Bioinspired Microorigami by Self-Folding Polymer Films

4D printing for biomedical applications

While three-dimensional (3D) printing excels at fabricating static constructs, it fails to emulate the dynamic behavior of native tissues or the temporal programmability desired for medical devices. Four-dimensional (4D) printing is an advanced additive manufacturing technology capable of fabricating constructs that can undergo pre-programmed changes in shape, property, or functionality when exposed to specific stimuli. In this Perspective, we summarize the advances in materials chemistry, 3D printing strategies, and post-printing methodologies that collectively facilitate the realization of temporal dynamics within 4D-printed soft materials (hydrogels, shape-memory polymers, liquid crystalline elastomers), ceramics, and metals. We also discuss and present insights about the diverse biomedical applications of 4D printing, including tissue engineering and regenerative medicine, drug delivery, in vitro models, and medical devices. Finally, we discuss the current challenges and emphasize the importance of an application-driven design approach to enable the clinical translation and widespread adoption of 4D printing.

Programmable spatial deformation by controllable off-center freestanding 4D printing of continuous fiber reinforced liquid crystal elastomer composites

Owing to their high deformation ability, 4D printed structures have various applications in origami structures, soft robotics and deployable mechanisms. As a material with programmable molecular chain orientation, liquid crystal elastomer is expected to produce the freestanding, bearable and deformable three-dimensional structure. However, majority of the existing 4D printing methods for liquid crystal elastomers can only fabricate planar structures, which limits their deformation designability and bearing capacity. Here we propose a direct ink writing based 4D printing method for freestanding continuous fiber reinforced composites. Continuous fibers can support freestanding structures during the printing process and improve the mechanical property and deformation ability of 4D printed structures. In this paper, the integration of 4D printed structures with fully impregnated composite interfaces, programmable deformation ability and high bearing capacity are realized by adjusting the off-center distribution of the fibers, and the printed liquid crystal composite can carry a load of up to 2805 times its own weight and achieve a bending deformation curvature of 0.33 mm^-1 at 150 °C. This research is expected to open new avenues for creating soft robotics, mechanical metamaterials and artificial muscles.

Modeling Self-Rollable Elastomeric Films for Building Bioinspired Hierarchical 3D Structures

In this work, an innovative model is proposed as a design tool to predict both the inner and outer radii in rolled structures based on polydimethylsiloxane bilayers. The model represents an improvement of Timoshenko's formula taking into account the friction arising from contacts between layers arising from rolling by more than one turn, hence broadening its application field towards materials based on elastomeric bilayers capable of large deformations. The fabricated structures were also provided with surface topographical features that would make them potentially usable in different application scenarios, including cell/tissue engineering ones. The bilayer design parameters were varied, such as the initial strain (from 20 to 60%) and the bilayer thickness (from 373 to 93 µm). The model matched experimental data on the inner and outer radii nicely, especially when a high friction condition was implemented in the model, particularly reducing the error below 2% for the outer diameter while varying the strain. The model outperformed the current literature, where self-penetration is not excluded, and a single value of the radius of spontaneous rolling is used to describe multiple rolls. A complex 3D bioinspired hierarchical elastomeric microstructure made of seven spirals arranged like a hexagon inscribed in a circumference, similar to typical biological architectures (e.g., myofibrils within a sarcolemma), was also developed. In this case also, the model effectively predicted the spirals' features (error smaller than 18%), opening interesting application scenarios in the modeling and fabrication of bioinspired materials.

Compressive Buckling Fabrication of 3D Cell-Laden Microstructures

Tissue architecture is a prerequisite for its biological functions. Recapitulating the three-dimensional (3D) tissue structure represents one of the biggest challenges in tissue engineering. Two-dimensional (2D) tissue fabrication methods are currently in the main stage for tissue engineering and disease modeling. However, due to their planar nature, the created models only represent very limited out-of-plane tissue structure. Here compressive buckling principle is harnessed to create 3D biomimetic cell-laden microstructures from microfabricated planar patterns. This method allows out-of-plane delivery of cells and extracellular matrix patterns with high spatial precision. As a proof of principle, a variety of polymeric 3D miniature structures including a box, an octopus, a pyramid, and continuous waves are fabricated. A mineralized bone tissue model with spatially distributed cell-laden lacunae structures is fabricated to demonstrate the fabrication power of the method. It is expected that this novel approach will help to significantly expand the utility of the established 2D fabrication techniques for 3D tissue fabrication. Given the widespread of 2D fabrication methods in biomedical research and the high demand for biomimetic 3D structures, this method is expected to bridge the gap between 2D and 3D tissue fabrication and open up new possibilities in tissue engineering and regenerative medicine.

