly, the incorporation of the photoemissive organic cation R + into the hybrid framework in R 2 MCl 4 leads to a nearly two-fold enhancement of the light emission efficiency with the measured photoluminescence quantum yield (PLQY) values of 6.04%, 10.40% and 11.21% for RCl, R 2 ZnCl 4 and R 2 CdCl 4 , respectively. In addition, the crystal structure of the hybrid R 2 MCl 4 ensures a stabilized PL emission, preventing the occurrence of the harmful organic photodimerization, which is a notorious problem for this class of organic emitters.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2020

Advanced Modular Sub-Atmospheric Hybrid Heat Engine (Final Report)

The Phase 1 Final Technical Report describes the results of the work completed during the “Advanced Modular Sub-Atmospheric Hybrid Heat Engine” project. A key part of the Phase 1 work was the completion of a thermodynamic cycle analysis for the MHHE at the selected module size. The hybrid heat engine has been developed as a modular unit (sized in the range of 500kW – 60MW) that can be used with modular coal or biomass gasifiers, with distributed power generation systems, with large power plants comprised of multiple generating units, and with natural gas compression stations. The MHHE will provide cleaner, more efficient, and lower cost generation with better load following capabilities than existing competing technologies with a singular generating source such as solar farm, gas turbine, or combustion engine. The drivers of the MHHE technology are: benefits of modular power generation (reduced equipment cost, construction cost and implementation time, connection ready on delivery, flexible scalability, serviceability), fuel flexibility, lowest cost power generation and reduced emissions.A logical progression of work and a clear path forward toward meeting the FOA goals and objectives have been established. Namely, a preliminary market analysis and primary fuel identification was completed first and then the modularity of the system was defined. The benefits of the proposed hybrid and modular heat engine were described when applied to modular coal gasifiers, distributed power generators, and larger power plants. Based on the market analysis, modularity, and chosen primary fuel, a conceptual design and layout of the hybrid heat engine was developed, analyzed, and characterized. The technology gaps already identified have been reviewed and expanded upon, and a test plan to address these gaps through bench scale testing in Phase 2 has been developed. Cost estimate methodology and considerations in support of a potential Phase 2 project have been described.

08 HYDROGEN↗

DOE OSTI2021

Reconfiguration of Amorphous Complex Oxides: A Route to a Broad Range of Assembly Phenomena, Hybrid Materials, and Novel Functionalities

This work demonstrate that reconfiguration of amorphous oxide layers drives the assembly of oxide-based and freestanding nanomembranes into 3D structures with a radius of a few hundred nanometers. Reconfiguration-driven assembly is a versatile approach to impart large strains and strain gradients in a broad palette of complex oxides. This capability allows for manipulating and enhancing ferroelectricity, flexoelectricity, piezoelectricity, superconductivity, and ferromagnetism in complex oxides. Moreover, by the approach presented in this work, strain-engineered oxides are obtained in the form of 3D structures that can be fabricated in parallel on any substrate, including large-area and single crystalline semiconductor substrates. This approach will create a vast expanse of possibilities to investigate and leverage strain-tunable effects in amorphous, poly-crystalline, and single-crystalline complex oxides. Reconfiguration-driven assembly of NMs also allows combining different materials in a radial geometry and through scalable processes. For example, radial superlattices of Si (or GaAs) and various complex oxides or alternating layers of different complex oxides (e.g., SrTiO 3 and LaAlO 3 ) could be fabricated by release and heating of bilayer NMs. Here, a broad palette of electronic band structures and spin–orbit interactions could then be obtained by tailoring the curvature of the self-assembled NMs and the materials that the heterostructure comprises.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2022

Plutonium Hybrid Materials: A Platform to Explore Assembly and Metal–Ligand Bonding

