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Abstract Herein, a new lightweight syntactic foam is reported with strong mechanical properties, unique multifunctionalities, and recyclability. Multifunctionality of materials and structures has gained ever‐increasing interest as an excellent approach to designing minimalistic systems. Inspired by nature, these materials can perform multiple functions besides bearing a load. Due to their shape‐changing and damage‐healing property, shape memory vitrimers (SMVs) are a great example of multifunctional materials readily exploited for many applications. Using nickel and silver‐plated hollow glass microbubbles (HGMs), an SMV‐based syntactic foam is introduced here that supplements the multifunctionality of SMVs with electrical conductivity and ferromagnetism, which enables a series of additional potentials such as strain sensing, damage monitoring, Joule heating, and electromagnetic interference shielding. Despite its low density and outstanding mechanical properties, this foam exhibits shape memory behavior, which can be triggered by an electrical current, and damage healing capability due to its reversible dynamic covalent bonds. Especially its recyclability makes recycling the expensive silver‐coated and nickel‐coated HGMs feasible, making this foam cost‐effective and environmentally sustainable. With its many features and economical manufacturability, this syntactic foam has a potential to be utilized in many applications, ranging from aerospace structures to biomedical devices to household items. 

Abstract Cultivated natural fibers have a huge possibility for green and sustainable reinforcement for polymers, but their limited load-bearing ability and flammability prevent them from wide applications in composites. According to the beam theory, normal stress is the maximum at the outermost layers but zero at the mid-plane under bending (with (non)linear strain distribution). Shear stress is the maximum at the mid-plane but manageable for most polymers. Accordingly, a laminated composite made of hybrid fiber-reinforced shape memory photopolymer was developed, incorporating strong synthetic glass fibers over a weak core of natural hemp fibers. Even with a significant proportion of natural hemp fibers, the mechanical properties of the hybrid composites were close to those reinforced solely with glass fibers. The composites exhibited good shape memory properties, with at least 52% shape fixity ratio and 71% shape recovery ratio, and 24 MPa recovery stress. After 40 s burning, a hybrid composite still maintained 83.53% of its load carrying capacity. Therefore, in addition to largely maintaining the load carrying capacity through the hybrid reinforcement design, the use of shape memory photopolymer endowed a couple of new functionalities to the composites: the plastically deformed laminated composite beam can largely return to its original shape due to the shape memory effect of the polymer matrix, and the flame retardancy of the polymer matrix makes the flammable hemp fiber survive the fire hazard. The findings of this study present exciting prospects for utilizing low-strength and flammable natural fibers in multifunctional load-bearing composites that possess both flame retardancy and shape memory properties. 

Abstract Damage healing in fiber reinforced thermoset polymer composites has been generally divided into intrinsic healing by the polymer itself and extrinsic healing by incorporation of external healing agent. In this study, we propose to use a hybrid extrinsic-intrinsic self-healing strategy to heal delamination in laminated composite induced by low velocity impact. Especially, we propose to use an intrinsic self-healing thermoset vitrimer as an external healing agent, to heal delamination in laminated thermoset polymer composites. To this purpose, we designed and synthesized a new vitrimer, machined it into powders, and strategically sprayed a layer of vitrimer powders at the interface between the laminas during manufacturing. Also, a thermoset shape memory polymer with fire-proof property was used as the matrix. As a result, incorporation of about 3% by volume of vitrimer powders made the laminate exhibit multifunctionalities such as repeated delamination healing, excellent shape memory effect, improved toughness and impact tolerance, and decent fire-proof properties. In particular, the novel vitrimer powder imparted the laminate with first cycle and second cycle delamination healing efficiencies of 98.06% and 85.93%, respectively. The laminate also exhibited high recovery stress of 65.6 MPa. This multifunctional composite laminate has a great potential in various engineering applications, for example, actuators, robotics, deployable structures, and smart fire-proof structures. 

Abstract High-performance lightweight architectures, such as metallic microlattices with excellent mechanical properties have been 3D printed, but they do not possess shape memory effect (SME), limiting their usages for advanced engineering structures, such as serving as a core in multifunctional lightweight sandwich structures. 3D printable self-healing shape memory polymer (SMP) microlattices could be a solution. However, existing 3D printable thermoset SMPs are limited to either low strength, poor stress memory, or non-recyclability. To address this issue, a new thermoset polymer, integrated with high strength, high recovery stress, perfect shape recovery, good recyclability, and 3D printability using direct light printing, has been developed in this study. Lightweight microlattices with various unit cells and length scales were printed and tested. The results show that the cubic microlattice has mechanical strength comparable to or even greater than that of metallic microlattices, good SME, decent recovery stress, and recyclability, making it the first multifunctional lightweight architecture (MLA) for potential multifunctional lightweight load carrying structural applications. 

This study investigates a neoteric approach in manufacturing lunar regolith-filled shape memory vitrimer (SMV) composites for extraterrestrial applications. A SMV with robust mechanical properties was combined with locally available lunar regolith to form a composite material. Fourier Transfer Infrared Spectroscopy (FTIR), Scanning Electron Microscope (SEM), Thermogravimetric Analysis (TGA), and X-ray fluorescence (XRF) were used to characterize the resin, the regolith simulant, and the prepared SMV-regolith composites. We explored conventional synthesis as well as 3D printing methods for manufacturing the composite. Glass fabric-reinforced laminated composites were also prepared to evaluate the impact tolerance and damage healing efficiency. Compressive strength, flexural strength, and impact resistance of the composite were tested at both room and elevated temperatures. A compressive strength of 96.0 MPa and 5.4 MPa were recorded for composite with 40 wt% regolith ratio at room and elevated temperatures, respectively. The glass fabric reinforced SMV-regolith laminate exhibited a bending strength of 232.7 MPa, good impact tolerance under low-velocity impact test, and good healing efficiency up to two damage healing cycles. The 3D printed SMV-regolith composite using a liquid crystal display (LCD)-based printer exhibited a good thermomechanical property with a compressive and tensile strength of 139.16 MPa and 13.99 MPa, respectively, and a good shape memory effect. However, the LCD-based printing using vat-photopolymerization limits the size of the printed samples. Nonetheless, this study shows that utilization of regolith to form advanced composite is possible. SMV regolith composite is a promising material for lunar base applications due to its simple manufacturing process, excellent mechanical properties, and low energy consumption. 

Herein, we report a new solar energy harvesting approach by connecting two form-stable phase change materials in a moist environment with dissolved carbon dioxide (CO₂).