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1. Sequential Self-Folding of Shape Memory Polymer Sheets by Laser Rastering Toward Origami-Based Manufacturing

   https://doi.org/10.1115/1.4050463  

   Abdulhafez, Moataz ; Line, Joshua ; Bedewy, Mostafa ( September 2021 , Journal of Manufacturing Science and Engineering)

   null (Ed.)

   Abstract Origami-based fabrication strategies open the door for developing new manufacturing processes capable of producing complex three-dimensional (3D) geometries from two-dimensional (2D) sheets. Nevertheless, for these methods to translate into scalable manufacturing processes, rapid techniques for creating controlled folds are needed. In this work, we propose a new approach for controlled self-folding of shape memory polymer sheets based on direct laser rastering. We demonstrate that rapidly moving a CO2 laser over pre-strained polystyrene sheets results in creating controlled folds along the laser path. Laser interaction with the polymer induces localized heating above the glass transition temperature with a temperature gradient across the thickness of the thin sheets. This gradient of temperature results in a gradient of shrinkage owing to the viscoelastic relaxation of the polymer, favoring folding toward the hotter side (toward the laser source). We study the influence of laser power, rastering speed, fluence, and the number of passes on the fold angle. Moreover, we investigate process parameters that produce the highest quality folds with minimal undesired deformations. Our results show that we can create clean folds up to and exceeding 90 deg, which highlights the potential of our approach for creating lightweight 3D geometries with smooth surface finishes that are challenging to create using 3D printing methods. Hence, laser-induced self-folding of polymers is an inherently mass-customizable approach to manufacturing, especially when combined with cutting for integration of origami and kirigami. 

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2. The form-finding and fabrication of an ultra-thin funicular bridge prototype made up of hollow glass units

   LU, Yao ; CREGAN, Matthew ; CHHADEH, Philipp A ; SEYEDAHMADIAN, Alireza ; BOLHASSANI, Mohammad ; Schneider, Jens ; YOST, Joseph R ; AKBARZADEH, Masoud ( October 2021 , International Association of Shell and Spatial Structures)

   The recent development of three-dimensional graphic statics (3DGS) has greatly increased the ease of designing complex and efficient spatial funicular structural forms [1]. The reciprocal diagram based 3DGS approaches not only generate highly efficient funicular structures [2], but also result in planarity constraints due to the polyhedron nature of the reciprocal diagrams [3]. Our previous research has shown the feasibility of leveraging this planarity by using planar glass sheets to materialize the 10m-span, double-layer glass bridge [3]. This paper is framed as a proof of concept for the 10m bridge and explores the form-finding, detail configuration, fabrication constraints, and assembly logic by designing and constructing a small-scale bridge prototype with a span of 2.5m. The prototype is designed in a modular approach, where each polyhedral cell of the form is materialized using a hollow glass unit (HGU) (Figure 1a), which can be prefabricated and preassembled, and therefore, greatly simplifies the assembly of the whole bridge. The compression-only form of the prototype is generated using the PolyFrame beta [4] plug-in for Rhinoceros [5]. The form-finding is carried out with a comprehensive consideration of a variety of parameters, including fabrication constraints, assembly ease, construction cost, and practicality. To start the form-finding process, a group of closed convex force polyhedrons is aggregated, controlling the topology of the form diagram and the orientations of the form elements. By manipulating the face tilting angles of the force diagram, the supported edges at the end of the bridge are all made horizontal, reducing the difficulty of the support design. Then, vertex locations and edge lengths of the form diagram are constrained, determining the final dimensions of both the bridge and the cells. After getting the geometry of the bridge, the detail developments are streamlined. Each of the 13 HGUs consists of two flat deck plates and a series of side plates (Figure 1b). To interlock the adjacent cells and prevent possible sliding, a male-female connection mechanism is introduced to the conjoint side plates of the HGUs (Figure 1b). Additionally, to eliminate the direct contact of the glass parts and prevent the stress concentration, two softer transparent materials are involved for connecting purposes. Within each HGU, silicon-based binding agent is used to hold the glass parts together; between the neighboring HGUs, plastic sheets are placed as interface materials (Figure 1b). Figure 1. a) The 2.5m-span small-scale prototype dome, b) Exploded view showing deck plates, side plates, male-female connection, and interface material For the fabrication of the glass parts, 5-axis Waterjet cutting techniques are applied. While the glass sheets for the deck plates can be purchased from the market, the irregular side plates with male-female connections need to be made from kiln-cast glass. In terms of the Waterjet cutting constraints, there is a max cutting angle of 60 degrees from vertical. With respect to this, all the glass parts are examined during the design process to ensure they all satisfy the cutting angle requirements. Aiming to achieve a fast and precise assembly, several assistant techniques are developed. On the local HGU level, assembly connectors are designed and 3D-printed to help locate the glass parts. On the global prototype level, the assembly sequence of the HGUs are simulated to avoid interference. Besides, a labeling system is also established to organize the fabricated parts and guide the entire assembly process. The design and construction of this small-scale prototype provide important information for the future development of the full-scale bridge regarding the interlocking detail design, the fabrication constraints, and assembly logic. The actual structural performance of the prototype awaits further investigation through-loading experiments. 

