Papers and Patents

80. C. Hu, B. Yuan, S. Jahan, & R. Panat*, “3D-AJP: Fabrication of Advanced Microarchitected Multi-Material Ceramic Structures via Binder-Free and Auxiliary-Free Aerosol Jet 3D Nanoprinting”, Advanced Science 2405334, 1-18 (2025). DOI  PDF.

79. S. Jahan, A. Jain, S. Frregonese, C. Hu, M. Bacca*, & R. Panat*, “Bed-of-Nails Effect: Unraveling the Insertion Behavior of Aerosol Jet 3D Printed Microneedle Array in Soft Tissue”, Extreme Mechanics Letters 77, 102301 (2025). DOI PDF.

78. R. Panat*, E. Yttri, and M. S. Saleh, “3D Printed Microelectrode Arrays”, US Patent #12,188,892 (2025). PDF

77. A. Parab, M. D. Nath, Y. Mane, Z. Godhrawala, R. Panat*, & S. Jejurikar*,“Role of MWCNTs for the effective detection of glucose in MWCNTs/NiO/MWCNTs stack prepared on paper electrode”, in revision.

76. M.A.S.R. Saadi, F. H. Likhi, M. D. Nath, R. Jayan, F. Zahin, M. Thakur, Y. Yuan, M. Islam, R. Panat, A. Karim, P. M. Ajayan, M. Rahman, “Algae-derived Nacre-like Dielectric Bionanocomposite with High Loading Hexagonal Boron Nitride for Green Electronics.” ACS Nano, DOI PDF

75. S Ritchie, C Hu, R Panat, “Realizing Arbitrary 3D Microarchitectures with Curved and near-Sharp Segments via Toolpath Strategies in Aerosol Jet Printing.” Additive Manufacturing, DOI PDF Supplementary PDF

74. S. Jahan, C. Hu, B. Yuan, SM. Ritchie, R. Panat, “Aerosol Jet 3D Printing of Gold Micropillars and Their Behavior Under Compressive Loads.” Additive Manufacturing, v. 92, 104385, August 2024. DOI PDF

73. Y. Jadhav, J. Berthel, C. Hu, R. Panat, J. Beuth, A. Barati Farimani, “Generative Lattice Units with 3D Diffusion for Inverse Design: GLU3D.” Advanced Functional Materials, June 2024. DOI PDF

72. Md. Azahar Ali, George Fei Zhang, Chunshan Hu, Bin Yuan, Shou-Jiang Gao, Rahul Panat, “An Advanced Healthcare Sensing Platform for Direct Detection of Viral Proteins in Seconds at Femtomolar Concentrations via Aerosol Jet 3D-Printed Nano and Biomaterials.” Advanced Materials Interfaces, March 2024. DOI PDF

71. Mert Arslanoglu, Bin Yuan, Rahul Panat, O. Burak Ozdoganlar, “3D Assembly of MXene Networks Using a Ceramic Backbone with Controlled Porosity.” Advanced Materials, Oct. 2023, p. 2304757. DOI PDF

70. R. Panat, J. Park, M. S. Saleh, and J. Lie, “Three-dimensional lattice batteries via additive manufacturing” U.S. Patent #11817588, issued November 2023. PDF

69. G. K. Fedder, R. Panat, J. Brenneman, D. Z. Tansel, “Stretchable 3D-printed circuit boards” U.S. Patent #11856708, issued December 2023. PDF

68. S. Ritchie, S. Kovacevic, P. Deshmukh, A. Christodoulides, J. Malen, S. D. Mesarovic, and R. P. Panat, “Shape distortion in sintering results from nonhomogeneous temperature activating a long-range mass transport,” Nature Communications, 14, 2667 (2023). DOI PDF video.

Here, we discover why part distortion happens in sintering-based AM processes!

