3D printed reversible shape changing soft actuators assisted by liquid crystal elastomers.

In this work, we advance printed active composites by combining 3D printing, printed electronics, and liquid crystal elastomers (LCEs) to achieve soft actuators with free-standing two-way shape changing behaviors. Incorporated LCE strips are activated by Joule heating produced by printed conductive wires, while uniaxial deformation of the LCE strip is utilized as a driving force to achieve bending in the printed composite. The bending behavior of laminated hinges is first characterized in order to obtain a precise control of actuation, which is then exploited to actuate four demonstrative designs: a morphing airplane, a miura-ori structure, a cubic box, and a soft crawler. The soft morphing airplane and miura-ori structure are designed and fabricated with multiple laminated hinges to demonstrate the synergistic actions during actuation. The cubic box is constructed to show the capability of sequential folding by implementing multiple groups of conductive wires to achieve accurately addressable heating with temporal control. Finally, the two-way transformation is utilized as a driving force for the locomotion of a soft crawler stimulated by a periodic rectangular wave current. These examples show the great potential of using the hybrid 3D printing and pick-and-place method and using LCEs to achieve controllable shape change structures for a variety of potential practical applications.

Free-Form Liquid Crystal Elastomers via Embedded 4D Printing.

Liquid crystal elastomers (LCEs) are a class of active materials that can generate rapid, reversible mechanical actuation in response to external stimuli. Fabrication methods for LCEs have remained a topic of intense research interest in recent years. One promising approach, termed 4D printing, combines the advantages of 3D printing with responsive materials, such as LCEs, to generate smart structures that not only possess user-defined static shapes but also can change their shape over time. To date, 4D-printed LCE structures have been limited to flat objects, restricting shape complexity and associated actuation for smart structure applications. In this work, we report the development of embedded 4D printing to extrude hydrophobic LCE ink into an aqueous, thixotropic gel matrix to produce free-standing, free-form 3D architectures without sacrificing the mechanical actuation properties. The ability to 4D print complex, free-standing 3D LCE architectures opens new avenues for the design and development of functional and responsive systems, such as reconfigurable metamaterials, soft robotics, or biomedical devices.

3D Printing of Ridged FeS2 Cathodes for Improved Rate Capability and Custom-Form Lithium Batteries.

Additive manufacturing can enable the fabrication of batteries in nonconventional form factors, enabling higher practical energy density due to improved material packing efficiency of power sources in devices. Furthermore, energy density can be improved by transitioning from conventional Li-ion battery materials to lithium metal anodes and conversion cathodes. Iron disulfide (FeS2) is a prominent conversion cathode of commercial interest; however, the direct-ink-write (DIW) printing of FeS2 inks for custom-form battery applications has yet to be demonstrated or optimized. In this work, DIW printing of FeS2 inks is used to systematically investigate the impact of ink solid concentration on rheology, film shape retention on arbitrary surfaces, cathode morphology, and electrochemical cell performance. We find that cathodes with a ridged interface, produced from the filamentary extrusion of highly concentrated FeS2 inks (60-70% solids w/w%), exhibit optimal power, uniformity, and stability when cycled at higher rates (in excess of C/10). Meanwhile, cells with custom-form, wave-shaped electrodes (printed FeS2 cathodes and pressed lithium anodes) are demonstrated and shown to exhibit similar performance to comparable cells in planar configurations, demonstrating the feasibility of printing onto complex geometries. Overall, the DIW printing of FeS2 inks is shown to be a viable path toward the making of custom-form conversion lithium batteries. More broadly, ridging is found to optimize rate capability, a finding that may have a broad impact beyond FeS2 and syringe extrusion.

4D Printing of Glass Fiber-Regulated Shape Shifting Structures with High Stiffness.

4D printing allows 3D printed structures to change their shapes overtime under external stimuli, finding a wide range of potential applications in actuators, soft robotics, active metamaterials, flexible electronics, and biomedical devices. However, most 4D printing uses soft polymers to accommodate large strain shape-changing capability at the price of low stiffness, which impedes their engineering applications. Here, we demonstrate an approach to design and manufacture self-morphing structures with large deformation and high modulus (∼4.8 GPa). The structures are printed by multimaterial direct ink writing (DIW) using composite inks that contain a high volume fraction of solvent, photocurable polymer resin, and short glass fibers as well as fumed silica. During printing, the glass fibers undergo shear-induced alignment through the nozzle, leading to highly anisotropic mechanical properties. The solvent is then evaporated, during which the aligned glass fibers enable anisotropic shrinkage in the parallel and perpendicular directions to the fiber alignment for shape shifting. A final postphotocuring step is applied to further increase the stiffness of the composite from ∼300 MPa to ∼4.8 GPa. A finite element analysis (FEA) model is developed to predict the influence of the solvent, fiber contents, and fiber orientation on the shape shifting. We demonstrate the anisotropic volume shrinkage of the structures can be used as active hinges to transform printed two-dimensional structures into complex three-dimensional structures with large shape-shifting and outstanding mechanical properties. This strategy for fabricating composite structures with programmable architectures and excellent mechanical properties shows potential applications in morphing lightweight structures with load-bearing capabilities.

Long Liquid Crystal Elastomer Fibers with Large Reversible Actuation Strains for Smart Textiles and Artificial Muscles.

A method for fabricating long, soft, and reversibly actuatable liquid crystal elastomer (LCE) fibers by using direct ink write (DIW) printing was developed. Here, the LCE was produced based on a two-stage thermal-photo curing reaction between a difunctional acrylate monomer and thiol. The LCE ink, mixed with nanoclay to increase the viscosity, was extruded through a nozzle onto a rotating mandrel to obtain a long fiber. After printing, the fiber was first thermally cured on the mandrel, then mechanically stretched, and photocured to achieve liquid crystal chain alignment for stress-free reversible activation. Upon optimizing the ink viscosity and DIW printing parameters, long fibers (up to 1.5 m long from the laboratory) were obtained. The resulting fiber had a modulus of 2 MPa, 51% actuation strain, and a failure strain of well over 100%. The potential of these fibers for applications was demonstrated. The LCE fibers were knit, sewn, and woven to form a variety of smart textiles. The fiber was also used to mimic bicep muscles with both large activation force and activation strain. By incorporating further intelligent characteristics, such as conductivity and biosensing into a single fiber, the LCE fibers could be potentially used for smart clothing, soft robotics, and biomedical devices.