Nanomaterials in 4D Printing: Expanding the Frontiers of Advanced Manufacturing

As an innovative technology, four-dimentional (4D) printing is built upon the principles of three-dimentional (3D) printing with an additional dimension: time. While traditional 3D printing creates static objects, 4D printing generates "responsive 3D printed structures", enabling them to transform or self-assemble in response to external stimuli. Due to the dynamic nature, 4D printing has demonstrated tremendous potential in a range of industries, encompassing aerospace, healthcare, and intelligent devices. Nanotechnology has gained considerable attention owing to the exceptional properties and functions of nanomaterials. Incorporating nanomaterials into an intelligent matrix enhances the physiochemical properties of 4D printed constructs, introducing novel functions. This review provides a comprehensive overview of current applications of nanomaterials in 4D printing, exploring their synergistic potential to create dynamic and responsive structures. Nanomaterials play diverse roles as rheology modifiers, mechanical enhancers, function introducers, and more. The overarching goal of this review is to inspire researchers to delve into the vast potential of nanomaterial-enabled 4D printing, propelling advancements in this rapidly evolving field.

Shape-Memory Polymers Based on Carbon Nanotube Composites

For the past two decades, researchers have been exploring the potential benefits of combining shape-memory polymers (SMP) with carbon nanotubes (CNT). By incorporating CNT as reinforcement in SMP, they have aimed to enhance the mechanical properties and improve shape fixity. However, the remarkable intrinsic properties of CNT have also opened up new paths for actuation mechanisms, including electro- and photo-thermal responses. This opens up possibilities for developing soft actuators that could lead to technological advancements in areas such as tissue engineering and soft robotics. SMP/CNT composites offer numerous advantages, including fast actuation, remote control, performance in challenging environments, complex shape deformations, and multifunctionality. This review provides an in-depth overview of the research conducted over the past few years on the production of SMP/CNT composites with both thermoset and thermoplastic matrices, with a focus on the unique contributions of CNT to the nanocomposite's response to external stimuli.

Evaluation of the Viability of 3D Printing in Recycling Polymers

The increased use of plastics in industrial and agricultural applications has led to high levels of pollution worldwide and is a significant challenge. To address this plastic pollution, conventional methods such as landfills and incineration are used, leading to further challenges such as the generation of greenhouse gas emissions. Therefore, increasing interest has been directed to identifying alternative methods to dispose of plastic waste from agriculture. The novelty of the current research arose from the lack of critical reviews on how 3-Dimensional (3D) printing was adopted for recycling plastics, its application in the production of agricultural plastics, and its specific benefits, disadvantages, and limitations in recycling plastics. The review paper offers novel insights regarding the application of 3D printing methods including Fused Particle Fabrication (FPF), Hot Melt Extrusion (HME), and Fused Deposition Modelling (FDM) to make filaments from plastics. However, the methods were adopted in local recycling setups where only small quantities of the raw materials were considered. Data was collected using a systematic review involving 39 studies. Findings showed that the application of the 3D printing methods led to the generation of agricultural plastics such as Polylactic Acid (PLA), Acrylonitrile Butadiene Styrene (ABS), Polyethylene Terephthalate (PET), and High-Density Polyethylene (HDPE), which were found to have properties comparable to those of virgin plastic, suggesting the viability of 3D printing in managing plastic pollution. However, limitations were also associated with the 3D printing methods; 3D-printed plastics deteriorated rapidly under Ultraviolet (UV) light and are non-biodegradable, posing further risks of plastic pollution. However, UV stabilization helps reduce plastic deterioration, thus increasing longevity and reducing disposal. Future directions emphasize identifying methods to reduce the deterioration of 3D-printed agricultural plastics and increasing their longevity in addition to UV stability.

Bridging Nanomanufacturing and Artificial Intelligence-A Comprehensive Review

Nanomanufacturing and digital manufacturing (DM) are defining the forefront of the fourth industrial revolution-Industry 4.0-as enabling technologies for the processing of materials spanning several length scales. This review delineates the evolution of nanomaterials and nanomanufacturing in the digital age for applications in medicine, robotics, sensory technology, semiconductors, and consumer electronics. The incorporation of artificial intelligence (AI) tools to explore nanomaterial synthesis, optimize nanomanufacturing processes, and aid high-fidelity nanoscale characterization is discussed. This paper elaborates on different machine-learning and deep-learning algorithms for analyzing nanoscale images, designing nanomaterials, and nano quality assurance. The challenges associated with the application of machine- and deep-learning models to achieve robust and accurate predictions are outlined. The prospects of incorporating sophisticated AI algorithms such as reinforced learning, explainable artificial intelligence (XAI), big data analytics for material synthesis, manufacturing process innovation, and nanosystem integration are discussed.