67. Yayati Jadhav, Joseph Berthel, Chunshan Hu, Rahul Panat, Jack Beuth, Amir Barati Farimani, “StressD: 2D Stress Estimation Using Denoising Diffusion Model.” Computer Methods in Applied Mechanics and Engineering, vol. 416, Nov. 2023, p. 116343. DOI PDF

66. J. Brenneman, M. Lovalekar, and R. P. Panat, “A Semi‐Empirical Model for Post‐yield Stress‐instability in the Stress‐Strain Response of Three‐dimensional Lattice Structures Under Compressive Loads,” Advanced Engineering Materials, 202201428 (2023). DOI PDF

65. M. S. Saleh, S. Ritchie, M. A. Nicholas, H. L. Gordon, C. Hu, S. Jahan, B. Yuan, R. Bezbaruah, J. W. Reddy, Z. Ahmed, M. Chamanzar, E. A. Yttri, and R. P. Panat, “CMU Array: A 3D Nano-Printed, Highly Customizable High-Density Microelectrode Array Platform,” Science Advances, 8, eabj4853,  (2022). DOI PDF

64. M. A. Ali, G. Fei Zhang, C. Hu, B. Yuan, S. Jahan, G. D. Kitsios, A. Morris, S.-J. Gao, R. P. Panat, “Ultra-Rapid and Ultra-Sensitive Detection of SARS-CoV-2 Antibodies in COVID-19 Patients via A 3D-Printed Nanomaterial-Based Biosensing Platform,” Journal of Medical Virology, 94 (12) 5808-5826,  (2022).  DOI PDF Journal Cover Image

Impact factor = 20.6, provided as many engineers may be unfamiliar with this journal

Front Cover Caption: The cover image is based on the Research Article Ultrarapid and ultrasensitive detection of SARS-CoV-2 antibodies in COVID-19 patients via a 3D-printed nanomaterial-based biosensing platform by Md. Azahar Ali et al., .

63. J. Brenneman, D. Z. Tansel, G. K. Fedder, and R. P. Panat, “High-conductivity crack-free three-dimensional electrical interconnects directly printed on soft PDMS substrates“, Advanced Materials Technologies, 2200396, 1-15 2022. DOI PDF

62. M. Arslanoglu, B. Ozdoganlar, and R. Panat, “Fabrication of porous silica with controllable and tunable porosity via freeze casting“, Journal of the American Ceramic Society, 105 (8), 5114-5130, 2022. DOI PDF 

61. M. A. Ali, C. Hu, F. Zhang, S. Jahan, B. Yuan, M. S. Saleh, S.-J. Gao, R. Panat, “N-protein based Ultrasensitive SARS-CoV-2 Antibody Detection in Seconds via 3D Nanoprinted Microarchitected Array Electrodes”, Journal of Medical Virology, 2022; 1 – 12. DOI PDF

60. M. A. Ali, C. Hu, B. Yuan, S. Jahan, M. S. Saleh, Z. Guo, A. J. Gellman, R. Panat, “Breaking the barrier to biomolecule limit-of-detection via 3D printed multi-length-scale graphene-coated electrodes”, Nature Communications, 12(1),7077-1 to 7077-16, 2021. DOI PDF

59. M. A. Ali, C. Hu, E. A. Yttri, and R. Panat, “Recent Advances in 3D Printing of Biomedical Sensing Devices“, Advanced Functional Materials, 2107671, 2021. DOI  PDF (Invited Review) Inside Cover

58. M. A. Ali, C. Hu, S. Jahan, B. Yuan, M. S. Saleh, E. Ju, S.-J. Gao, and R. Panat, “Sensing of COVID-19 Antibodies in Seconds via Aerosol Jet Printed Three Dimensional Electrodes”, Advanced Materials, 33(7) 2006647, 2021. DOI  PDF; Selected for Adv Mater Cover Image

Our group has achieved testing of COVID-19 antibodies in 10 seconds!!

CMU News: Imagine a 10-second COVID-19 antibody test—we’re on our way!; Advanced Science News

Cover of Adv Mater: In article number 2006647, Rahul Panat and co‐workers report the development of a 10‐second COVID‐19 antibody test that represents the fastest detection of this pathogen biomarker. The test uses an electrochemical cell consisting of aerosol jet nanoprinted 3D micropillar electrodes coated with reduced graphene oxide and viral antigens. This generic platform could be a game‐changer in controlling the spread of infectious diseases during pandemics.