In this work, we report the synthesis of five new hybrid materials containing the [PuCl 6 ] 2- anion and charge balancing, non-covalent interaction donating 4-X-pyridinium (X = H, Cl, Br, I) cations. Single crystals of the title compounds were grown and harvested from acidic, chloride-rich, aqueous media and their structures were determined via X-ray diffraction. Compounds 1-4, (4XPyH) 2 [PuCl 6 ] and 5, (4IPyH) 4 [PuCl 6 ] · 2Cl, exhibit two distinct sheet-like structure types. Structurally relevant non-covalent interactions were tabulated from crystallographic data and verified computationally using electrostatic surface potential maps and the quantum theory of atoms in molecules (QTAIM) approach. The strength of the hydrogen and halogen bonds was quantified using Kohn-Sham density functional theory and a hierarchy of acceptor-donor pairings established. In turn, the PuIV-Cl bonds were studied using the QTAIM and natural localized molecular orbital (NLMO) approaches to delineate the underlying bond mechanism and hybrid atomic orbital contributions therein. Energy decomposition (ED) and natural ED analyses were also explored to probe the bond mechanism and, more broadly, explore the efficacy of these techniques in studying these anionic systems. The results of the PuIV-Cl bond analyses were compared across composition via analogous treatments of previously reported [PuO 2 Cl 4 ] 2- and [PuCl 3 (H 2 O) 5 ] molecular units. In summary, our study indicates that the Pu-Cl bonds are predominately ionic, yet exhibit small varying degrees of covalent character that increase from [PuCl 3 (H 2 O) 5 ], [PuO 2 Cl 4 ] 2- , to [PuCl 6 ] 2- , while the participation of the Pu based s/d and f orbitals concurrently decrease and increase, respectively.

transuranic↗

DOE OSTI2024

Posterior comparison of model dynamics in several hybrid turbulence model forms

Hybrid turbulence models that can accurately reproduce unsteady three-dimensional flow physics across the entire range of grid scales and turbulence dynamics from Reynolds-averaged Navier–Stokes (RANS), through large-eddy simulation (LES), down to direct numerical simulations (DNS) are of increasing interest to the turbulence modeling community. However, despite decades of research and development, the basic tasks of eliminating poor-performing hybrid RANS-LES models and accelerating adoption of superior models through well-designed validation and verification have yet to occur. As a step in this direction, in this work we evaluate thirteen different hybrid RANS-LES models via systematic grid refinement of decaying homogeneous isotropic turbulence. We further derive a novel mathematical framework for assessing the energy partitioning dynamics of each Hybrid RANS-LES model, wherein model-to-model variations in energy partitioning can be interpreted as different feedback mechanisms operating on a low-dimensional nonlinear dynamical system. We found that model forms similar to the flow simulation methodology—also often termed very-large eddy simulation—are dynamically inconsistent with DNS at all resolutions. Additionally, we found a strong dynamical similarity in the feedback mechanisms of all models related to detached eddy simulation and partially averaged Navier–Stokes that is inherent to their general model forms.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2020

Infiltration synthesis of hybrid nanocomposite resists for advanced nanolithography

In this work, we demonstrate a simple ex-situ inorganic infiltration route for transforming standard organic resists into highperformance positive tone hybrid resist platform. A model thin film PMMA-AlOx hybrid resist system has been synthesized by hybridization of PMMA with AlOx and investigated for electron beam lithography. The approach possesses full controllability of the resist performance in terms of critical does, patterning contrast reaching up to 30 and etch resistance for plasma-based pattern transfer processes. The high selectivity Si etching capability demonstrated using a lowtemperature cryo-Si etch process, based on the controlled infiltration outperforms commercial resists and typical hard mask material thermal SiO 2 , with estimated achievable selectivity in excess of ~300. Si nanostructures down to ~30 nm with aspect ratio up to ~17 are also transferred into the Si substrate. Easy implementation and adaptability for different inorganic infiltrations, this platform is well capable of potentially delivering the resist performance and throughput necessary for EUV lithography.

