Bio-Inspired Motion Mechanisms: Computational Design and Material Programming of Self-Adjusting 4D-Printed Wearable Systems

Recent Advances in 4D Printing of Advanced Materials and Structures for Functional Applications

4D printing has attracted tremendous worldwide attention during the past decade. This technology enables the shape, property, or functionality of printed structures to change with time in response to diverse external stimuli, making the original static structures alive. The revolutionary 4D-printing technology offers remarkable benefits in controlling geometric and functional reconfiguration, thereby showcasing immense potential across diverse fields, including biomedical engineering, electronics, robotics, and photonics. Here, a comprehensive review of the latest achievements in 4D printing using various types of materials and different additive manufacturing techniques is presented. The state-of-the-art strategies implemented in harnessing various 4D-printed structures are highlighted, which involve materials design, stimuli, functionalities, and applications. The machine learning approach explored for 4D printing is also discussed. Finally, the perspectives on the current challenges and future trends toward further development in 4D printing are summarized.

3D-printed liquid metal polymer composites as NIR-responsive 4D printing soft robot

4D printing combines 3D printing with nanomaterials to create shape-morphing materials that exhibit stimuli-responsive functionalities. In this study, reversible addition-fragmentation chain transfer polymerization agents grafted onto liquid metal nanoparticles are successfully employed in ultraviolet light-mediated stereolithographic 3D printing and near-infrared light-responsive 4D printing. Spherical liquid metal nanoparticles are directly prepared in 3D-printed resins via a one-pot approach, providing a simple and efficient strategy for fabricating liquid metal-polymer composites. Unlike rigid nanoparticles, the soft and liquid nature of nanoparticles reduces glass transition temperature, tensile stress, and modulus of 3D-printed materials. This approach enables the photothermal-induced 4D printing of composites, as demonstrated by the programmed shape memory of 3D-printed composites rapidly recovering to their original shape in 60 s under light irradiation. This work provides a perspective on the use of liquid metal-polymer composites in 4D printing, showcasing their potential for application in the field of soft robots.

A conceptual design of circular adaptive façade module for reuse

Climate change has an impact on the ecosystem, and subsequently, it affects the built environment. Building envelope has a vital role in controlling the integration between indoor and outdoor environmental quality. The responsivity of the façade has proven its efficiency in optimizing the global energy performance of buildings. Adaptive façades are multifunctional reconciling envelope dynamic systems that improve sustainability with the purpose of utilizing environmental parameters. This paper tackles the research gap in integrating façades circularity, adaptive envelopes, and design for disassembly. The research investigates the merge between biodegradability, circularity of adaptive façades components, and interior space micro-climate control for energy efficiency. This paper presents a proof of concept for a circular adaptive façade during two phases in its life cycle: operation and reuse phases. A scientific quantitative method took place which is based on a hybrid method; computational simulation, smart control, and an up-scale model. Adaptability is investigated through the façade life cycle from design to disassembly instead of demolition and consequent waste production, by exploiting sustainable materials. As a result, an empirical prototype is constructed. The prototype provides 3 levels of adaptability across the design, operation, and disassembly for reuse. Subsequently, this work proposes an up-scale physical model that can help in mitigating the climate change effects.

Adhesion Behavior in Fish: From Structures to Applications

In nature, some fish can adhere tightly to the surface of stones, aquatic plants, and even other fish bodies. This adhesion behavior allows these fish to fix, eat, hide, and migrate in complex and variable aquatic environments. The adhesion function is realized by the special mouth and sucker tissue of fish. Inspired by adhesion fish, extensive research has recently been carried out. Therefore, this paper presents a brief overview to better explore underwater adhesion mechanisms and provide bionic applications. Firstly, the adhesion organs and structures of biological prototypes (e.g., clingfish, remora, Garra, suckermouth catfish, hill stream loach, and goby) are presented separately, and the underwater adhesion mechanisms are analyzed. Then, based on bionics, it is explained that the adhesion structures and components are designed and created for applications (e.g., flexible gripping adhesive discs and adhesive motion devices). Furthermore, we offer our perspectives on the limitations and future directions.