Electro-Mechanical Characterisation and Damage Monitoring by Acoustic Emission of 3D-Printed CB/PLA

Even though the influence of the printing direction on the mechanical properties of 3D-printed samples by fused filament fabrication is established in the literature, very little is known about mechanical and electrical coupling. In this study, electrically conductive polylactic acid filled with carbon black particles undergoes monotonic and repeated progressive tensile loading to better understand the influence of the printing direction on the electro-mechanical properties of three-dimensional-printed samples. The objective is to analyse the electro-mechanical behaviour of this composite for its potential application as an actuator. The classical laminate theory is also applied to evaluate the relevance of this theory in predicting the mechanical characteristics of this material. In addition, a comprehensive damage analysis is performed using acoustic emission, infrared thermography, scanning electron microscopy, and X-ray microcomputed tomography imaging. Results show that the degradation of the mechanical and electrical properties is highly influenced by the printing direction. The appearance and development of crazes in 0° filaments are highlighted and quantified. The conclusions drawn by this study underline the interest in using longitudinal and unidirectional printing directions to improve the conductive path within the samples. Furthermore, the evolution of the resistance throughout the experiments emphasizes the need to control the implemented voltage in the design of future electro-thermally triggered actuators.

4D Printing: The Development of Responsive Materials Using 3D-Printing Technology

Additive manufacturing, widely known as 3D printing, has revolutionized the production of biomaterials. While conventional 3D-printed structures are perceived as static, 4D printing introduces the ability to fabricate materials capable of self-transforming their configuration or function over time in response to external stimuli such as temperature, light, or electric field. This transformative technology has garnered significant attention in the field of biomedical engineering due to its potential to address limitations associated with traditional therapies. Here, we delve into an in-depth review of 4D-printing systems, exploring their diverse biomedical applications and meticulously evaluating their advantages and disadvantages. We emphasize the novelty of this review paper by highlighting the latest advancements and emerging trends in 4D-printing technology, particularly in the context of biomedical applications.

Shape-Morphing Antenna Array by 4D-Printed Multimaterial Miura Origami

The rapid development of four-dimensional (4D) printing technology has resulted in its application in various fields, including radiofrequency (RF) electronics. Moreover, because origami-inspired RF electronics provide a physically deformable geometry, they are good candidates for reconfigurable RF applications. However, previous origami-inspired RF electronics have generally been fabricated on paper for easy folding and unfolding. Although this facilitates easy fabrication, the resultant structures suffer from a lack of rigidity and stability. In this paper, we propose a 4D-printed multimaterial Miura origami structure for RF spectrum applications. For thermal actuation and robustness, the proposed structure consists of high-temperature durable cores with shape memory polymer (SMP) hinges. The high-temperature durable cores provide rigidity to the desired part and reduce the level of distortion of the conductive pattern, while the SMP hinges enable shape morphing. To demonstrate the feasibility of the technique for RF electronics, a shape-morphing pattern reconfigurable antenna array is designed at 2.4 GHz using the proposed 4D-printed multimaterial structure. Through numerical and experimental demonstrations, the proposed antenna's maximum beam direction is changed from 0° to 50° by thermally morphing the Miura origami. In addition, the antenna successfully recovers to its memorized original state.

Fabrication of 3D Printed Polylactic Acid/Polycaprolactone Nanocomposites with Favorable Thermo-Responsive Cyclic Shape Memory Effects, and Crystallization and Mechanical Properties