77 NANOSCIENCE AND NANOTECHNOLOGY↗

DOE OSTI2024

Geospatial Data Platform for All

Spatiotemporal data has evolved in scale due to augmented use in cross-domain applications. Simultaneously, there is substantial growth in the availability of Geographic Information Systems (GIS) data provided by the United States Geological Survey (USGS) along with other federal, state, county, or local agencies through open-data portals and public access APIs. However, data availability does not equate with accessibility. Large-scale analyses and applications require robust, performant data management with co-location of data storage and computing. The insufficiency of data management infrastructure compels researchers to adopt ad hoc project- specific GIS data storage solutions (e.g., copying data to High-Performance computer file systems). As an ad hoc storage strategy does not scale, it hampers cross-domain analyses causing difficulty in data reuse and utilizing existing code bases. Furthermore, GIS data is complex and requires expertise to analyze and manipulate due to its intricate data structures and data-specific projection transformations. Despite the challenges, we recognize that derived GIS data products, e.g., satellite or LIDAR-based images, can be used in downstream applications such as AI by domain, but non-GIS experts. To address the data needs and overcome the challenges, we are working towards a GIS Data Platform focused on efficient data storage, data discovery and access, and an API to enable common workflows. We propose a knowledge-graph (KG) approach for data discovery, whereby datasets are semantically linked to higher- level constructs such as projects and research areas. The semantic data links enable researchers to explore datasets in a top-down approach by specifying relevant and meaningful terms (assists in finding hidden data). An advantage is that the nodes and edges in a knowledge graph create built-in semantic documentation. Deeper spatiotemporal connections between data sources can be encoded via Graph Neural Networks (GNN) (Zhang et al., 2021). The KG approach can be extended to integrate the data itself in a Virtual KG (VKG). Our work will derive inspiration from large-scale VKG efforts that have been undertaken or are currently underway as part of the OpenStreetMap project (Ding et al., 2021). For DOE Data Days, we share the proposed geospatial data platform hybrid (cloud/on-prem) architecture, our work-to-date on storing, retrieving, and transforming LiDAR and raster data relevant to two important NREL use-cases, including the Renewable Energy Potential (reV) Model, and present our proposal for a KG based data discovery engine.

data platform↗

DOE OSTI2021

Terry Turbopump Expanded Operating Band Modeling and Simulation Efforts in Fiscal Year 2021 Extended Period of Performance (Final Report)

This report documents the progress made under the Terry Turbine Expanded Operating Band (TTEXOB) program's modeling and simulation (MODSIM) initiative at Sandia National Laboratories (SNL ). It describes the US Federal Fiscal Year 2021 (FY21) extended period-of-performance MODSIM work completed since the closure of FY20 with due reference to the Texas A&M University (TAMU) hybrid milestone 5/6 experimental program. This work, which falls under Milestone 7 of the program, provides a counterpart to the various experiments. The overall TTEXOB program and its milestone-based approach are described in the program's Summary Plan. Details of the individual milestone test plans can be found in the corresponding detailed test plan, e.g. the Milestone 3 and 4 Detailed Test Plan. SNL MODISM is conducted alongside experiments performed at TAMU, and SNL technical staff regularly consults with TAMU on the experimental program. In FY21, MELCOR code models and capabilities were exercised in two different contexts: experimental comparisons to the TAMU ZS-1 and GS-2, and stand-alone analyses of a station black-out (SBO) scenario in a generic boiling water reactor (BWR). Code to experiment comparisons met with fair success when turbine losses were well characterized as for the ZS-1 turbine. Both deterministic and Bayesian calibration processes were used to find a recommended turbine torque multiplier for ZS-1 type turbines. This process could be repeated for GS-2 type turbines if GS-2 losses were better understood. Stand-alone generic BWR SBO calculations revealed that three different modes of self-regulating turbopump behavior may be observed depending on certain modeling parameters and choices having to do with turbine nozzles. Aspects of this predicted behavior may have been observed in TAMU GS-2 experiments.

