Mechanical evaluation of 3D printed biomimetic non-Euclidean saddle geometries mimicking the mantis shrimp.

Engineering design has drawn inspiration from naturally occurring structures to advance manufacturing processes and products, termed biomimetics. For example, the mantis shrimp, orderStomatopoda, is capable of producing one of the fastest appendage strikes in the world with marginal musculoskeletal displacement. The extreme speed of the mantis shrimp's raptorial appendage is due to the non-Euclidean hyperbolic paraboloid (i.e. saddle) shape within the dorsal region of the merus, which allows substantial energy storage through compression in the sagittal plane. Here, investigation of 3D printed synthetic geometries inspired by the mantis shrimp saddle geometry has revealed insights for elastic energy storage (i.e. spring-like) applications. Saddles composed of either astiffor aflexibleresin were investigated for spring response to explore the geometric effects. By modulating the saddle geometry and testing the spring response, it was found that, for thestiffresin, the spring constant was improved as the curvature of the contact and orthogonal faces were maximized and minimized, respectively. For theflexibleresin, it was found that the spring constant increased by less than 250 N mm-1as the saddle geometry changed, substantiating that the flexible component of mantis saddles does not contribute to energy storage capabilities. The geometries of two saddles from the mantis shrimp speciesO. scyllaruswere estimated and exhibited similar trends to manufactured saddles, suggesting that modulating saddle geometry can be used for tailored energy storage moduli in spatially constrained engineering applications.

Impact of Backbone Composition on Homopolymer Dynamics and Brush Block Copolymer Self-Assembly.

Four series of brush block copolymers (BBCP), with near identical side chain compositions but varying backbone structures, were synthesized to investigate the effect of backbone structure on the process of thermal BBCP self-assembly to photonic crystals (PCs). Each of the self-assembled PC films were examined by reflection measurements, small angle X-ray scattering measurements, and scanning electron microscopy to compare the resulting properties of the polymeric photonic crystal and the nanostructured morphology impacted by the backbone structure. It was found that the composition of the brush backbone within a BBCP has a dramatic effect on the ability of the BBCP to self-assemble into ordered nanostructures and on the local ordering of the nanostructure morphology accessed with higher molecular weight (MW) BBCPs (> 1,500 kg/mol). BBCPs with a norbornene imide-based backbone were able to thermally self-assemble to longer wavelength reflecting PCs and had higher fidelity ordering of lamellar nanostructures with higher MW polymers. By analyzing the melt rheological responses of the backbone compositions, both as linear polymers and homobrush polymers, it was concluded that the inherent fragility of the backbone promotes enhanced local ordering in the lamellar nanostructure morphology as well as access to larger domain sizes.

3D printing using powder melt extrusion.

Additive manufacturing promises to revolutionize manufacturing industries. However, 3D printing of novel build materials is currently limited by constraints inherent to printer designs. In this work, a bench-top powder melt extrusion (PME) 3D printer head was designed and fabricated to print parts directly from powder-based materials rather than filament. The final design of the PME printer head evolved from the Rich Rap Universal Pellet Extruder (RRUPE) design and was realized through an iterative approach. The PME printer was made possible by modifications to the funnel shape, pressure applied to the extrudate by the auger, and hot end structure. Through comparison of parts printed with the PME printer with those from a commercially available fused filament fabrication (FFF) 3D printer using common thermoplastics poly(lactide) (PLA), high impact poly (styrene) (HIPS), and acrylonitrile butadiene styrene (ABS) powders (< 1 mm in diameter), evaluation of the printer performance was performed. For each build material, the PME printed objects show comparable viscoelastic properties by dynamic mechanical analysis (DMA) to those of the FFF objects. However, due to a significant difference in printer resolution between PME (X-Y resolution of 0.8 mm and a Z-layer height calibrated to 0.1 mm) and FFF (X-Y resolution of 0.4 mm and a Z-layer height of 0.18 mm), as well as, an inherently more inconsistent feed of build material for PME than FFF, the resulting print quality, determined by a dimensional analysis and surface roughness comparisons, of the PME printed objects was lower than that of the FFF printed parts based on the print layer uniformity and structure. Further, due to the poorer print resolution and inherent inconsistent build material feed of the PME, the bulk tensile strength and Young's moduli of the objects printed by PME were lower and more inconsistent (49.2 ± 10.7 MPa and 1620 ± 375 MPa, respectively) than those of FFF printed objects (57.7 ± 2.31 MPa and 2160 ± 179 MPa, respectively). Nevertheless, PME print methods promise an opportunity to provide a platform on which it is possible to rapidly prototype a myriad of thermoplastic materials for 3D printing.