Shape Morphable Hydrogel/Elastomer Bilayer for Implanted Retinal Electronics

Direct fabrication of a three-dimensional (3D) structure using soft materials has been challenging. The hybrid bilayer is a promising approach to address this challenge because of its programable shape-transformation ability when responding to various stimuli. The goals of this study are to experimentally and theoretically establish a rational design principle of a hydrogel/elastomer bilayer system and further optimize the programed 3D structures that can serve as substrates for multi-electrode arrays. The hydrogel/elastomer bilayer consists of a hygroscopic polyacrylamide (PAAm) layer cofacially laminated with a water-insensitive polydimethylsiloxane (PDMS) layer. The asymmetric volume change in the PAAm hydrogel can bend the bilayer into a curvature. We manipulate the initial monomer concentrations of the pre-gel solutions of PAAm to experimentally and theoretically investigate the effect of intrinsic mechanical properties of the hydrogel on the resulting curvature. By using the obtained results as a design guideline, we demonstrated stimuli-responsive transformation of a PAAm/PDMS flower-shaped bilayer from a flat bilayer film to a curved 3D structure that can serve as a substrate for a wide-field retinal electrode array.

3D Self-Assembled Microelectronic Devices: Concepts, Materials, Applications

Modern microelectronic systems and their components are essentially 3D devices that have become smaller and lighter in order to improve performance and reduce costs. To maintain this trend, novel materials and technologies are required that provide more structural freedom in 3D over conventional microelectronics, as well as easier parallel fabrication routes while maintaining compatability with existing manufacturing methods. Self-assembly of initially planar membranes into complex 3D architectures offers a wealth of opportunities to accommodate thin-film microelectronic functionalities in devices and systems possessing improved performance and higher integration density. Existing work in this field, with a focus on components constructed from 3D self-assembly, is reviewed, and an outlook on their application potential in tomorrow's microelectronics world is provided.

Biomimetic Nonuniform, Dual-Stimuli Self-Morphing Enabled by Gradient Four-Dimensional Printing

Programmable nonuniform deformation is of great significance for self-shape-morphing systems that are commonly seen in biological systems and also has practical applications in drug delivery, biomedical devices and robotics, etc. Here, we present a novel gradient four-dimensional (4D) printing method toward biomimetic nonuniform, dual-stimuli self-morphing. By modeling and printing graded active materials with water swelling properties, we can configure continuously smooth gradients of volume fraction of the active material in bilayer structures. The variation of swelling ratio mismatch between the two layers can be delicately regulated, which results in the programmable nonuniform shape transformation. The shape-shifting results can be predicted by the established mathematical model and computational simulations. Furthermore, we demonstrate dual-stimuli self-morphing structures by printing the graded water-responsive elastomer materials onto a heat-shrinkable shape memory polymer, which could produce different shape changes in response to humidity and different temperatures. This method pioneers a versatile approach to broaden the design space for 4D printing and will be compatible with a wide range of active materials meeting various requirements in diverse potential applications.

Folding 2D Structures into 3D Configurations at the Micro/Nanoscale: Principles, Techniques, and Applications

Compared to their 2D counterparts, 3D micro/nanostructures show larger degrees of freedom and richer functionalities; thus, they have attracted increasing attention in the past decades. Moreover, extensive applications of 3D micro/nanostructures are demonstrated in the fields of mechanics, biomedicine, optics, etc., with great advantages. However, the mainstream micro/nanofabrication technologies are planar ones; therefore, they cannot be used directly for the construction of 3D micro/nanostructures, making 3D fabrication at the micro/nanoscale a great challenge. A promising strategy to overcome this is to combine the state-of-the-art planar fabrication techniques with the folding method to produce 3D structures. In this strategy, 2D components can be easily produced by traditional planar techniques, and then, 3D structures are constructed by folding each 2D component to specific orientations. In this way, not only will the advantages of existing planar techniques, such as high precision, programmable patterning, and mass production, be preserved, but the fabrication capability will also be greatly expanded without complex and expensive equipment modification/development. The goal here is to highlight the recent progress of the folding method from the perspective of principles, techniques, and applications, as well as to discuss the existing challenges and future prospectives.