73 NUCLEAR PHYSICS AND RADIATION PHYSICS↗

DOE OSTI2025

In Situ Analysis of Electron-Induced Chemical Transformations in Vapor-Phase-Synthesized Al-Based Inorganic–Organic Hybrid Thin Films for EUV Resist Platform

The rapid advancement and stringent requirements of extreme ultraviolet (EUV) lithography technology necessitate the development of advanced photoresist systems for next-generation microelectronics. Recent studies have demonstrated that inorganic-based hybrid photoresists offer notable improvements in EUV sensitivity, etch resistance, and greater insusceptibility to pattern collapse compared to their purely organic counterparts. However, variations in the synthesis/coating approaches and chemistry of inorganic–organic photoresists can result in distinct exposure mechanisms. In this work, an Al-based hybrid thin film resist system synthesized via molecular (atomic) layer deposition (MLD or MALD) is explored, focusing on its electron-beam and EUV patterning mechanisms. The Al-based hybrid thin films are deposited using trimethylaluminum (TMA) and the organic precursor hydroquinone, exhibiting a saturated growth rate within the temperature range of 150–200°C. In diluted tetramethylammonium hydroxide (TMAH)-based developer solutions, the electron-irradiated Al-based hybrid thin film system behaves as a negative tone resist, achieving a sensitivity of 10.4 mC/cm 2 at 0.1 kV electron beam lithography (EBL). Chemical changes induced by electron exposure are also analyzed in this study using X-ray photoelectron spectroscopy (XPS), Raman spectroscopy, and a unique infrared spectroscopy setup, revealing the potential cross-linking pathways. To further correlate the electron-induced chemical transformations with those mediated by EUV irradiations, a combination of X-ray photoemission electron microscopy/low-energy electron microscopy (XPEEM/LEEM) system is also employed. In conclusion, this study provides critical insights into the mechanisms underlying solubility switching and contributes to the design of advanced resist materials for EUV lithography.

36 MATERIALS SCIENCE↗

DOE OSTI2025

HOLISTIC ENERGY EFFICIENCY ANALYSIS OF ELECTRIFIED OFF-HIGHWAY MATERIAL HANDLER: FROM DRIVE CYCLE CHARACTERIZATION TO POWERTRAIN, HYDRAULIC, AND THERMAL SYSTEM PERFORMANCE

Three complexities surrounding the operation and testing of hybrid electric, heavy-duty nonroad machines have been addressed experimentally and using 1D simulation. Their resolutions have been intertwined with the development of a prototype machine that was proven to reduce fuel consumption in excess of 20%. A real-world drive cycle that leveraged hydraulic cylinder position was developed and utilized to ensure accurate reproduction of hydraulic work between the baseline and hybrid machines, while simultaneously maintaining less than 5% RMS error in position for main load handling functions. The newly developed, machine-specific drive cycle also contributed towards making equivalent comparisons in energy consumption between machine types through composite performance metrics that were extrapolated over a typical shift duration. Lastly, this work addressed thermal management energy consumption, a topic of increasing popularity when discussing electrified vehicles, by proposing a 1.4% energy savings through special mechanization and control of cooling system components.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2023

Efficient Solar Spectrum-Like White-Light Emission in Zinc-Based Zero-Dimensional Hybrid Metal Halides

Organic–inorganic metal halides (OIMHs) with high-efficiency solar spectrum-like emission are attracting broad and current interest. Here, in this work, five 0D Zn-based hybrid halides are synthesized based on aromatic organic cations with different carbon-chain lengths: C 6 H 5 CH 2 NH 3 + (PMA + ) and C 6 H 5 (CH 2 ) 4 NH 3 + (PBA + ). (PMA) 2 ZnCl 4 exhibits the highest photoluminescence quantum yield of 37.2% of reported Zn-based white-emission OIMHs. The emission spectrum of (PBA) 2 ZnI 4 indicates a color rendering index of 98, which is the highest among single-component white-light-emitting phosphors. Spectral characterizations and density functional theory calculations demonstrate that the extremely broad emission of (PBA) 2 ZnI 4 originates from the synergistic emission of organic cations and self-trapped excitons. The optical properties of the obtained (PMA) 2 ZnBr 4 , (PMA) 2 ZnI 4 ·H 2 O, and (PBA) 2 ZnCl 4 are also characterized for comparison, and with the same organic cations, the PLQY decreases from chloride to bromide to iodide. This work demonstrates that the selection of appropriate organics and halogens can enable fine tuning of single-component white-light emission, satisfying varying needs for solid-state lighting.