4D Printing in Biomedical Engineering: Advancements, Challenges, and Future Directions

4D printing has emerged as a transformative technology in the field of biomedical engineering, offering the potential for dynamic, stimuli-responsive structures with applications in tissue engineering, drug delivery, medical devices, and diagnostics. This review paper provides a comprehensive analysis of the advancements, challenges, and future directions of 4D printing in biomedical engineering. We discuss the development of smart materials, including stimuli-responsive polymers, shape-memory materials, and bio-inks, as well as the various fabrication techniques employed, such as direct-write assembly, stereolithography, and multi-material jetting. Despite the promising advances, several challenges persist, including material limitations related to biocompatibility, mechanical properties, and degradation rates; fabrication complexities arising from the integration of multiple materials, resolution and accuracy, and scalability; and regulatory and ethical considerations surrounding safety and efficacy. As we explore the future directions for 4D printing, we emphasise the need for material innovations, fabrication advancements, and emerging applications such as personalised medicine, nanomedicine, and bioelectronic devices. Interdisciplinary research and collaboration between material science, biology, engineering, regulatory agencies, and industry are essential for overcoming challenges and realising the full potential of 4D printing in the biomedical engineering landscape.

Cross-Sectional 4D-Printing: Upscaling Self-Shaping Structures with Differentiated Material Properties Inspired by the Large-Flowered Butterwort (Pinguicula grandiflora)

Extrusion-based 4D-printing, which is an emerging field within additive manufacturing, has enabled the technical transfer of bioinspired self-shaping mechanisms by emulating the functional morphology of motile plant structures (e.g., leaves, petals, capsules). However, restricted by the layer-by-layer extrusion process, much of the resulting works are simplified abstractions of the pinecone scale's bilayer structure. This paper presents a new method of 4D-printing by rotating the printed axis of the bilayers, which enables the design and fabrication of self-shaping monomaterial systems in cross sections. This research introduces a computational workflow for programming, simulating, and 4D-printing differentiated cross sections with multilayered mechanical properties. Taking inspiration from the large-flowered butterwort (Pinguicula grandiflora), which shows the formation of depressions on its trap leaves upon contact with prey, we investigate the depression formation of bioinspired 4D-printed test structures by varying each depth layer. Cross-sectional 4D-printing expands the design space of bioinspired bilayer mechanisms beyond the XY plane, allows more control in tuning their self-shaping properties, and paves the way toward large-scale 4D-printed structures with high-resolution programmability.

Codesign of Biobased Cellulose-Filled Filaments and Mesostructures for 4D Printing Humidity Responsive Smart Structures

Hygromorphic smart structures are advantageous as passively actuated systems for generating movement, with applications ranging from weather-responsive architectural building skins to adaptive wearables and microrobotics. Four-dimensional (4D) printing is a valuable method for multiscale fabrication and physical programming of such structures. However, material limitations in terms of printability, responsiveness, and mechanical properties are major bottlenecks in achieving reliable and repeatable humidity-responsive actuation. We propose a codesign method for 4D printing hygromorphic structures through fused filament fabrication, incorporating parallel development of (1) biobased cellulose-filled filaments with varying stiffness and hygroresponsiveness, and (2) designed mesoscale structuring in printed elements. We first describe the design of a pallet of filaments produced by compounding cellulose powder in mass ratios of 0-30% within two matrix polymers with high and low stiffness. We then present the design, fabrication, and testing of a series of 4D-printed prototypes tuned to change shape, that is, open and close, in response to relative humidity (RH). The structures can fully transform in conditions of 35-90% RH, which corresponds to naturally occurring shifts in RH in daily and seasonal weather cycles. Furthermore, their motion is fast (within the range of minutes), fully reversible, and repeatable in numerous cycles. These results open new opportunities for the utilization of 4D printing and natural resources for the development of functional humidity-responsive smart structures.

A perspective on plant robotics: from bioinspiration to hybrid systems

As miscellaneous as the Plant Kingdom is, correspondingly diverse are the opportunities for taking inspiration from plants for innovations in science and engineering. Especially in robotics, properties like growth, adaptation to environments, ingenious materials, sustainability, and energy-effectiveness of plants provide an extremely rich source of inspiration to develop new technologies-and many of them are still in the beginning of being discovered. In the last decade, researchers have begun to reproduce complex plant functions leading to functionality that goes far beyond conventional robotics and this includes sustainability, resource saving, and eco-friendliness. This perspective drawn by specialists in different related disciplines provides a snapshot from the last decade of research in the field and draws conclusions on the current challenges, unanswered questions on plant functions, plant-inspired robots, bioinspired materials, and plant-hybrid systems looking ahead to the future of these research fields.

