Bioinspired Double-Broadband Switchable Microwave Absorbing Grid Structures with Inflatable Kresling Origami Actuators.

Tunable radar stealth structures are critical components for future military equipment because of their potential to further enhance the design space and performance. Some previous investigations have utilized simple origami structures as the basic adjusting components but failed to achieve the desired broadband microwave absorbing characteristic. Herein, a novel double-broadband switchable microwave absorbing grid structure has been developed with the actuators of inflatable Kresling origami structures. Geometric constraints are derived to endow a bistable feature with this origami configuration, and the stable states are switched by adjusting the internal pressure. An ultra-broadband microwave absorbing structure is proposed with a couple of complementary microwave stealth bands, and optimized by a particle swarm optimization algorithm. The superior electromagnetic performance results from the mode switch activating different absorbing components at corresponding frequencies. A digital adjusting strategy is applied, which effectively achieves a continuously adjusting effect. Further investigations show that the proposed structure possesses superior robustness. In addition, minimal interactions are found between adjacent grid units, and the electromagnetic performance is mainly related to the duty ratio of the units in different states. They have enhanced the microwave absorbing performance of grid structures through a tunable design, a provided a feasible paradigm for other tunable absorbers.

Inverse Design of Energy-Absorbing Metamaterials by Topology Optimization.

Compared with the forward design method through the control of geometric parameters and material types, the inverse design method based on the target stress-strain curve is helpful for the discovery of new structures. This study proposes an optimization strategy for mechanical metamaterials based on a genetic algorithm and establishes a topology optimization method for energy-absorbing structures with the desired stress-strain curves. A series of structural mutation algorithms and design-domain-independent mesh generation method are developed to improve the efficiency of finite element analysis and optimization iteration. The algorithm realizes the design of ideal energy-absorbing structures, which are verified by additive manufacturing and experimental characterization. The error between the stress-strain curve of the designed structure and the target curve is less than 5%, and the densification strain reaches 0.6. Furthermore, special attention is paid to passive pedestrian protection and occupant protection, and a reasonable solution is given through the design of a multiplatform energy-absorbing structure. The proposed topology optimization framework provides a new solution path for the elastic-plastic large deformation problem that is unable to be resolved by using classical gradient algorithms or genetic algorithms, and simplifies the design process of energy-absorbing mechanical metamaterials.

Recent Progress in Active Mechanical Metamaterials and Construction Principles.

Active mechanical metamaterials (AMMs) (or smart mechanical metamaterials) that combine the configurations of mechanical metamaterials and the active control of stimuli-responsive materials have been widely investigated in recent decades. The elaborate artificial microstructures of mechanical metamaterials and the stimulus response characteristics of smart materials both contribute to AMMs, making them achieve excellent properties beyond the conventional metamaterials. The micro and macro structures of the AMMs are designed based on structural construction principles such as, phase transition, strain mismatch, and mechanical instability. Considering the controllability and efficiency of the stimuli-responsive materials, physical fields such as, the temperature, chemicals, light, electric current, magnetic field, and pressure have been adopted as the external stimuli in practice. In this paper, the frontier works and the latest progress in AMMs from the aspects of the mechanics and materials are reviewed. The functions and engineering applications of the AMMs are also discussed. Finally, existing issues and future perspectives in this field are briefly described. This review is expected to provide the basis and inspiration for the follow-up research on AMMs.

Rapid Volatilization Induced Mechanically Robust Shape-Morphing Structures toward 4D Printing.