57. P. Borade, M. A. Ali, S. Jahan, T. Sant, K. Bogle, R. Panat, S. Jejurikar, “MoS₂ Nanosheet-Modified NiO Layers on Conducting Carbon Paper for Glucose Sensing”, ACS Applied Nano Materials, 4, pp.6609-6619 (2021).DOI PDF

56. Md. Taibur Rahman and R. Panat, “Aerosol Jet 3D Printing and High Temperature Characterization of Nickel Nanoparticle Films”, Manufacturing Letters, 29, pp.5 (2021). DOI PDF 

55. J. Brenneman, D. Tansel, G. Fedder, and R. Panat, “Interfacial Delamination and Delamination Mechanism Maps for 3D Printed Flexible Electrical Interconnects”, Extreme Mechanics Letters, 43, pp. 101199 (2021). DOI PDF 

This work appeared on the cover of vol. 43 of EML.

54. M. Sadeq Saleh^§, C. Hu^§, J. Brenneman, A. M. A. Mutairi, and R. Panat, “3D Printed Three-dimensional Metallic Microlattices with Controlled and Tunable Mechanical Properties via Aerosol Jet 3D Printing”, Additive Manufacturing, 39, 101856 (2021). DOI PDF 
^§ Equal contribution

53. M. Hamid, S. Saleh, A. Afrozian, R. Panat, and H. Zbib, “Modeling of porosity and grain size effects on mechanical behavior of additively manufactured structures”, Additive Manufacturing,  28, pp. 101833, 2021. DOI PDF

52. P. Borade, T. Sant, A. Gokarna, K. Joshi, R. Panat, S. Jejurikar, “Role of defects in modulating the near band edge emissions of sub-micron ZnO crystals”, Optical Materials, 109, pp. 110348, 2020. DOI PDF

51. Y. Zhu, J. Li, M. S. Saleh, R. Panat, J. Park, “Towards High-Performance Li-ion Batteries via Optimized Three-dimensional Micro-lattice Electrode Architectures”, Journal of Power Sources, 476, 228593, 1-18, 2020. DOI PDF

50. D. Tansel, J. Brenneman, G. Fedder, R. Panat, “Mechanical Characterization of Polydimethylsiloxane (PDMS) Exposed to Thermal Histories up to 300 °C in a Vacuum Environment”, Journal of Micromechanics and Microengineering, 30, pp. 067001, 2020.  DOI PDF

49. B., Mallesham, F. Manciu, S. Tan, R. Panat, C. V. Ramana, ” Unravelling the Sintering Temperature Induced Phase Transformations in Ba(Fe_0.7Ta_0.3)O_3-δ Ceramics”,  Ceramics International, 46 (14), pp. 23257, 2020. DOI PDF

48. M. Sadeq Saleh, S. M. Ritchie, M. A. Nicholas, R. Bezbaruah, J. W. Reddy, M. Chamanzar, E. A. Yttri, R. P. Panat, “CMU Array: A 3D Nano-Printed, Customizable Ultra-High-Density Microelectrode Array Platform” Submitted, preprint available on BioRxiv, 742346 (2019). DOI PDF

46. S. Manandhar, A. Battu, S. Tan, R. Panat, V. Shutthanandan, C. V . Ramana, “Effect of Ti Doping on the Crystallography, Phase, Surface/Interface Structure and Optical Band Gap of Ga₂O₃ Thin Films”, Journal of Materials Science, 54, pp.11526–11537 (2019). DOI PDF

45. R. Danaei, T. Varghese, M. Ahmadzadeh, J. McCloy, C. Hollar, M. Sadeq Saleh, J. Park, Y. Zhang, R. Panat, “Ultrafast Fabrication of Thermoelectric Films by Pulsed Light Sintering of Colloidal Nanoparticles on Flexible and Rigid Substrates”, Advanced Engineering Materials, 21, pp. 1800800 (2019). DOI PDF

44. Y. Arafat, S. T. Sultana, I. Dutta, R. Panat, “Effect of Additives on the Microstructure of Electroplated Tin Films”, Journal of the Electrochemical Society, 165 (16), D816-D824 (2018). DOI PDF

Interesting Sn microstructures never obtained before were realized by changing additives to a methanesulfonic acid electroplating bath. See paper for complete characterization including cathodic polarization plots and mechanisms of film formation.

