Encoding of direct 4D printing of isotropic single-material system for double-curvature and multimodal morphing. (July 2022)

• Record Type: Journal Article
• Authors: Zou, Bihui; Song, Chao; He, Zipeng; Ju, Jaehyung
• Is Part Of: Extreme mechanics letters. Volume 54(2022)
• Publication Date: 2022-07
• Subjects: Direct 4D printing -- Doubly curved surfaces -- Self-actuation -- Inverse design; Mechanics -- Periodicals; Mechanics, Applied -- Periodicals; Mechanics; Electronic journals; Periodicals; 531.05
• DOI: 10.1016/j.eml.2022.101779
• Languages: English
• ISSNs: 2352-4316

Abstract

Abstract: The ability to morph flat sheets into complex 3D shapes is extremely useful for fast manufacturing and saving materials while also allowing volumetrically efficient storage and shipment and a functional use. Direct 4D printing is a compelling method to morph complex 3D shapes out of as-printed 2D plates. However, most direct 4D printing methods require multi-material systems involving costly machines. Moreover, most works have used an open-cell design for shape shifting by encoding a collection of 1D rib deformations, which cannot remain structurally stable. Here, we demonstrate the direct 4D printing of an isotropic single-material system to morph 2D continuous bilayer plates into doubly curved and multimodal 3D complex shapes whose geometry can also be locked after deployment. We develop an inverse-design algorithm that integrates extrusion-based 3D printing of a single-material system to directly morph a raw printed sheet into complex 3D geometries such as a doubly curved surface with shape locking. Furthermore, our inverse-design tool encodes the localized shape-memory anisotropy during the process, providing the processing conditions for a target 3D morphed geometry. Our approach could be used for conventional extrusion-based 3D printing for various applications including biomedical devices, deployable structures, smart textiles, and pop-up Kirigami structures.