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3. Behavior of polyhedral built-up glass compression members

   Yost, Joseph Robert ; Akbarzadeh, Masoud ; Bolhassani, Mohammad ; Ryan, Liam ; Schneider, Jens ; Chhadeh, Philipp Amir ( July 2021 , International Conference on Civil Engineering and Architectural Design)

   null (Ed.)

   This research presents an experimental program executed to understand the strength and stiffness properties of hollow built-up glass compression members that are intended for use in the modular construction of all glass, compression-dominant, shell-type structures. The proposed compression-dominant geometric form has been developed using the methods of form finding and three-dimensional graphical statics. This research takes the first steps towards a new construction methodology for glass structures where individual hollow glass units (HGU) are assembled using an interlocking system to form large, compression-dominant, shell-type structures, thereby exploiting the high compression strength of glass. In this study, an individual HGU has an elongated hexagonal prism shape and consists of two deck plates, two long side plates, and four short side plates, as is shown in Figure 1. Connections between glass plates are made using a two-sided transparent structural adhesive tape. The test matrix includes four HGUs, two each fabricated with 1 mm and 2 mm thick adhesive tape. All samples are dimensioned 64 cm on the long axis of symmetry, 51 cm on the short axis of symmetry, and are 10 cm in width. Glass plates are all 10 mm thick annealed float glass with geometric fabrication done using 5-axis abrasive water jet cutting. HGU assembly is accomplished using 3D printed truing clips and results in a rigid three-dimensional glass frame. Testing was done with the HGU oriented such that load was introduced on the short side edges of the two deck plates, resulting in an asymmetric load-support condition. A soft interface material was used between the HGU and steel plates of the hydraulic actuator and support for the purpose of avoiding premature cracking from local stress concentrations on the glass edges at the load and support locations. Force was applied in displacement control at 0.25 mm/minute with a full array of displacement and strain sensors. Test results for load vs. center deck plate transverse deflection are shown in Figure 2. All samples failed explosively by flexural buckling with no premature cracking on the load and support edges of the deck plates. Strain and deformation data clearly show the presence of second-order behavior resulting from bending deformation perpendicular to the plane of the deck plates. In general, linear axial behavior transitions to nonlinear second-order behavior, with increasing rates in deflection and strain growth, ultimately ending in glass fracture on the tension surfaces of the buckled deck plates. The failure resulted in near-complete disintegration of the deck plates, but with no observable cracking in any side plates and a secure connection on all adhesive tape. Results of the experimental program clearly demonstrate the feasibility of using HGUs for modular construction of compression dominant all-glass shell-type structures. This method of construction can significantly reduce the self-weight of the structure, and it will inspire the use of sustainable materials in the construction of efficient structures. 

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4. Addressable, Stretchable Heating Silicone Sheets

   https://doi.org/10.1002/admt.201900276  

   Bilodeau, R. Adam ; Yuen, Michelle C. ; Kramer‐Bottiglio, Rebecca ( August 2019 , Advanced Materials Technologies)

   Research into new active materials for soft robots has generated promising new thermally responsive materials for functions such as variable stiffness, on‐demand shape change, and actuation. These new thermally responsive materials require a form of addressable thermal control that is compliance‐matched to its host system. In response to this need, this work presents stretchable, addressable heating silicone sheets that can control soft, thermally responsive materials. The sheets are created using layer‐by‐layer deposition of a bulk conductive elastomer that can be Joule heated, with embedded liquid–metal microchannels used as electrodes. This combination allows the bulk, addressed material to be stretched and twisted while in operation. Local, addressable heating is demonstrated in a silicone‐based composite that is capable of cyclic strains of up to 40%, while still self‐heating to over 100 °C. The heating sheets are demonstrated as a thermal control platform in both color changing and stretch‐and‐hold operations using all silicone‐based composites. Additionally, this platform is bonded to a variable‐stiffness polymer that, with its selective heating capability, enables folding at targeted locations.

    

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5. Shape memory polymers for self‐folding via compression of thermoplastic sheets

   https://doi.org/10.1002/app.46889  

   Hubbard, Amber M. ; Davis, Duncan S. ; Dickey, Michael D. ; Genzer, Jan ( August 2018 , Journal of Applied Polymer Science)

   We report a simple method to strain, and thereby program, shape memory polymers by compressing planar thermoplastic sheets. This work is motivated by the limited number of commercially available prestrained polymer sheets; current examples include: Shrinky Dinks, Eastman's Embrace, and polyurethane shrink films. However, these commercial specimens limit the sample thickness, polymer composition, and amount of stored strain. We show here that melt pressing can strain thermoplastic sheets over a range of thicknesses and polymer chemical compositions. After pressing (and thus, straining), the polymer sheets can self‐fold out‐of‐plane into complex geometries using two different actuation mechanisms, both of which locally release strain stored in the polymer. Three‐dimensional geometries are attained experimentally with both thick (~12 mm) and thin (~1 mm) strained polymer samples with a range of polymer compositions. Digital image correlation maps the strain profile within the melt pressed samples while a Mooney–Rivlin and geometric model predicts the average strain and folding response of the samples, respectively. The model predictions agree well with experimental results. These findings enable self‐folding with a broader design space such as polymer chemical composition, sample thickness, strain within the sample, and external stimulus. Techniques presented here should translate to other thermoplastic polymers, thus making this technique a viable tool to increase the available pool of materials available for self‐folding devices. © 2018 Wiley Periodicals, Inc. J. Appl. Polym. Sci.2018,135, 46889.

    

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