Mechanically programmed shape change in laminated elastomeric composites

3D-printed auxetic-structured intervertebral disc implant for potential treatment of lumbar herniated disc

In this study, a novel artificial intervertebral disc implant with modified “Bucklicrystal” structure was designed and 3D printed using thermoplastic polyurethane. The new implant has a unique auxetic structure with building blocks joined “face-to-face”. The accompanied negative Poisson’s ratio enables its excellent energy absorption and stability under compression. The deformation and load distribution behavior of the implant under various loading conditions (bending, torsion, extension and flexion) has been thoroughly evaluated through finite element method. Results show that, compared to natural intervertebral disc and conventional 3D implant, our new implant exhibits more effective stress transfer and attenuation under practical loading conditions. The implant's ability to contract laterally under compression can be potentially used to alleviate the symptoms of lumbar disc herniation. Finally, the biocompatibility of the implant was assessed in vitro and its ability to restore the physiological function of the disc segment was validated in vivo using an animal model.

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Auxetic-structured IVD implant features negative Poisson's ratio (NPR) behavior.

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Modified “Bucklicrystal”structure exhibits better energy absorption and stability.

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The stress effectively and evenly transfers/attenuates in the auxetic implant.

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Auxetic implant potentially alleviates the symptoms of lumbar disc herniation.

Macromolecule conformational shaping for extreme mechanical programming of polymorphic hydrogel fibers

Mechanical properties of hydrogels are crucial to emerging devices and machines for wearables, robotics and energy harvesters. Various polymer network architectures and interactions have been explored for achieving specific mechanical characteristics, however, extreme mechanical property tuning of single-composition hydrogel material and deployment in integrated devices remain challenging. Here, we introduce a macromolecule conformational shaping strategy that enables mechanical programming of polymorphic hydrogel fiber based devices. Conformation of the single-composition polyelectrolyte macromolecule is controlled to evolve from coiling to extending states via a pH-dependent antisolvent phase separation process. The resulting structured hydrogel microfibers reveal extreme mechanical integrity, including modulus spanning four orders of magnitude, brittleness to ultrastretchability, and plasticity to anelasticity and elasticity. Our approach yields hydrogel microfibers of varied macromolecule conformations that can be built-in layered formats, enabling the translation of extraordinary, realistic hydrogel electronic applications, i.e., large strain (1000%) and ultrafast responsive (~30 ms) fiber sensors in a robotic bird, large deformations (6000%) and antifreezing helical electronic conductors, and large strain (700%) capable Janus springs energy harvesters in wearables.

Long-Term Thermal Aging of Modified Sylgard 184 Formulations

Primarily used as an encapsulant and soft adhesive, Sylgard 184 is an engineered, high-performance silicone polymer that has applications spanning microfluidics, microelectromechanical systems, mechanobiology, and protecting electronic and non-electronic devices and equipment. Despite its ubiquity, there are improvements to be considered, namely, decreasing its gel point at room temperature, understanding volatile gas products upon aging, and determining how material properties change over its lifespan. In this work, these aspects were investigated by incorporating well-defined compounds (the Ashby–Karstedt catalyst and tetrakis (dimethylsiloxy) silane) into Sylgard 184 to make modified formulations. As a result of these additions, the curing time at room temperature was accelerated, which allowed for Sylgard 184 to be useful within a much shorter time frame. Additionally, long-term thermal accelerated aging was performed on Sylgard 184 and its modifications in order to create predictive lifetime models for its volatile gas generation and material properties.

Mechanoactivation of Color and Autonomous Shape Change in 3D-Printed Ionic Polymer Networks

Stimuli-responsive materials can enhance the field of three-dimensional (3D) printing by generating objects that change shape in response to external cues. While temperature and pH are common inputs for initiating a response in a 3D-printed object, there are few examples of using a mechanical input to afford a response. Herein, we report a suite of mechanochromic ionic liquid gel inks that can be used to fabricate 3D-printed objects that use a single mechanoactivation event to elicit both a mechanochromic response and an autonomous shape change. Direct-ink write 3D printing was used to deposit ionic liquid gel inks to create multimaterial objects that underwent a predetermined mechanoactivated shape change (mechanomorphic) when the sample was pulled and then released. When spiropyran was incorporated into the inks, the onset of spiropyran isomerization into its purple merocyanine form occurred at strains dependent upon the particular ion gel ink formulation. We suggest that the color onset could be used as a simple indicator for when the strain required to achieve a predetermined change in shape has been reached, potentially serving as real-time visual cue for the user. Such morphing 3D-printed structures with integrated instructions have potential application to areas including stowable structures as well as multiresponsive autonomous components and sensors.

On the Synergistic Effect of Multi-Walled Carbon Nanotubes and Graphene Nanoplatelets to Enhance the Functional Properties of SLS 3D-Printed Elastomeric Structures

Elastomer-based porous structures realized by selective laser sintering (SLS) are emerging as a new class of attractive multifunctional materials. Herein, a thermoplastic polyurethane (TPU) powder for SLS was modified by 1 wt.% multi-walled carbon nanotube (MWCNTs) or a mixture of MWCNTs and graphene (GE) nanoparticles (70/30 wt/wt) in order to investigate on both the synergistic effect provided by the two conductive nanostructured carbonaceous fillers and the correlation between formulation, morphology, and final properties of SLS printed porous structures. In detail, porous structures with a porosity ranging from 20% to 60% were designed using Diamond (D) and Gyroid (G) unit cells. Results showed that the carbonaceous fillers improve the thermal stability of the elastomeric matrix. Furthermore, the TPU/1 wt.% MWCNTs-GE-based porous structures exhibit excellent electrical conductivity and mechanical strength. In particular, all porous structures exhibit a robust negative piezoresistive behavior, as demonstrated from the gauge factor (GF) values that reach values of about −13 at 8% strain. Furthermore, the G20 porous structures (20% of porosity) exhibit microwave absorption coefficients ranging from 0.70 to 0.91 in the 12–18 GHz region and close to 1 at THz frequencies (300 GHz–1 THz). Results show that the simultaneous presence of MWCNTs and GE brings a significant enhancement of specific functional properties of the porous structures, which are proposed as potential actuators with relevant electro-magnetic interference (EMI) shielding properties.