In this work, 3D printed polylactic acid (PLA)/polycaprolactone (PCL) nanocomposites with favorable thermo-responsive cyclic shape memory effects (SMEs) and crystallization and mechanical properties were fabricated using a two-step method. First, an isocyanate-terminated PCL diol (PCL-NCO) was synthesized through the reaction between isocyanate groups of hexamethylene diisocyanate and active hydroxyl groups of PCL diol, and its physicochemical properties were characterized. A PLA/PCL blend with a PCL content of 50 wt% was fabricated via fused filament fabrication (FFF) 3D printing, and the influence of the PCL-NCO on the SME of the PLA/PCL blend was studied. The results indicated that the PCL-NCO significantly improved the cyclic shape memory performance of 3D printed PLA/PCL blends and was proved to be an effective interface compatibilizer for the blend system. Subsequently, the structure and properties of 3D printed PLA/PCL nanocomposites were investigated in detail by adding cellulose nanocrystal-organic montmorillonite (CNC-OMMT) hybrid nanofillers with different contents. It was found that the hybrid nanofillers greatly enhanced crystallization and mechanical properties of the nanocomposites due to adequate dispersion. The modification of the PLA/PCL blend and the preparation of the 3D printed nanocomposite can not only prolong the service life of a shape memory polymer product, but also broaden its application scope in advanced fields.

Ethical Issues of 4D Printed Medical Devices

Since the dawn of additive manufacturing technologies in the 1980s and 90s, now commonly named 3D printing, the possibility of processing raw materials into freeform designed objects with unprecedented shape complexity opened new avenues for the development of medical devices. Indeed, the geometries of nature and the human body are extremely multifaceted, with even fractal- like or multiscale levels of detail, counting with functional gradients of properties, including topology and topography optimizations, to cite some interesting features. In consequence, classical subtracting manufacturing technologies, shape forming tools, and mass production chains are suboptimal for personalizing medical devices and adequately emulating life.

Study on modified poplar wood powder/polylactic acid high toughness green 3D printing composites

In order to alleviate environmental pollution and the shortage of petroleum resources, improve the utilization of renewable materials, the research of biodegradable green composite materials has become a research hotspot. In this paper, Poplar Wood powder(PWP) and Polylactic acid(PLA) were selected, adding poly lactic acid graft maleic anhydride (MPLA) and Silane coupling agent KH-550 (KH550) as a compatibilizer and coupling agent to improve interface compatibility, at the same time, poly Butylenedioate-co-terephthalate (PBAT) and poly Butylene Succinate (PBS) were added to improve the toughness of the composites. The experimental results show that, the impact strength of 20 %-KMPP/PBAT/PBS composite modified by MPLA and KH550 was 20.70 kJ/m^-2. Secondly, the hydrophobic angle of the composite material is as high as 112°. It is found that the high content of PWP with small particle size (200 mesh) can make it more evenly dispersed in the composite material, and the cross section of the composite material was smooth. The modified composite was 4.24$/kg, which reduced the cost by 28.07 %. The research results have opened up a new way to develop 3D printed biomass composites with low cost, high compatibility, high toughness and good environmental adaptability, and broadened the application scope and value of the composites.

Evaluation of the Physical and Shape Memory Properties of Fully Biodegradable Poly(lactic acid) (PLA)/Poly(butylene adipate terephthalate) (PBAT) Blends

Biodegradable polymers have recently become popular; in particular, blends of poly(lactic acid) (PLA) and poly(butylene adipate terephthalate) (PBAT) have recently attracted significant attention due to their potential application in the packaging field. However, there is little information about the thermomechanical properties of these blends and especially the effect induced by the addition of PBAT on the shape memory properties of PLA. This work, therefore, aims at producing and investigating the microstructural, thermomechanical and shape memory properties of PLA/PBAT blends prepared by melt compounding. More specifically, PLA and PBAT were melt-blended in a wide range of relative concentrations (from 85/15 to 25/75 wt%). A microstructural investigation was carried out, evidencing the immiscibility and the low interfacial adhesion between the PLA and PBAT phases. The immiscibility was also confirmed by differential scanning calorimetry (DSC). A thermogravimetric analysis (TGA) revealed that the addition of PBAT slightly improved the thermal stability of PLA. The stiffness and strength of the blends decreased with the PBAT amount, while the elongation at break remained comparable to that of neat PLA up to a PBAT content of 45 wt%, while a significant increment in ductility was observed only for higher PBAT concentrations. The shape memory performance of PLA was impaired by the addition of PBAT, probably due to the low interfacial adhesion observed in the blends. These results constitute a basis for future research on these innovative biodegradable polymer blends, and their physical properties might be further enhanced by adding suitable compatibilizers.