43. R. Panat, J.Park, M. S. Saleh, and J. Li, “3D-Printed Lattice Batteries”, Homeland Defense Information Analysis Center (HDIAC) Journal, 5 (4), pp. 11 (2018). Link

42. J. Li, X. Liang, R. Panat, and J. Park, “Enhanced Battery Performance through Three-Dimensional Structured Electrodes: Experimental and Modeling Study” Journal of the Electrochemical Society, 165 (14), A3566-A3573 (2018). DOI PDF

41. R. Panat and D. Heo, “Three-dimensional passive components”, U.S. Patent #9969001, issued May 2018. PDF

40. T. C. Karni, R. Garg, S. Rastogi, R. Panat, and M. S. Saleh, “Nanowire-Mesh Templated Growth of Out-of-Plane Three-Dimensional Fuzzy Graphene”, U.S.  Patent Application # WO/2018/195108, filed April 2018. PDF

39. R. Panat and D. Heo, “Three-dimensional sub-mm wavelength sub-THz frequency antennas on flexible and in-situ cured dielectric using printed metal structures”, U.S. Patent # 10086432, issued Oct 2018. PDF

38. M. Sadeq Saleh, Jie Li, Jonghyun Park, and Rahul Panat, “3D Printed Hierarchically-Porous Microlattice Electrode Materials for Exceptionally High Specific Capacity and Areal Capacity Lithium Ion Batteries”, Additive Manufacturing, Vol.23, pp 70-78 (2018). DOI PDF

The research appeared in several media outlets  including Forbes Magazine….
1- Forbes Magazine: See How This New 3D Printing Method Could Make Your Smartphone Last Longer
2- Green Car Congress: CMU-led team develops 3D printing method  for exceptionally high capacity batteries
4- Printed electronics:  3D printing the next generation of batteries
5- 3D Printing Industry: 3D Printing creates major advance for longer lasting batteries
6- CMU news: 3D Printing the next generation of batteries
7- German Media: New “Aerosol Jet” method relies on 3D printing for electrodes of lithium-ion batteries and promises longer battery life
8- Japanese media: 3D打印技术造出微观多孔锂电池，容量提升了4倍

37. Y. Arafat, R. Panat, I. Dutta, “Highly Stretchable Metal Films on Polymer Substrates: Mechanics and Mechanisms”, IEEE ITherm2018, pp. 32-36 (2018). DOI PDF

36. M. Sadeq Saleh, Mehdi HamidVishkasougheh, H. Zbib, and R. Panat, “Polycrystalline Micropillars by a Novel 3-D Printing Method and Their Behavior under Compressive Loads”, Scripta Materialia,  Volume 149, 144–149, 2018. DOI PDF

35. M. T. Rahman, R. Moser, H. Zbib, C. V. Ramana, and R. Panat, “3D Printed High Performance High Temperature Sensors”, Journal of Applied Physics,  123, 024501, 2018. DOI

CMU News: 3D Printing Remakes the Strain Gauge
News on Physics.org
News on Business Standard (Indian News)
News on 3D Print Magazine

33. J. Geng, M. T. Rahman, R. Panat, and L. Li, “Self-assembled Axisymmetric Microscale Periodic Wrinkles on Elastomer Fibers”, ASME Journal of Micro and Nano-manufacturing, Vol. 5, Issue 2, pp. 021006, 2017. DOI PDF  

32. R. Sun, H. Yang, M. Rock, R. Danaei, R. Panat, M. Kessler, and L. Li, “Manufacturing PDMS Micro Lens Array using Spin Coating under a Multiphase System”, Journal of Micromechanics and Microengineering, Vol. 27(5), pp.1, 2017. DOI PDF

