skip to main content
US FlagAn official website of the United States government
dot gov icon
Official websites use .gov
A .gov website belongs to an official government organization in the United States.
https lock icon
Secure .gov websites use HTTPS
A lock ( lock ) or https:// means you've safely connected to the .gov website. Share sensitive information only on official, secure websites.


Title: Multiscale Heterogeneous Polymer Composites for High Stiffness 4D Printed Electrically Controllable Multifunctional Structures
Abstract 4D printing is an emerging field where 3D printing techniques are used to pattern stimuli‐responsive materials to create morphing structures, with time serving as the fourth dimension. However, current materials utilized for 4D printing are typically soft, exhibiting an elastic modulus (E) range of 10−4to 10 MPa during shape change. This restricts the scalability, actuation stress, and load‐bearing capabilities of the resulting structures. To overcome these limitations, multiscale heterogeneous polymer composites are introduced as a novel category of stiff, thermally responsive 4D printed materials. These inks exhibit anEthat is four orders of magnitude greater than that of existing 4D printed materials and offer tunable electrical conductivities for simultaneous Joule heating actuation and self‐sensing capabilities. Utilizing electrically controllable bilayers as building blocks, a flat geometry is designed and printed that morphs into a 3D self‐standing lifting robot, setting new records for weight‐normalized load lifted and actuation stress when compared to other 3D printed actuators. Furthermore, the ink palette is employed to create and print planar lattice structures that transform into various self‐supporting complex 3D shapes. These contributions are integrated into a 4D printed electrically controlled multigait crawling robotic lattice structure that can carry 144 times its own weight.  more » « less
Award ID(s):
2047683
PAR ID:
10483910
Author(s) / Creator(s):
; ; ; ;
Publisher / Repository:
Wiley
Date Published:
Journal Name:
Advanced Materials
Volume:
36
Issue:
30
ISSN:
0935-9648
Format(s):
Medium: X
Sponsoring Org:
National Science Foundation
More Like this
  1. As an innovative technology, four‐dimentional (4D) printing is built upon the principles of three‐dimentional (3D) printing with an additional dimension: time. While traditional 3D printing creates static objects, 4D printing generates “responsive 3D printed structures”, enabling them to transform or self‐assemble in response to external stimuli. Due to the dynamic nature, 4D printing has demonstrated tremendous potential in a range of industries, encompassing aerospace, healthcare, and intelligent devices. Nanotechnology has gained considerable attention owing to the exceptional properties and functions of nanomaterials. Incorporating nanomaterials into an intelligent matrix enhances the physiochemical properties of 4D printed constructs, introducing novel functions. This review provides a comprehensive overview of current applications of nanomaterials in 4D printing, exploring their synergistic potential to create dynamic and responsive structures. Nanomaterials play diverse roles as rheology modifiers, mechanical enhancers, function introducers, and more. The overarching goal of this review is to inspire researchers to delve into the vast potential of nanomaterial‐enabled 4D printing, propelling advancements in this rapidly evolving field. 
    more » « less
  2. Creating 3D printed structures from materials with shape memory properties allows these structures to change form, modifying configuration or function over time in response to external stimuli such as temperature, light, electrical current, etc. This area of additive manufacturing has come to be known as 4D printing. A variety of geometries have been previously explored in the context of 4D printing, including foldable surfaces (e.g. Origami), lattices, and bio-inspired shapes. However, with advances in solid modeling software tools, more sophisticated spatially- varying lattices are now easily generated to further optimize the mechanical performance and functionality of a 4D printed structure. In this work, complex lattices are created to bend at specific locations with intentionally-reduced stiffness and improved compliance based on locally-reduced strut dimensions. By experimentally demonstrating more complex geometries in the study of 4D printing, new applications can be considered that were not previously possible, with tailored performance allowing for balancing between weight and actuation. 
    more » « less
  3. Lightweight and strong structural materials attract much attention due to their strategic applications in sports, transportation, aerospace, and biomedical industries. Nacre exhibits high strength and toughness from the brick-and-mortar–like structure. Here, we present a route to build nacre-inspired hierarchical structures with complex three-dimensional (3D) shapes by electrically assisted 3D printing. Graphene nanoplatelets (GNs) are aligned by the electric field (433 V/cm) during 3D printing and act as bricks with the polymer matrix in between as mortar. The 3D-printed nacre with aligned GNs (2 weight %) shows lightweight property (1.06 g/cm 3 ) while exhibiting comparable specific toughness and strength to the natural nacre. In addition, the 3D-printed lightweight smart armor with aligned GNs can sense its damage with a hesitated resistance change. This study highlights interesting possibilities for bioinspired structures, with integrated mechanical reinforcement and electrical self-sensing capabilities for biomedical applications, aerospace engineering, as well as military and sports armors. 
    more » « less
  4. Abstract In this research, we investigate multi-stimuli responsive multimaterial structures by combining shape memory polymers (SMPs) with magnetoactive fillers. Our objective is to design 3D-printed composites with local and global magnetoactive filler gradients, which exhibit complex shape actuation under magnetic and thermal fields. We first carry out a rheological study of SMP dispersions containing surface-treated magnetic particles to understand the effect of magnetic particle surface treatment, additives content, and shear rate on the complex flow behavior. Our findings reveal that dispersions filled with surface-treated magnetic particles exhibit enhanced shear thinning behavior and shape integrity compared to unfunctionalized dispersions. The improved rheological behavior and shape integrity are important results that indicate that PEG-functionalized SMP composites are promising candidates for direct ink printing. To create complex actuation, a 3D printing system is designed in a way that the magnetic particle-SMP dispersions are oriented using both shear and an external magnetic field, enabling a local angular gradient of magnetic particles. In addition, a global gradient is designed-in by varying the volume fraction of magnetic particles in the SMP suspensions. By adjusting the local and global gradients of magnetic particles within the SMP, different actuation patterns can be achieved. SEM analysis confirms the presence of the global gradient in iron oxide particles and their alignment along the magnetic field direction post-printing. Vibrating Sample Magnetometry (VSM) studies reveal an improved mass magnetization along the length of the printed samples, moving away from the printing origin. In addition, the iron oxide weight percent in the samples increases from 2.5 wt.% at the printing origin to 12.5wt.% at the end, creating a pronounced Fe3O4 global gradient. These findings contribute to the development of advanced stimuli-responsive materials with tunable properties for various applications where complex shape actuation is required, including soft robotics, and biomedical devices. 
    more » « less
  5. Untethered stimuli-responsive soft materials with programmed sequential self-folding are of great interest due to their ability to achieve task-specific shape transformation with complex final configuration. Here, reversible and sequential self-folding soft actuators are demonstrated by utilizing a temperature-responsive nanocomposite hydrogel with different folding speeds but the same chemical composition. By varying the UV light intensity during the photo-crosslinking of the nanocomposite hydrogel, different types of microstructures can be realized via phase separation mechanisms, which allow to control the folding speeds. The self-folding structures are fabricated by integrating two dissimilar materials (i.e., a nanocomposite hydrogel and an elastomer) into hinge-based bilayer structures via extrusion-based 3D printing. It has been demonstrated that the folding kinetics can be accelerated by more than one order of magnitude due to the phase-separated microstructure formed by the relatively weaker UV intensity (≈10 mW cm-2) compared to the one formed by stronger UV intensity (≈100 mW cm-2). 3D structures with sequential self-folding capabilities are realized by prescribing actuation speeds and folding angles to specific hinges of the nanocomposite hydrogel. Sequential folding box and self-locking latch structures are fabricated to demonstrate the ability to capture and hold objects underwater. 
    more » « less