Bending, curling, and twisting in polymeric bilayers

Polyolefin thermoplastic elastomer (POE) bilayers of varying length (L) to width (W) ratio are formed through traditional polymer processing. Each layer is completely isotropic but the bilayers have an elastic recovery mismatch such that when stretched, one layer recovers to a different extent than the other. Upon stretching bilayers from low to moderate strains and releasing the bilayer bends (curvature, κ, κ < 1/L). Stretching to moderate strain and releasing results in bilayer curling (1/L ≤ κ < 1/W). Finally, stretching to high strains and releasing such that κ ≥ 1/W results in twisting into a helix for L/W > 2π bilayers and rolling into a cylinder for L/W < 2π bilayers. Varying W can change the helical pitch, lp, of twisted bilayers. The twisted bilayer helical rise angle varies between θ = 60 and 90°. Metastability, i.e., bilayers that show a combination of the two behaviors, is observed at long absolute L or short absolute W. The bilayers are modeled using Euler-Bernoulli beam theory to show that the curvature can be predicted using the elastic recovery of the layer that recovers more.

Helical Structures Mimicking Chiral Seedpod Opening and Tendril Coiling

Helical structures are ubiquitous in natural and engineered systems across multiple length scales. Examples include DNA molecules, plants' tendrils, sea snails' shells, and spiral nanoribbons. Although this symmetry-breaking shape has shown excellent performance in elastic springs or propulsion generation in a low-Reynolds-number environment, a general principle to produce a helical structure with programmable geometry regardless of length scales is still in demand. In recent years, inspired by the chiral opening of Bauhinia variegata's seedpod and the coiling of plant's tendril, researchers have made significant breakthroughs in synthesizing state-of-the-art 3D helical structures through creating intrinsic curvatures in 2D rod-like or ribbon-like precursors. The intrinsic curvature results from the differential response to a variety of external stimuli of functional materials, such as hydrogels, liquid crystal elastomers, and shape memory polymers. In this review, we give a brief overview of the shape transformation mechanisms of these two plant's structures and then review recent progress in the fabrication of biomimetic helical structures that are categorized by the stimuli-responsive materials involved. By providing this survey on important recent advances along with our perspectives, we hope to solicit new inspirations and insights on the development and fabrication of helical structures, as well as the future development of interdisciplinary research at the interface of physics, engineering, and biology.

Programming shape and tailoring transport: advancing hygromorphic bilayers with aligned nanofibers

Natural systems utilize nanofiber architectures to guide water transport, tune mechanical properties, and actuate in response to their environment. In order to harness these properties, a hygromorphic bilayer composite comprised of a self-assembled fiber network and an aligned electrospun fiber network was fabricated. Molecular gel self-assembly was utilized to increase hydrophobicity and strength in one layer, while aligned electrospun poly(vinyl alcohol) (PVA) nanofibers increased the rate of hydration and facilitated tunable actuation in the other. Interfacing these two fiber networks in a poly(ethylene oxide-co-epichlorohydrin) (EO-EPI) matrix led to hydration-driven actuation with tunable curvature. Specifically, variations in fiber alignment were achieved by cutting at 0, 90, and 45 degree angles in relation to the length edge of the composite. Along with the ability to program the natural curvature, the utilization of aligned nanofibers increased water transport compared to random nanofiber systems, resulting in a reduction in response time from 20+ minutes to 2-3 minutes.

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.

Direct 4D printing via active composite materials

We describe an approach to print composite polymers in high-resolution three-dimensional (3D) architectures that can be rapidly transformed to a new permanent configuration directly by heating. The permanent shape of a component results from the programmed time evolution of the printed shape upon heating via the design of the architecture and process parameters of a composite consisting of a glassy shape memory polymer and an elastomer that is programmed with a built-in compressive strain during photopolymerization. Upon heating, the shape memory polymer softens, releases the constraint on the strained elastomer, and allows the object to transform into a new permanent shape, which can then be reprogrammed into multiple subsequent shapes. Our key advance, the markedly simplified creation of high-resolution complex 3D reprogrammable structures, promises to enable myriad applications across domains, including medical technology, aerospace, and consumer products, and even suggests a new paradigm in product design, where components are simultaneously designed to inhabit multiple configurations during service.

One-Component Dual Actuation: Poly(NIPAM) Can Actuate to Stable 3D Forms with Reversible Size Change

A rare example of a one-component dual actuator is provided, which displays irreversible change in shape by rolling on contact with water and reversible size change on changing the temperature. The actuator has a bilayer structure with aligned and randomly oriented fibers of poly(N-isopropyl acrylamide). A combination of anisotropic E modulus and temperature dependent swelling/shrinkage provides the dual actuation.