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Abstract Repairing fractured metals to extend their useful lifetimes advances sustainability and mitigates carbon emissions from metal mining and processing. While high‐temperature techniques are being used to repair metals, the increasing ubiquity of digital manufacturing and “unweldable” alloys, as well as the integration of metals with polymers and electronics, call for radically different repair approaches. Herein, a framework for effective room‐temperature repair of fractured metals using an area‐selective nickel electrodeposition process refered to as electrochemical healing is presented. Based on a model that links geometric, mechanical, and electrochemical parameters to the recovery of tensile strength, this framework enables 100% recovery of tensile strength in nickel, low‐carbon steel, two “unweldable” aluminum alloys, and a 3D‐printed difficult‐to‐weld shellular structure using a single common electrolyte. Through a distinct energy‐dissipation mechanism, this framework also enables up to 136% recovery of toughness in an aluminum alloy. To facilitate practical adoption, this work reveals scaling laws for the energetic, financial, and time costs of healing, and demonstrates the restoration of a functional level of strength in a fractured standard steel wrench. Empowered with this framework, room‐temperature electrochemical healing can open exciting possibilities for the effective, scalable repair of metals in diverse applications. 

Abstract Owing to the fact that effective properties of low‐density cellular solids heavily rely on their underlying architecture, a variety of explicit and implicit techniques exists for designing cellular geometries. However, most of these techniques fail to present a correlation among architecture, internal forces, and effective properties. This paper introduces an alternative design strategy based on the static equilibrium of forces, equilibrium of polyhedral frames, and reciprocity of form and force. This novel approach reveals a geometric relationship among the truss system architecture, topological dual, and equilibrium of forces on the basis of 3D graphic statics. This technique is adapted to devise periodic strut‐based cellular architectures under certain boundary conditions and they are manipulated to construct shell‐based (shellular) cells with a variety of mechanical properties. By treating the materialized unit cells as representative volume elements (RVE), multiscale homogenization is used to investigate their effective linear elastic properties. Validated by experimental tests on 3D printed funicular materials, it is shown that by manipulating the RVE topology using the proposed methodology, alternative strut materialization schemes, and rational addition of bracing struts, cellular mechanical metamaterials can be systematically architected to demonstrate properties ranging from bending‐ to stretching‐dominated, realize metafluidic behavior, or create novel hybrid shellulars. 

In this research study, the fracture strength of flat 10 mm thick annealed glass sheets having an abrasive water-jet cut surface and bearing against a transparent interface material is experimentally investigated. The transparent interface material is necessary to provide axial-compressive force continuity in modular compression-dominant all- glass shell structures. A series of short glass columns were tested in axial compression under a variety of load cases, which included cyclic, creep, and monotonic-to-fracture loading. A target glass fracture bearing stress of 36.6 MPa is identified and represents an upper bound bearing stress for annealed glass compression members failing in a flexural buckling mode. The study concludes the transparent thermoplastic material, known as Surlyn, was able to achieve a fracture strength that exceeds the target value and that the fracture strength is not affected by cyclic or creep loading. Consequently, column-related failure limit states will occur before glass fracture is associated with interface bearing. Glass fracture occurs in Type-I mode, reflecting the presence of interface tensile stress. Furthermore, the monotonic bearing stiffness in the service range of 5 to 15 MPa is increased by 20 % and 16 % for samples subjected to cyclic and creep loading, respectively, relative to monotonic-only samples. 

This paper aims to advance the field of additive manufacturing by producing multimaterial objects with intricate topological features and polylithic material distribution through an integrated approach. First, we develop a Single-Nozzle Multi-Filament (SNMF) system equipped with active mixing to blend multiple filaments and deposit a programmable mixture. The system can also deposit gradient transitions between different materials within a single print. Second, we establish a numerical model to represent the material transitional behavior and validated it with experiments. The model enables the precise control of the material transitional interface to ensure high material fidelity. Third, we propose three strategies for designing and modeling multimaterial objects catering to different application scenarios, including image sampling, 2D discrete patches, and 3D surface division. The system’s capabilities were validated through six case studies designed and fabricated through the above approaches for distinct application scenarios, demonstrating the successful materialization of complex designs with multiple functionalities. 