31. M. T. Rahman, J. Gomez, K. Mireles, P. Wo, J. Marcial, M. Kessler, J. McCloy, C. Ramana, and R. Panat, “High temperature physical and chemical stability and oxidation reaction kinetics of Ni-Cr nanoparticles”, Journal of Physical Chemistry – C, Vol.121 (7), pp. 4018–4028, 2017. DOI PDF

30. I. Dutta and R. Panat,” Highly stretchable interconnect devices and systems”, US Patent #9770759, issued Sept 2017. PDF

29. R. Panat and B. Jaiswal, “Nanowires coated on traces in electronic devices”, US Patent #9627320, issued April 2017. PDF

28. R. Panat and L. Lei, “Low-cost fiber optic sensor for large strain”, US Patent #9846276, issued December 2017.PDF

27. J. Li, M. Leu, R. Panat and J. Park, “A Hybrid Three-Dimensionally Structured Electrode for Lithium-ion Batteries via 3D Printing”, Materials and Design, Vol. 119, pp. 417-424, 2017. DOI PDF

26. Brian Paul, Rahul Panat, Christina Mastrangelo, and David Kim, and David Johnson “Manufacturing of Smart Goods: Current State, Future Potential, and Research Recommendations”,  ASME Journal of Micro and Nano-manufacturing, Vol. 4, Issue 4, pp. 044001-1 to 044001-12, 2016. DOI PDF

25. Y. Arafat, I. Dutta, R. Panat, “On the Deformation Mechanisms and Electrical Behavior of Highly Stretchable Metallic Interconnects on Elastomer Substrates”, Journal of Applied Physics, Vol. 120, Issue 11, pp. 115103-1 to 11, 2016. DOI PDF

24. M. T. Rahman, J. McCloy, C. V. Ramana, and R. Panat, “Structure, Electrical Characteristics and High-Temperature Stability of Aerosol Jet Printed Silver Nanoparticle Films”, Journal of Applied Physics, Vol. 120, Issue 7, pp. 075305-1 to 11, 2016. DOI PDF

23. M. T. Rahman, A. Rahimi, S. Gupta, and R. Panat, “Microscale Additive Manufacturing and Modeling of Interdigitated Capacitive Touch Sensors”, Sensors and Actuators A: Physical, Vol. 248, 94-103, 2016. DOI PDF

22. H. Yang, M. T. Rahman, D. Du, R. Panat, and Y. Lin, “3-D Printed Adjustable Microelectrode Arrays for Electrochemical Sensing and Biosensing”, Sensors and Actuators B: Chemical, Vol. 230, 600-606, 2016. DOI PDF

21. Y. Arafat, I. Dutta, R. Panat, “Super-stretchable Metallic Interconnects on Polymer with a Linear Strain of up to 100%” Applied Physics Letters, 107, 081906, 2015. DOI PDF

20. M. T. Rahman, L. Renaud, M. Renn, D. Heo, R. Panat, “Aerosol Based Direct-Write Micro-Additive Fabrication Method for Sub-mm 3-D Metal-Dielectric Structures” Journal of Micromechanics and Microengineering, Vol. 25 (10), 107002 (2015). DOI PDF

19. R. Panat, “A Model for Crack Initiation in the Li-ion Battery Electrodes”, Thin Solid Films, Vol. 596, pp. 174 178 (2015). DOI PDF

18. M. T. Rahman, L. Renaud, M. Renn, D. Heo, R. Panat, “3-D Antenna Structures Using Novel Direct-Write Additive Manufacturing Method”, ASME 2015 International Technical Conference and Exhibition on Packaging and Integration of Electronic and Photonic Microsystems, Paper No. IPACK2015-48187, pp. V003T03A002 (2015). DOI

17. Y. Arafat, I. Dutta, R. Panat, “Highly Stretchable Interconnects for Flexible Electronics Applications” ASME 2015 International Technical Conference and Exhibition on Packaging and Integration of Electronic and Photonic Microsystems, Paper No. IPACK2015-48130, pp. V002T02A029 (2015). DOI PDF 