Inspired by diverse shape-shifting phenomena in nature, various man-made shape programmable materials have been developed for applications in actuators, deployable devices, and soft robots. However, fabricating mechanically robust shape-morphing structures with on-demand, rapid shape-transformation capability, and high load-bearing capacity is still a great challenge. Herein, we report a mechanically robust and rapid shape-shifting material system enabled by the volatilization of a non-fully-reacted, volatile component in a partially cured cross-linking network obtained from photopolymerization. Volume shrinkage induced by the loss of the volatile component is exploited to drive complex shape transformations. After shape transformation, the residual monomers, cross-linkers, and photoinitiators that cannot volatilize still exist in the network, which is ready for a further photopolymerization to significantly stiffen the initial material. Guided by analytic models and finite element analysis, we experimentally demonstrate that a variety of shape transformations can be achieved, including both 2D-to-3D and 3D-to-3D' transformations, such as a buckyball self-folding from a 2D hexagonal lattice sheet and multiple pop-up structures transforming from their initial compact configurations. Moreover, we show that an ultra-low-weight 3D Miura-ori structure transformed from a 2D sheet can hold more than 1600 times its weight after stiffness improvement via postcuring. This work provides a versatile and low-cost method to fabricate rapid and robust shape-morphing structures for potential applications in soft robots, deployable antennas, and optical devices.

Mechanics of shape distortion of DLP 3D printed structures during UV post-curing.

Digital light processing (DLP) three-dimensional (3D) printing technology has advantages of fast printing speed and high printing precision. It can print objects with small and complex geometrical features and has been widely used in jewelry manufacturing and dentistry. In DLP printing, it is common to use post-treatment with UV light irradiation to improve the final mechanical properties. However, it was found that the UV post-curing process can lead to shape distortion and thus reduction of dimension accuracy. In this paper, we combined photopolymerization reaction kinetics and Euler-Bernoulli beam theory to study UV post-curing induced shape distortion of thin structures prepared by DLP 3D printing. Experiments were conducted to characterize the evolution of mechanical behavior of printed samples during the post-printing process, which was correlated to printing parameters (printing time of single-layer, height of single-layer and printing UV intensity), post-curing UV light intensity and the thickness of the strip. Moreover, post-curing induced distortion was used for the fabrication of 3D structures.

Grayscale digital light processing 3D printing for highly functionally graded materials.

Three-dimensional (3D) printing or additive manufacturing, as a revolutionary technology for future advanced manufacturing, usually prints parts with poor control of complex gradients for functional applications. We present a single-vat grayscale digital light processing (g-DLP) 3D printing method using grayscale light patterns and a two-stage curing ink to obtain functionally graded materials with the mechanical gradient up to three orders of magnitude and high resolution. To demonstrate the g-DLP, we show the direct fabrication of complex 2D/3D lattices with controlled buckling and deformation sequence, negative Poisson's ratio metamaterial, presurgical models with stiffness variations, composites for 4D printing, and anti-counterfeiting 3D printing.

3D Printing of Auxetic Metamaterials with Digitally Reprogrammable Shape.

Two-dimensional lattice structures with specific geometric features have been reported to have a negative Poisson's ratio, termed as auxetic metamaterials, that is, stretching-induced expansion in the transversal direction. In this paper, we designed a novel auxetic metamaterial; by utilizing the shape memory effect of the constituent materials, the in-plane moduli and Poisson's ratios can be continuously tailored. During deformation, the curved meshes ensure the rotation of the mesh joints to achieve auxetics. The rotations of these mesh joints are governed by the mesh curvature, which continuously changes during deformation. Because of the shape memory effect, the mesh curvature after printing can be programmed, which can be used to tune the rotation of the mesh joints and the mechanical properties of auxetic metamaterial structures, including Poisson's ratios, moduli, and fracture strains. Using the finite element method, the deformation of these auxetic meshes was analyzed. Finally, we designed and fabricated gradient/digital patterns and cylindrical shells and used the auxetics and shape memory effects to reshape the printed structures.

A finite deformation theory of desolvation and swelling in partially photo-cross-linked polymer networks for 3D/4D printing applications.

