Nanofibers are versatile materials that are attractive for a wide range of applications, including filtration, biomedical substrates, catalyst supports, and mechanical reinforcement, among others. Nanofiber research has seen the development of several techniques that are adapt at fiber production; however, fiber alignment within complex geometries remains a challenge. One potential path to creating aligned fiber structures is the 3D printing of nanofiber-containing inks. Unfortunately, this approach is not without challenges, as nozzle clogging and limits both the length and concentration of nanofibers that can successfully be printed. Here, we demonstrate a process to fabricate tows of aligned ceramic nanofibers via 3D printing and processing of an all-polymer ink (i.e., containing no preformed nanofibers). Nanofibers self-assemble within 3D printed roads during thermal curing and are converted into ceramics via pyrolysis. Individual tows show flexible responses to strain and can be fabricated into complicated shapes such as meshes and springs. We anticipate that the combined 3D printing and self-assembly methodology described as well as the flexible and mechanically robust ceramics nanofiber structures created will be significantly enabling for future research and development exploration as well as producing high-temperature aerospace components.
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