Multi-layer spatial structures usually take considerable external loads with a small material usage at all scales. Polyhedral graphic statics (PGS) provides a method to design multi-layer funicular polyhedral structures, and the structural forms are usually materialized as space frames. Our previous research shows that the intrinsic planarity of the polyhedral geometries can be harnessed for efficient fabrication and construction processes using flat-sheet materials. Sheet-based structures are advantageous over conventional space frame systems because sheets can provide more load paths and constrain the kinematic degrees of freedom of the nodes. Therefore, they are more capable of taking a wider variety of load cases compared to space frames. Moreover, sheet materials can be fabricated into complex shapes using CNC milling, laser cutting, water jet cutting, and CNC bending techniques. However, not all sheets are necessary as long as the load paths are preserved and the system does not have kinematic degrees of freedom. To find an efficient set of faces that satisfies the requirements, this paper first incorporates and adapts the matrix analysis method to calculate the kinematic degrees of freedom for sheet-based structures. Then, an iterative algorithm is devised to help find a reduced set of faces with zero kinematic degrees of freedom. To attest to the advantages of this method over bar-node construction, a comparative study is carried out using finite element analysis. The results show that, with the same material usage, the sheet-based system has improved performance than the framework system under a range of loading scenarios. 

In this experimental research a transparent thermoplastic manufactured by the DOW Corporation and known as Surlyn is investigated for use as an interface material in fabrication of an all-glass pedestrian bridge. The bridge is modular in construction and fabricated from a series of interlocking hollow glass units (HGU) that are geometrically arranged to form a compression dominant structural system. Surlyn is used as a friction-based interface between neighbouring HGUs preventing direct glass-to-glass contact. An experimental program consisting of axial loading of short glass columns (SGC) sandwiched between Surlyn sheets is used to quantify the bearing capacity at which glass fracture occurs at the glass-Surlyn interface location. Applied load cases include 100,000 cycles of cyclic load followed by 12 hours of sustained load followed by monotonic load to cracking, and monotonic loading to cracking with no previous load history. Test results show that Surlyn functions as an effective interface material with glass fracture occurring at bearing stress levels in excess of the column-action capacity of an individual HGU. Furthermore, load cycling and creep loading had no effect on the glass fracture capacity. However, the load history had a nominal effect on Surlyn, increasing stiffness and reducing deformation. 

Multi-layer spatial structures usually take considerable external loads with very limited material usage at all scales, and Polyhedral Graphic Statics (PGS) provides a method to design multi-layer funicular polyhedral structures. The structural forms usually materialized as space frames. Our previous research shows that the intrinsic planarity of the polyhedral geometries can be harnessed for efficient fabrication and construction processes using flat-sheet materials. Sheet-based structures are advantageous over the conventional space frame systems because sheets can provide more load paths and constrain the kinematic degrees of freedom of the nodes. Therefore, they can take a wider range of load compared to space frames. Moreover, sheet materials can be fabricated to complex shapes using CNC milling, laser cutting, water jet cutting, and CNC bending techniques. However, not all sheets are necessary as long as the load paths are preserved, and the system does not have kinematic degrees of freedom. To find a reduced set of faces that satisfies the requirements, this paper incorporates and adapts the matrix analysis method to calculate the kinematic degree of freedom of sheet-based structure. Built upon this, an iterative algorithm is devised to help find the reduced set of faces with zero kinematic degree of freedom. To attest the advantage of this method over bar-node construction, a comparative study is carried out using finite element analysis. The result shows that, with the same material usage, the sheet-based system has improved performance than the framework system under a wide range of loading scenarios. 

Nature has always been the master of design skills to which humans only aspire to, but new approaches bring that aspiration closer to our reach than ever before. Through 4.5 billion years of iterations, nature has shown us its extraordinary craftsmanship, breeding a variety of species whose body structures have gradually evolved to adapt to natural phenomena and make full use of their unique characteristics. The dragonfly wing, among body structure is an extreme example of efficient use of materials and minimal weight while remaining strong enough to withstand the tremendous forces of flight. It has long been the object of scientific research examining its structural advantages to applying their principles to fabricated designs.1 We can imitate its form and create duplicates, but thoroughly understanding the dragonfly wing’s mechanism, behavior and design logic is no trivial task. 

Polyhedral Graphic Statics (PGS) is an effective tool for form-finding and constructing complex yet efficient spatial funicular structures. The intrinsic planarity of polyhedral geometries can be leveraged for efficient fabrication and construction using flat sheet materials, such as glass. Our previous research used PGS for the form-finding of a 3 m-span, modular glass bridge prototype to be built with thirteen unique hollow glass units (HGUs) in a compression-only configuration. This paper reports its design optimization, fabrication, and subsequent modular assembly process. The computational modeling of the geometries is facilitated with the efficient half-face data structure provided by PolyFrame, a software that implements PGS. Regular float glass and acrylic are selected as the main structural materials, and they are fabricated using 5-axis water jet cutting and CNC milling techniques. With the help of 3 M™ Very High Bond tape, the glass parts and acrylic parts are bonded as HGUs, which serve as the basic structural and assembly modules. Surlyn sheets are used as interface material to prevent glass-to-glass direct contact between HGUs. The digital model is also simulated using ANSYS to ensure the effectiveness of the design. Due to the lightweight of the HGUs, the assembly of the bridge can be done by one person without the requirement of any heavy construction machinery.