Dual-responsive, shape-switching bilayers enabled by liquid crystal elastomers

Materials that change shape are attractive candidates to replace traditional actuators for applications with power or size restrictions. In this work, we design a polymeric bilayer that changes shape in response to both heat and water by the incorporation of a water-responsive hydrophilic polymer with a heat-responsive liquid crystal elastomer. The distinct shape changes based on stimulus are controlled by the molecular order, and consequently the anisotropic modulus, of a liquid crystal elastomer. In response to water, the hydrophilic polymer layer expands, bending the bilayer along the path dictated by the anisotropic modulus of the liquid crystal elastomer layer, which is approximately 5 times higher along the molecular orientation than in perpendicular directions. We demonstrate that by varying the direction of this stiffer axis in LCE films, helical pitch of the swollen bilayer can be controlled from 0.1 to 20 mm. By spatially patterning the stiffer axis with a resolution of 900 μm², we demonstrate bilayers that fold and bend based on the pattern within the LCE. In response to heat, the liquid crystal elastomer contracts along the direction of molecular order, and when this actuation is constrained by the hydrophilic polymer, this contraction results in a 3D shape that is distinct from the shape seen in water. Furthermore, by using the vitrification of the dry hydrophilic polymer this 3D shape can be retained in the bilayer after cooling. By utilizing sequential exposure to heat and water, we can drive the initially flat bilayer to reversibly shift between 3D shapes.

Bio nano ink for 4D printing membrane proteins

Photo curable bio-nano ink was designed, developed and printed using a stereolithographic printer.

Biomimetic 4D printing

Shape-morphing systems can be found in many areas, including smart textiles, autonomous robotics, biomedical devices, drug delivery and tissue engineering. The natural analogues of such systems are exemplified by nastic plant motions, where a variety of organs such as tendrils, bracts, leaves and flowers respond to environmental stimuli (such as humidity, light or touch) by varying internal turgor, which leads to dynamic conformations governed by the tissue composition and microstructural anisotropy of cell walls. Inspired by these botanical systems, we printed composite hydrogel architectures that are encoded with localized, anisotropic swelling behaviour controlled by the alignment of cellulose fibrils along prescribed four-dimensional printing pathways. When combined with a minimal theoretical framework that allows us to solve the inverse problem of designing the alignment patterns for prescribed target shapes, we can programmably fabricate plant-inspired architectures that change shape on immersion in water, yielding complex three-dimensional morphologies.

Self-Assembled On-Chip-Integrated Giant Magneto-Impedance Sensorics

A novel method relying on strain engineering to realize arrays of on-chip-integrated giant magneto-impedance (GMI) sensors equipped with pick-up coils is put forth. The geometrical transformation of an initially planar layout into a tubular 3D architecture stabilizes favorable azimuthal magnetic domain patterns. This work creates a solid foundation for further development of CMOS compatible GMI sensorics for magnetoencephalography.

Elasto-Capillary Folding Using Stop-Programmable Hinges Fabricated by 3D Micro-Machining

We show elasto-capillary folding of silicon nitride objects with accurate folding angles between flaps of (70.6 ± 0.1)° and demonstrate the feasibility of such accurate micro-assembly with a final folding angle of 90°. The folding angle is defined by stop-programmable hinges that are fabricated starting from silicon molds employing accurate three-dimensional corner lithography. This nano-patterning method exploits the conformal deposition and the subsequent timed isotropic etching of a thin film in a 3D shaped silicon template. The technique leaves a residue of the thin film in sharp concave corners which can be used as an inversion mask in subsequent steps. Hinges designed to stop the folding at 70.6° were fabricated batchwise by machining the V-grooves obtained by KOH etching in (110) silicon wafers; 90° stop-programmable hinges were obtained starting from silicon molds obtained by dry etching on (100) wafers. The presented technique has potential to achieve any folding angle and opens a new route towards creating structures with increased complexity, which will ultimately lead to a novel method for device fabrication.

Shape-responsive liquid crystal elastomer bilayers

Monodomain liquid crystal elastomers (LCEs) are shape-responsive materials, but shape changes are typically limited to simple uniaxial extensions or contractions. Here, we demonstrate that complex surface patterns and shape changes, including patterned wrinkles, helical twisting, and reversible folding, can be achieved in LCE-polystyrene (PS) bilayers. LCE-PS bilayer shape changes are achieved in response to simple temperature changes and can be controlled through various material parameters including overall aspect ratio and LCE and polystyrene film thicknesses. Deposition of a patterned PS film on top of an LCE enables the preparation of an elastomer that reversibly twists and a folding leaf-like elastomer, which opens and closes in response to temperature changes. The phenomena are captured through finite element simulations, in quantitative agreement with experiments.