Photopolymerization is a process strongly dependent on the light field in the resin. This typically results in a non-uniformly crosslinked network where some parts of the network are fully cross-linked while other parts are partially crosslinked. The partially crosslinked part could exhibit a high volume expansion upon swelling and a high volume shrinkage upon desolvation. Through control over the light field in the photopolymer resin, this feature has been used to create solvent responsive shape changing structures as well as 3D/4D printed smart devices, showing promising application potential. In this paper, we develop a finite deformation theory to consider the nonuniform crosslink density of the network and the interaction between different species inside the network. The mechanical properties of the network are correlated with the reaction process and the existence of residual uncrosslinked monomers is included in the partially crosslinked network. The efficiency of the theory is proved by the finite element simulations of two special applications of the partially crosslinked network.

3D printing of complex origami assemblages for reconfigurable structures.

Origami engineering principles have recently been applied to a wide range of applications, including soft robots, stretchable electronics, and mechanical metamaterials. In order to achieve the 3D nature of engineered structures (e.g. load-bearing capacity) and capture the desired kinematics (e.g., foldability), many origami-inspired engineering designs are assembled from smaller parts and often require binding agents or additional elements for connection. Attempts at direct fabrication of 3D origami structures have been limited by available fabrication technologies and materials. Here, we propose a new method to directly 3D print origami assemblages (that mimic the behavior of their paper counterparts) with acceptable strength and load-bearing capacity for engineering applications. Our approach introduces hinge-panel elements, where the hinge regions are designed with finite thickness and length. The geometrical design of these hinge-panels, informed by both experimental and theoretical analysis, provides the desired mechanical behavior. In order to ensure foldability and repeatability, a novel photocurable elastomer system is developed and the designs are fabricated using digital light processing-based 3D printing technology. Various origami assemblages are produced to demonstrate the design flexibility and fabrication efficiency offered by our 3D printing method for origami structures with enhanced load bearing capacity and selective deformation modes.

Hydrophilic/Hydrophobic Composite Shape-Shifting Structures.

Swelling-induced shape transformation has been widely investigated and applied to the design and fabrication of smart polymer devices, such as soft robotics, biomedical devices, and origami patterns. Previous shape-shifting designs using soft hydrogels have several limitations, including relatively small actuation force, slow responsive speed, and relatively complicated fabrication process. In this paper, we develop a novel hydrophilic/hydrophobic composite structure by using photopolymers. The rubbery nature of the materials used in this composite provides desirable actuation speed and actuation force. The photocurable polymer system could be easily patterned by using the digital light processing technique. Experiments and theoretical analysis were conducted to study the actuation process. We also fabricated several three-dimensional water-responsive shape-shifting structures, including structures with sequential actuation behavior. Finally, the directional bending behavior of the hydrophilic/hydrophobic bilayer plate was investigated.

High-Speed 3D Printing of High-Performance Thermosetting Polymers via Two-Stage Curing.

Design and direct fabrication of high-performance thermosets and composites via 3D printing are highly desirable in engineering applications. Most 3D printed thermosetting polymers to date suffer from poor mechanical properties and low printing speed. Here, a novel ink for high-speed 3D printing of high-performance epoxy thermosets via a two-stage curing approach is presented. The ink containing photocurable resin and thermally curable epoxy resin is used for the digital light processing (DLP) 3D printing. After printing, the part is thermally cured at elevated temperature to yield an interpenetrating polymer network epoxy composite, whose mechanical properties are comparable to engineering epoxy. The printing speed is accelerated by the continuous liquid interface production assisted DLP 3D printing method, achieving a printing speed as high as 216 mm h-1 . It is also demonstrated that 3D printing structural electronics can be achieved by combining the 3D printed epoxy composites with infilled silver ink in the hollow channels. The new 3D printing method via two-stage curing combines the attributes of outstanding printing speed, high resolution, low volume shrinkage, and excellent mechanical properties, and provides a new avenue to fabricate 3D thermosetting composites with excellent mechanical properties and high efficiency toward high-performance and functional applications.

Dissolution of epoxy thermosets via mild alcoholysis: the mechanism and kinetics study.