Polymer-dispersed liquid crystal elastomers as moldable shape-programmable material

The current development of soft shape-memory materials often results in materials that are typically limited to the synthesis of thin-walled specimens and usually rely on complex, low-yield manufacturing techniques to fabricate macro-sized, solid three-dimensional objects. However, such geometrical limitations and slow production rates can significantly hinder their practical implementation. In this work, we demonstrate a shape-memory composite material that can be effortlessly molded into arbitrary shapes or sizes. The composite material is made from main-chain liquid crystal elastomer (MC-LCE) microparticles dispersed in a silicone polymer matrix. Shape-programmability is achieved via low-temperature induced glassiness and hardening of MC-LCE inclusions, which effectively freezes-in any mechanically instilled deformations. Once thermally reset, the composite returns to its initial shape and can be shape-programmed again. Magnetically aligning MC-LCE microparticles prior to curing allows the shape-programmed artefacts to be additionally thermomechanically functionalized. Therefore, our material enables efficient morphing among the virgin, thermally-programmed, and thermomechanically-controlled shapes.

Combined aza-Michael and radical photopolymerization reactions for enhanced mechanical properties of 3D printed shape memory polymers

3D printed shape memory polymers (SMP) were formed by combining aza-Michael addition and light initiated radical polymerization. Amine consumption and acrylate conversion were monitored by 1H-NMR and Fourier transform infrared spectroscopies. Dynamic mechanical analysis and cyclic thermomechanical tensile tests enabled direct observation of the polymer network changes. Increased homogeneity of the 3D network and enhanced SMP properties were achieved after the reaction between residual acrylate functions trapped in the vitrified medium with the secondary amines formed during the process. This allows the fabrication of shape memory objects by 3D printing.

Smart Film Actuators for Biomedical Applications

Taking inspiration from the extremely flexible motion abilities in natural organisms, soft actuators have emerged in the past few decades. Particularly, smart film actuators (SFAs) demonstrate unique superiority in easy fabrication, tailorable geometric configurations, and programmable 3D deformations. Thus, they are promising in many biomedical applications, such as soft robotics, tissue engineering, delivery system, and organ-on-a-chip. In this review, the latest achievements of SFAs applied in biomedical fields are summarized. The authors start by introducing the fabrication techniques of SFAs, then shift to the topology design of SFAs, followed by their material selections and distinct actuating mechanisms. After that, their biomedical applications are categorized in practical aspects. The challenges and prospects of this field are finally discussed. The authors believe that this review can boost the development of soft robotics, biomimetics, and human healthcare.

3D/4D Printing Application for Shape Memory Materials

This new Special Issue of Materials entitled "3D/4D Printing Application for Shape Memory Materials" aims to publish original and review papers dealing with basic and applied research on this emerging technology [...].

Shape Memory Polymer-Based Endovascular Devices: Design Criteria and Future Perspective

Devices for the endovascular embolization of intracranial aneurysms (ICAs) face limitations related to suboptimal rates of lasting complete occlusion. Incomplete occlusion frequently leads to residual flow within the aneurysm sac, which subsequently causes aneurysm recurrence needing surgical re-operation. An emerging method for improving the rates of complete occlusion both immediately after implant and in the longer run can be the fabrication of patient-specific materials for ICA embolization. Shape memory polymers (SMPs) are materials with great potential for this application, owing to their versatile and tunable shape memory properties that can be tailored to a patient’s aneurysm geometry and flow condition. In this review, we first present the state-of-the-art endovascular devices and their limitations in providing long-term complete occlusion. Then, we present methods for the fabrication of SMPs, the most prominent actuation methods for their shape recovery, and the potential of SMPs as endovascular devices for ICA embolization. Although SMPs are a promising alternative for the patient-specific treatment of ICAs, there are still limitations that need to be addressed for their application as an effective coil-free endovascular therapy.

Electrospinning for the Modification of 3D Objects for the Potential Use in Tissue Engineering

Electrospinning is often investigated for biotechnological applications, such as tissue engineering and cell growth in general. In many cases, three-dimensional scaffolds would be advantageous to prepare tissues in a desired shape. Some studies thus investigated 3D-printed scaffolds decorated with electrospun nanofibers. Here, we report on the influence of 3D-printed substrates on fiber orientation and diameter of a nanofiber mat, directly electrospun on conductive and isolating 3D-printed objects, and show the effect of shadowing, taking 3D-printed ears with electrospun nanofiber mats as an example for potential and direct application in tissue engineering in general.