36 MATERIALS SCIENCE↗

DOE OSTI2021

Engineering hybrid textile braids for tendon and ligament repair application

Abstract Challenges involving tendon and ligament repair have motivated the investigation of new strategies to improve clinical outcomes. These have been mainly based on polymer constructs, which may be non‐biodegradable or biodegradable. The former typically fails due to lack of device integration and the latter demands a complex balance between biodegradability and tissue ingrowth, often failing due to insufficient mechanical properties. This work presents the development of hybrid braids based on polyethylene terephthalate (PET) and polylactic acid (PLA) yarns. A textile technique was used to fabricate braids based on 16 multifilament yarns of varying PLA/PET composition. The composition was varied to maximize biodegradability while ensuring mechanical performance. The braids' morphology, physical and mechanical properties were characterized. As production parameters and architecture were maintained, the braids exhibited similar porosity and wicking ability. The breaking force and stiffness decreased significantly as the number of PLA yarns increased, although strain levels remained constant. Braids containing 10 and 12 PET yarns (out of the total 16 yarns) demonstrated good creep and force‐relaxation behavior, as well as resistance to cyclic loading. These compositions were selected for future work, to be assembled into more elaborate structures to mimic the fibrous organization and tensile properties of different tendons/ligaments.

Peixoto, Tânia↗

DOE OSTI2026

Coherence-mediated quantum thermometry in a hybrid circuit quantum electrodynamics architecture

Quantum thermometry plays a critical role in the development of low-temperature sensors and quantum information platforms. Here, in this work, we propose and analyze a hybrid circuit quantum electrodynamics architecture in which a superconducting qubit is dispersively coupled to two distinct bosonic modes: one initialized in a weak coherent state as a phase reference and information buffer and the other coupled to a thermal environment. We show that the qubit serves as a sensitive readout of the probe mode, mapping the interplay between thermal and coherent photon-number fluctuations onto measurable dephasing. This coherence-mediated mechanism enables improved sensitivity to thermal energy fluctuations in the sub-millikelvin regime through Ramsey interferometry. We derive analytic expressions for the probe coherence envelope, compute the quantum Fisher information for temperature estimation, and demonstrate numerically that the presence of a coherent reference enhances the qubit's sensitivity to small changes in thermal photon occupancy. Our results establish a coherence-enabled approach to thermometry and provide a scalable platform for future calorimetric sensing in high-energy physics and quantum metrology.

Zhu, Shaojiang [Fermi National Accelerator Laborat↗

DOE OSTI2023

Investigation of 3D printed lightweight hybrid composites via theoretical modeling and machine learning

Hybrid composites combine two or more different fillers to achieve multifunctional or advanced material properties, such as lightweight and enhanced mechanical properties. The properties of the composites significantly depend on their microstructures, which can be tailored via advanced 3D printing processes. Understanding the process-structure-property relationships is critical to enable the design and engineering of novel hybrid composites for applications in aerospace, automotive, and protective coatings. Here, for this work, we develop 3D printable and lightweight hybrid composites and leverage the conventional design of experiments, a theoretical hybrid model, and an image-driven machine learning (ML) method to investigate their mechanical behaviors. The hybrid composites are formulated with elastomer matrix, microfillers, and thin-shell particles, enabling a significant degree of design freedom of microstructures with densities and mechanical properties varying up to 70% and 91%, respectively. Our statistical analysis indicates that the 3D printing path direction and the microfibers fraction are dominating process parameters with contribution percentages of 45.3% and 57.7% on the specific stiffness and strength, respectively. A hybrid mechanics model is developed based on a simple Weibull distribution function and classical single-filler models to effectively capture the variations in mechanical properties, however, it overestimates the values due to its statistical constraints and idealization of experimental uncertainty. The image-driven ML model leverages the microscale images directly without losing the structural details, shows more accurate predictions with experimental data, and has 48.6% lower root mean square error than the theoretical model.

3D printing↗