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4D Composites

Professor Richard S. Trask Dr Anna B. BakerDr Tom M. Llewellyn-JonesDr Simon Bates

[email protected]

4D CompositesProfessor Richard Trask

Experiment!

4D MaterialsThis is a 3D printed multi-layered hydrophilic-hydrophobic

polyurethane architecture with designed actuation


4D CompositesApplication of biological principles for future manufacturing?

“growth that causes an organism to develop its shape”

“interaction of system‐intrinsic capacities and external environmental forces”


4D CompositesApplication of biological principles for future manufacturing?

In biologically engineered architectures, ‘morphogenesis’, is described as a process of evolutionary development and growth that causes an organism to develop its shape through the interaction of system‐intrinsic capacities and external environmental

forces.

[Espinosa et al, 2009].


Interaction mechanism1. Sequential activation

2. Linear vs non-linear movement3. Independent folding/ bending/ twisting

4. Coupled movement – folding/ bending/ twisting

Smart dynamic structure

Smart static structure

Smart material

Printer toolpath programming1. Optimisation algorithm

2. Origami/ Kirigami principles

3D Printer1. Printer resolution

2. Multi-materials deposition

Stimulus1. Biological – protein/ enzyme

2. Chemical – pH/ H2O/ oxidation/ reduction3. Physical – ultrasound/ light/ temperature

4DPrinting

Sequence showing the self‐folding of a 4D‐Printed multi‐material single strand

into a coil, zig‐zag, hexagon

AB Baker, DF Wass, RS Trask, Sensors and Actuators B: Chemical, Vol 254, January 2018, 519‐525

4D‐Printing – Additive Manufacturing of Smart Materials

[Trask Group, 2018]

4D CompositesDesigned and Programmed for Self-Assembly


4D Composites4D field-effect additive manufacturing

Field effect alignment

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1mm

P W

PZT

P R

λ2

Mic

rogr

aph

Aco

ustic

fie

ld

Act

ive

sour

ces

φx = 0, φy = π/2

In‐plane instantaneous alignment

Field effect alignment additive manufacturing

Llewellyn‐Jones TM, Drinkwater BW, Trask RS 2016 3D printed components with ultrasonically arranged microscale structure, Smart Materials and Structures 25 (2), 02LT01


4D Composites4D field-effect additive manufacturing

1mm

P W

PZT

P R

λ2

Field effect alignment additive manufacturing

Llewellyn‐Jones TM, Drinkwater BW, Trask RS 2016 3D printed components with ultrasonically arranged microscale structure, Smart Materials and Structures 25 (2), 02LT01


• Hydrophilic‐hydrophobic polyurethane responsive hinges • 3D printer ‐ Ultimaker Original desktop 3D printer with Flex3 drive extruder. Print speed ~ 20 mm s‐1• Materials – TPU Ninjaflex (elastomer) and Tecophillic TPU (hydrogel) • Modify print pathways to promote new actuation pathways• Upon hydration the trilayer bends out‐of‐plane at the location of the skin gaps.

4D Composites4D materials for additive manufacturing


4D Composites4D materials for additive manufacturing


4D Composites4D materials for additive manufacturingHydrophilic‐hydrophobic polyurethane responsive actuated SINGLE DIRECTION hinges for the folding and deployment of complex origami tessellations

Tool paths for cube a) bottom elastomer skin, b) middle hydrogel core and c) top elastomer skin

Tool paths for octahedron a) bottom elastomer skin, b) middle hydrogel core and c) top elastomer skin


4D Composites4D materials for additive manufacturingHydrophilic‐hydrophobic polyurethane responsive actuated MULTI‐DIRECTIONAL hinges for the folding and deployment of complex origami tessellations


Future Directions and Challenges• Extension of printing process to create an even

more diverse range of shape-changes, including:

• Non-planar 4D constructs – (1) the application of a curved-layer tool-path (i.e. individual layers with variable z) to enable buckling domes, and (2) printing on cylindrical print beds creating tubular bilayer/trilayer architectures for application in keyhole surgery

• Hierarchical 4D movement – ‘4D materiome’ where different actuation strategies occur at different length scales.

• Actuation speed - the introduction of a porogen (dissolvable particles used to create a porous structure) to control the rate of actuation of the hinges and through the combination of non-porous and porous hydrogels enable sequential actuation.

• Actuation sequence – single vs multi stimuli, coupled or independent movement (bending and/or twisting), and non-linear vs linear

3D printed PU skin

3D Printed hydrogel core and hinge gap

Material Building Blocks

Additive

Fusion

Subtractive

Process

Property Structure

Function & Requirements

4D MATERIOME

Material Building Blocks

Additive

Fusion

Subtractive

Property Structure

Function & Requirements

Active SensingFeedback Loop

Leng

th S

cale

Hie

rarc

hica

l Len

gth


Experiment - Outcome!

• Direct control of the print pathways and in‐fill direction during 3D construction, permits the realisation of reversible organic movement, rather than being limited to traditional origami folds.

• The dissimilar processing temperatures of the TPU and hydrogel permit stacked assembly of complex folding/ bending patterns

Hydrophilic‐hydrophobic polyurethane for actuated TAILORED BENDING for deployment of complex ‘organic’ architectures.

4D Composites

Professor Richard S. Trask Dr Anna BakerDr Tom Llewellyn-JonesDr Simon Bates

[email protected]

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