In Situ Synthesis of Gold Nanoparticles in Layer-by-Layer Polymeric Coatings for the Fabrication of Optical Fiber Sensors

A new method is proposed to tune the interferometric response of wavelength-based optical fiber sensors. Using the nanoparticle in situ synthesis (ISS) technique, it is possible to synthesize gold nanoparticles (AuNPs) within a pre-existing polymeric thin film deposited at the end-face of an optical fiber. This post-process technique allows us to adjust the optical response of the device. The effect of the progressive synthesis of AuNPs upon polymeric film contributed to a remarkable optical contrast enhancement and a very high tuning capability of the reflection spectra in the visible and near-infrared region. The spectral response of the sensor to relative humidity (RH) variations was studied as a proof of concept. These results suggest that the ISS technique can be a useful tool for fiber optic sensor manufacturing.

Volumetric Additive Manufacturing of Shape Memory Polymers

Shape memory polymers (SMPs) are stimuli responsive materials with programmable recovery from a deformed state. SMP behavior is often impacted by manufacturing features like layering that can impart anisotropic responses....

Advanced Infill Designs for 3D Printed Shape-Memory Components

Poly(lactic acid) (PLA) is one of the most often used polymers in 3D printing based on the fused deposition modeling (FDM) method. On the other hand, PLA is also a shape memory polymer (SMP) with a relatively low glass transition temperature of ~60 °C, depending on the exact material composition. This enables, on the one hand, so-called 4D printing, i.e., printing flat objects which are deformed afterwards by heating them above the glass transition temperature, shaping them and cooling them down in the desired shape. On the other hand, objects from PLA which have been erroneously deformed, e.g., bumpers during an accident, can recover their original shape to a certain amount, depending on the applied temperature, the number of deformation cycles, and especially on the number of broken connections inside the object. Here, we report on an extension of a previous study, investigating optimized infill designs which avoid breaking in 3-point bending tests and thus allow for multiple repeated destruction and recovery cycles with only a small loss in maximum force at a certain deflection.

Experimental and computational analysis of a pharmaceutical-grade shape memory polymer applied to the development of gastroretentive drug delivery systems

The present paper aims at developing an integrated experimental/computational approach towards the design of shape memory devices fabricated by hot-processing with potential for use as gastroretentive drug delivery systems (DDSs) and for personalized therapy if 4D printing is involved. The approach was tested on a plasticized poly(vinyl alcohol) (PVA) of pharmaceutical grade, with a glass transition temperature close to that of the human body (i.e., 37 °C). A comprehensive experimental analysis was conducted in order to fully characterize the PVA thermo-mechanical response as well as to provide the necessary data to calibrate and validate the numerical predictions, based on a thermo-viscoelastic constitutive model, implemented within a finite element framework. Particularly, a thorough thermal, mechanical, and shape memory characterization under different testing conditions and on different sample geometries was first performed. Then, a prototype consisting of an S-shaped device was fabricated, deformed in a temporary compact configuration and tested. Simulation results were compared with the results obtained from shape memory experiments carried out on the prototype. The proposed approach provided useful results and recommendations for the design of PVA-based shape memory DDSs.

Design, Construction and Tests of a Low-Cost Myoelectric Thumb

Myoelectric signals can be used to control prostheses or exoskeletons as well as robots, i.e., devices assisting the user or replacing a missing part of the body. A typical application of myoelectric prostheses is the human hand. Here, the development of a low-cost myoelectric thumb is described, which can either be used as an additional finger or as prosthesis. Combining 3D printing with inexpensive sensors, electrodes, and electronics, the recent project offers the possibility to produce an individualized myoelectric thumb at significantly lower costs than commercial myoelectric prostheses. Alternatively, a second thumb may be supportive for people with special manual tasks. These possibilities are discussed together with disadvantages of a second thumb and drawbacks of the low-cost solution in terms of mechanical properties and wearing comfort. The study shows that a low-cost customized myoelectric thumb can be produced in this way, but further research on controlling the thumb as well as improving motorization are necessarily to make it fully usable for daily tasks.

Optical elements from 3D printed polymers

3D printing belongs to the emerging technologies of our time. Describing diverse specific techniques, 3D printing enables rapid production of individual objects and creating shapes that would not be produced with other techniques. One of the drawbacks of typical 3D printing processes, however, is the layered structure of the created parts. This is especially problematic in the production of optical elements, which in most cases necessitate highly even surfaces. To meet this challenge, advanced 3D printing techniques as well as other sophisticated solutions can be applied. Here, we give an overview of 3D printed optical elements, such as lenses, mirrors, and waveguides, with a focus on freeform optics and other elements for which 3D printing is especially well suited.