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1. FiberWire: Embedding Electronic Function into 3D Printed Mechanically Strong, Lightweight Carbon Fiber Composite Objects

   https://doi.org/10.1145/3290605.3300797  

   Swaminathan, Saiganesh; Ozutemiz, Kadri Bugra; Majidi, Carmel; Hudson, Scott E. (April 2019, Proceedings of the 2019 CHI Conference on Human Factors in Computing Systems)

   Abstract: 3D printing offers significant potential in creating highly customized interactive and functional objects. However, at present ability to manufacture functional objects is limited by available materials (e.g., various polymers) and their process properties. For instance, many functional objects need stronger materials which may be satisfied with metal printers. However, to create wholly interactive devices, we need both conductors and insulators to create wiring, and electronic components to complete circuits. Unfortunately, the single material nature of metal printing, and its inherent high temperatures, preclude this. Thus, in 3D printed devices, we have had a choice of strong materials, or embedded interactivity, but not both. In this paper, we introduce a set of techniques we call FiberWire, which leverages a new commercially available capability to 3D print carbon fiber composite objects. These objects are light weight and mechanically strong, and our techniques demonstrate a means to embed circuitry for interactive devices within them. With FiberWire, we describe a fabrication pipeline takes advantage of laser etching and fiber printing between layers of carbon-fiber composite to form low resistance conductors, thereby enabling the fabrication of electronics directly embedded into mechanically strong objects. Utilizing the fabrication pipeline, we show a range of sensor designs, their performance characterization on these new materials and finally three fully printed example object that are both interactive and mechanically strong -- a bicycle handle bar with interactive controls, a swing and impact sensing golf club and an interactive game controller (Figure 1). 

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2. Large Biaxial Recovered Strains in Self‐Shrinking 3D Shape‐Memory Polymer Parts Programmed via Printing with Application to Improve Cell Seeding

   https://doi.org/10.1002/admt.202201997  

   Pieri, Katy; Liu, Di; Soman, Pranav; Zhang, Teng; Henderson, James H. (May 2023, Advanced Materials Technologies)

   Abstract Trapping of strain in layers deposited during extrusion‐based (fused filament fabrication) 3D printing has previously been documented. If fiber‐level strain trapping can be understood sufficiently and controlled, 3D shape‐memory polymer parts could be simultaneously fabricated and programmed via printing (programming via printing; PvP), thereby achieving precisely controlled 3D‐to‐3D transformations of complex part geometries. Yet, because previous studies have only examined strain trapping in solid printed parts—such as layers or 3D objects with 100% infill—fundamental aspects of the PvP process and the potential for PvP to be applied to printing of porous 3D parts remain poorly understood. This work examines the extent to which strain can be trapped in individual fibers and in fibers that span negative space and the extent to which infill geometry affects the magnitude and recovery of strain trapped in porous PvP‐fabricated 3D parts. Additionally, multiaxial shape change of porous PvP‐fabricated 3D parts are for the first time studied, modeled, and applied in a proof‐of‐concept application. This work demonstrates the feasibility of strain trapping in individual fibers in 1D, 2D, and 3D PvP‐fabricated parts and illustrates the potential for PvP to provide new strategies to address unmet needs in biomedical and other fields. 

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3. Fully 3D‐Printed Miniature Soft Hydraulic Actuators with Shape Memory Effect for Morphing and Manipulation

   https://doi.org/10.1002/adma.202402517  

   Qing, Haitao; Chi, Yinding; Hong, Yaoye; Zhao, Yao; Qi, Fangjie; Li, Yanbin; Yin, Jie (June 2024, Advanced Materials)

   Abstract Miniature shape‐morphing soft actuators driven by external stimuli and fluidic pressure hold great promise in morphing matter and small‐scale soft robotics. However, it remains challenging to achieve both rich shape morphing and shape locking in a fast and controlled way due to the limitations of actuation reversibility and fabrication. Here, fully 3D‐printed, sub‐millimeter thin‐plate‐like miniature soft hydraulic actuators with shape memory effect (SME) for programable fast shape morphing and shape locking, are reported. It combines commercial high‐resolution multi‐material 3D printing of stiff shape memory polymers (SMPs) and soft elastomers and direct printing of microfluidic channels and 2D/3D channel networks embedded in elastomers in a single print run. Leveraging spatial patterning of hybrid compositions and expansion heterogeneity of microfluidic channel networks for versatile hydraulically actuated shape morphing, including circular, wavy, helical, saddle, and warping shapes with various curvatures, are demonstrated. The morphed shapes can be temporarily locked and recover to their original planar forms repeatedly by activating SME of the SMPs. Utilizing the fast shape morphing and locking in the miniature actuators, their potential applications in non‐invasive manipulation of small‐scale objects and fragile living organisms, multimodal entanglement grasping, and energy‐saving manipulators, are demonstrated. 

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4. Enabling Recycling of Multi-Material 3D Printed Objects through Computational Design and Disassembly by Dissolution

   https://doi.org/10.1145/3706598.3714080  

   Wen, Xin; Bae, S Sandra; Rivera, Michael L (April 2025, ACM)

   Multi-material 3D printing combines the functional properties of different materials (e.g., mechanical, electrical, color) within a single object that is fabricated without manual assembly. However, this presents sustainability challenges as multi-material objects cannot be easily recycled. Because each material has a different processing temperature, considerable effort must be used to separate them for recycling. This paper presents a computational fabrication technique to generate dissolvable interfaces between different materials in a 3D printed object without affecting the object’s intended use. When the interfaces are dissolved, the object is disassembled to enable recycling of the individual materials. We describe the computational design of these interfaces alongside experimental evaluations of their strength and water solubility. Finally, we demonstrate our technique across 9 multi-material 3D printed objects of varying structural and functional complexity. Our technique enables us to recycle 89.97% of the total mass of these objects, promoting greater sustainability in 3D printing. 

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5. 3-D PRINTING OF DIELECTRIC ELECTROACTIVE POLYMER ACTUATORS AND CHARACTERIZATION OF DIELECTRIC FLEXIBLE MATERIALS

   Gonzalez, David; Newell, Brittany; Garcia, Jose; Noble, Lucas; Mamer, Trevor (October 2018, ASME Conference on Smart Materials, Adaptive Structures, and Intelligent Systems (SMASIS))

   Dielectric electroactive polymers are materials capable of mechanically adjusting their volume in response to an electrical stimulus. However, currently these materials require multi-step manufacturing processes which are not additive. This paper presents a novel 3D printed flexible dielectric material and characterizes its use as a dielectric electroactive polymer (DEAP) actuator. The 3D printed material was characterized electrically and mechanically and its functionality as a dielectric electroactive polymer actuator was demonstrated. The flexible 3-D printed material demonstrated a high dielectric constant and ideal stress-strain performance in tensile testing making the 3-D printed material ideal for use as a DEAP actuator. The tensile stress- strain properties were measured on samples printed under three different conditions (three printing angles 0°, 45° and 90°). The results demonstrated the flexible material presents different responses depending on the printing angle. Based on these results, it was possible to determine that the active structure needs low pre-strain to perform a visible contractive displacement when voltage is applied to the electrodes. The actuator produced an area expansion of 5.48% in response to a 4.3 kV applied voltage, with an initial pre-strain of 63.21% applied to the dielectric material. 

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