16. Z. Song, T. Ma, R Tang, Q. Cheng, X. Wang, D. Krishnaraju, R. Panat, C. K. Chan, H. Yu, and H. Jiang, “Origami Lithium Ion Batteries”, Nature Communications, 5:3140, (2014). DOI PDF

15. R. Panat, S. Dattaguru, H. Balkan, Y. Min, H. Seh, X. Zhao, “Mechanical Reliability of Embedding of Components in Ultra-High Performance Microprocessors”, IEEE Transactions on Device and Materials Reliability, Vol. 4 (5), 857 (2014). DOI PDF

14. R. Panat, E. Parks, and J. Wang, “Effects of triboelectrostactic changing between polymer surfaces in manufacturing and test of integrated circuit packages”, IEEE Transactions on Components, Packaging and Manufacturing Vol. 4 (5), 943 (2014). DOI PDF

13. N. Raravikar and R. Panat, “Nanolithographic method of manufacturing an embedded passive device for a microelectronic application, and microelectronic device containing the same”, US Patent #8068328, issued May 2014. PDF

12. R. Panat, “On the data and analysis of research output of India and China: India has significantly fallen behind China”, Scientometrics (Springer), Vol. 100 (2), 471-481 (2014). DOI PDF

11. R. Panat, V. Dimitrova, S. Selvamundiany, K. Ishiko, and D. Sun, “The application of Lean Six Sigma to the configuration control in Intel’s manufacturing R&D environment”, International Journal of Lean Six Sigma, Vol. 5 No. 4, 444-459 (2014). DOI PDF

10. Y. Min, R. Olmedo, M. Hill, K. Radhakrishnan, K. Aygun, M. Kabiri-badr, R. Panat, S. Dattaguru, and H. Balkan, “Embedded Capacitors in the Next Generation Processor”, 63rd ECTC Conference, IEEE, 1225-1229 (2013). DOI PDF

9. N. Raravikar, R. Panat, and S. Jadhav, “A tombstone initiation model for small form factor surface mount passives” IEEE Transactions on Components, Packaging and Manufacturing, Vol. 2 (9), 1486-1491 (2012). DOI PDF

8. Li Yan, R. Panat, R. Mulligan, P. Srinath, and A. Raman, “The application of 2D X-ray hot stage in flip chip package failure analysis”, IEEE Transactions on Device and Materials Reliability, Vol. 11 (1), 141-147 (2011). DOI PDF

7. R. Panat, K.J. Hsia and D.G. Cahill, “Evolution of surface waviness in thin films via volume and surface diffusion”, Journal of Applied Physics, 97, 013521 (2005). DOI

6.  R. Panat, K.J. Hsia and J. Oldham, “Rumpling instability in thermal barrier systems under isothermal conditions in vacuum”, Philosophical Magazine, 85 (1), 45-64 (2005).DOI PDF 

5. R. Panat and K.J. Hsia, “Experimental investigation of the bond coat rumpling instability under cyclic and isothermal temperature histories in thermal barrier systems,” Proceedings of the Royal Society of London, Series A, Vol. 460, 1957-1979 (2004). DOI PDF 

4. R. Panat, S. Zhang and K.J. Hsia, “Bond coat surface rumpling in thermal barrier coatings” Acta Materialia, 51, 239-249 (2003).DOI PDF

3. S. Zhang, R. Panat and K.J. Hsia, “Influence of surface morphology on the adhesion strength of aluminum/epoxy interfaces”, Journal of Adhesion Science and Technology, 17 (12), 1685-1711 (2003). DOI PDF

2. R. Panat, K. Jakus, J.E. Ritter and P. Shah, “Erosion and strength degradation of an elastic modulus graded alumina-glass composite,” Ceramic Engineering and Science Proceedings, 21, 3 (2000) 635. DOI PDF

1.  J.E. Ritter, K. Jakus, R. Panat, “Impact damage and strength degradation of fused silica,” MRS Symposium Proceedings, 531 (1998) 53. DOI