Design, fabrication and application of self-spiraling pattern-driven 4D-printed actuator

Self-spiraling actuators are widely found in nature and have high research and actuator-application value in self-lock and self-assembly. Four-dimensional (4D) printing is a new generation additive manufacturing of smart materials and has shown great potential for the fabrication of multi-functional and customized structures. The microarchitecture design of a bilayer actuator could bring flexible and diversified self-spiraling behaviors and more possibilities for practical application by combing 4D printing. This work investigates the stimuli effects of fiber patterns and fabrication parameters on self-spiraling behaviors of the bilayer actuator via both experimental and theoretical methods. This work may potentially provide pattern design guidance for 4D-printed self-spiraling actuators to meet different application requirements.

4D Printing of Freestanding Liquid Crystal Elastomers via Hybrid Additive Manufacturing

Liquid crystal elastomers (LCE) are appealing candidates among active materials for 4D printing, due to their reversible, programmable and rapid actuation capabilities. Recent progress has been made on direct ink writing (DIW) or Digital Light Processing (DLP) to print LCEs with certain actuation. However, it remains a challenge to achieve complicated structures, such as spatial lattices with large actuation, due to the limitation of printing LCEs on the build platform or the previous layer. Herein, a novel method to 4D print freestanding LCEs on-the-fly by using laser-assisted DIW with an actuation strain up to -40% is proposed. This process is further hybridized with the DLP method for optional structural or removable supports to create active 3D architectures in a one-step additive process. Various objects, including hybrid active lattices, active tensegrity, an actuator with tunable stability, and 3D spatial LCE lattices, can be additively fabricated. The combination of DIW-printed functionally freestanding LCEs with the DLP-printed supporting structures thus provides new design freedom and fabrication capability for applications including soft robotics, smart structures, active metamaterials, and smart wearable devices.

Bioinspired Self-Shaping Clay Composites for Sustainable Development

Bioinspired self-shaping is an approach used to transform flat materials into unusual three-dimensional (3D) shapes by tailoring the internal architecture of the flat material. Bioinspiration and bioinspired materials have a high potential for fostering sustainable development, yet are often fashioned out of expensive and synthetic materials. In this work, we use bioinspiration to endow clay with self-shaping properties upon drying. The composites created are based on clay and starch, and the internal architecture is built using celery fibers. The viscosity, shrinkage, and bending of the architected composite monolayers are studied for several compositions by measuring penetration depth and using optical characterization methods. Bilayer structures inspired from plants are then processed using a simple hand layup process to achieve bending, twisting, and combinations of those after drying. By layering a mixture of 32 vol% clay, 25.8 vol% starch, and 42.2 vol% water with 40 wt% embedded aligned celery fibers, it is possible to obtain the desired shape change. The work presented here aims at providing a simple method for teaching the concept of bioinspiration, and for creating new materials using only clay and plant-based ingredients. Rejuvenating clay with endowed self-shaping properties could further expand its use. Furthermore, the materials, methods, and principles presented here are affordable, simple, largely applicable, and could be used for sustainable development in the domain of education as well as materials and structures.

Mono-Material 4D Printing of Digital Shape-Memory Components

Dynamic shading systems in buildings help reduce solar gain. Actuated systems, which depend on renewable energy with reduced mechanical parts, further reduce building energy consumption compared to traditional interactive systems. This paper investigates stimuli-responsive polymer application in architectural products for sustainable energy consumption, complying with sustainable development goals (SDGs). The proposed research method posits that, by varying the infill percentage in a pre-determined manner inside a 3D-printed mono-material component, directionally controlled shape change can be detected due to thermal stimuli application. Thus, motion behavior can be engineered into a material. In this study, PLA+, PETG, TPU and PA 6 printed components are investigated under a thermal cycle test to identify a thermally responsive shape-memory polymer candidate that actuates within the built environment temperature range. A differential scanning calorimetry (DSC) test is carried out on TPU 95A and PA 6 to interpret the material shape response in terms of transitional temperatures. All materials tested show an anisotropic shape-change reaction in a pre-programmed manner, complying with the behavior engineered into the matter. Four-dimensional (4D)-printed PA6 shows shape-shifting behavior and total recovery to initial position within the built environment temperature range.