Thermoset dissolution based on degradable bond or exchange reaction has been recently utilized to achieve thermosetting polymer dissolution and recycling. In this paper, an industrial grade epoxy thermoset was utilized as a model system to demonstrate the thermoset dissolution via solvent assisted transesterification (or alcoholysis) with high efficiency under mild conditions. The anhydride-cured epoxy thermoset was depolymerized by selective ester bond cleavage in 1,5,7-triazabicyclo[4,4,0]dec-5-ene (TBD)-alcohol solution below 180 °C at ordinary pressure in less than two hours. The epoxy dissolution proceeded in a surface erosion mode via transesterification that was coupled with catalyst-alcohol diffusion. Based on this observation, a surface layer model containing three layers, namely the gel layer, solid swollen layer and pure polymer layer was used to analyze the thermoset dissolution kinetics. The epoxy dissolution kinetics was derived from the surface layer model, which could be used to predict the dissolution rate during the diffusion-rate-controlled dissolution process well. The results show that alcohols with larger diffusivity and better solubility lead to a higher alcohol/catalyst concentration in the gel layer and promote faster erosion and dissolution of epoxy. This is the first work to show that it is possible to depolymerize industrial epoxy using the principle of dynamic bonds with fast dissolution rate at mild temperature under ordinary pressure.

Origami by frontal photopolymerization.

Origami structures are of great interest in microelectronics, soft actuators, mechanical metamaterials, and biomedical devices. Current methods of fabricating origami structures still have several limitations, such as complex material systems or tedious processing steps. We present a simple approach for creating three-dimensional (3D) origami structures by the frontal photopolymerization method, which can be easily implemented by using a commercial projector. The concept of our method is based on the volume shrinkage during photopolymerization. By adding photoabsorbers into the polymer resin, an attenuated light field is created and leads to a nonuniform curing along the thickness direction. The layer directly exposed to light cures faster than the next layer; this nonuniform curing degree leads to nonuniform curing-induced volume shrinkage. This further introduces a nonuniform stress field, which drives the film to bend toward the newly formed side. The degree of bending can be controlled by adjusting the gray scale and the irradiation time, an easy approach for creating origami structures. The behavior is examined both experimentally and theoretically. Two methods are also proposed to create different types of 3D origami structures.

Desolvation Induced Origami of Photocurable Polymers by Digit Light Processing.

Self-folding origami is of great interest in current research on functional materials and structures, but there is still a challenge to develop a simple method to create freestanding, reversible, and complex origami structures. This communication provides a feasible solution to this challenge by developing a method based on the digit light processing technique and desolvation-induced self-folding. In this new method, flat polymer sheets can be cured by a light field from a commercial projector with varying intensity, and the self-folding process is triggered by desolvation in water. Folded origami structures can be recovered once immersed in the swelling medium. The self-folding process is investigated both experimentally and theoretically. Diverse 3D origami shapes are demonstrated. This method can be used for responsive actuators and the fabrication of 3D electronic devices.

Effects of oxygen on light activation in covalent adaptable network polymers.

Light activated polymers are a novel group of active materials that deform when irradiated with light at specific wavelengths. This paper focuses on the understanding and evaluation of light activated covalent adaptable networks formed by radical polymerization reactions, which have potential applications as novel actuators, surface patterning, and light-induced bending and folding. In these polymer networks, free radicals are generated upon light irradiation and lead to evolution of the polymer network structure through bond exchange reactions. It is well known that oxygen is an important inhibitor in radical-based chemistry as oxygen reacts with free radicals and renders them as inactive species towards further propagation and reaction. However, it is unclear how radical depletion by oxygen may affect the light-induced actuation. This paper studies the effects of oxygen on both stress relaxation and bending actuation. Light induced stress relaxation experiments are conducted in an environmental chamber where the concentration of oxygen is controlled by the nitrogen flow. A constitutive model that considers oxygen diffusion, radical termination due to oxygen, and the polymer network evolution is developed and used to study the stress relaxation and bending, and the model predictions agree well with experiments. Parametric studies are conducted to identify the situations where the effects of oxygen are negligible and other conditions where they must be considered.