4d printing with smart materials

4D PRINTING WITH

SMART MATERIALSMT5009 – ANALYZING HI-TECH OPPORTUNITIES

Presented by: Imran Ahmad Khan (A0102875E)

Liew Chin Siew (A0098560W)

Loy Yoke Yuan (A0055354H)

Lu Wanheng (A0107258E)

Myint Phone Naing (A0033823M)

Soh Kok Boon Anthony (A0133008W)

1

Outline

• What is 4D Printing?

• Important Technology Aspects of 4D Printing

• SMART Materials’ Properties and Development

• Future Trend Analysis

• Conclusion

2

Outline





• Conclusion

3

3D Printing• An additive printing technique for making three dimensional

solid objects from a digital file

• An improvised form of rapid proto-typing.

• Based on the first Patent published in 1984 under

Stereolithography (SLA).

• Selective laser sintering (SLS) and Fused Deposition

Modeling (FDM) are others common technologies beside

SLA

4

Lix 3D pen – US$ 140

Another Dimension?"We're proposing that the fourth dimension is Time and that over time static objects will transform and adapt“

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"The rigid material becomes a structure and the other layer is the force that can start bending and twisting it. Imagine water pipes that can expand to cope with different capacities or flows and save digging up the street.“

Mr Tibbits, MIT's (Interview with BBC - 2013)

SMART Material

which can

transform upon

external stimuli

3D Printer

Introduction Video to 4D Printing

6

• https://www.youtube.com/watch?v=GIEhi_sAkU8

https://www.youtube.com/watch?v=GIEhi_sAkU8

Overview of 4D Object

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Transformative materials without control is useless.

Smart

Materials

Some materials change physical property upon energy input

Materials expand upon heat

Materials bend upon electric energy

Energy Source

Natural energy source such as heat, pressure, etc

Controlled energy source such as current, electromagnetic wave

Arrange transformative material in precise angle, position

3D printer

4D Object

Precise Positioning

Control

Outline





• Conclusion

8

Important Aspects of 4D Printing

4D Printing

Simulation Software

Multi materials printer

SMART materials

9

Simulation software for self-assembly and design constraints optimization. Autodesk CATIA Open Source

3D printer with capability to print multiple SMART materials Stratasys ROVA SolidView GeoMagic

Materials that change shape upon external stimuli Shape memory alloy Self healing

materials

Simulation Software

• Cyborg 4D Simulation Software

• Cyborg, a design platform spanning applications from the nano-

scale to the human-scale.

• This software allows for simulated self-assembly and programmable

materials as well as optimization for design constraints and joint

folding.

• The aim is to tightly couple this new cross-disciplinary and cross-

scalar design tool with the real-world material transformation of 4D

printing.

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Source: http://www.autodeskresearch.com/projects/cyborg

Software Cost Reduction with Open

Source Technology

11

Top reasons for adopting Open Source1. Quality2. Lower total cost of

ownership3. Ease of deployment4. Ability to access

source code, add features and fix code yourself

5. Better competitive features and technical capabilities

6. Better IT security

Source: Survey results from Black Duck Software

Multi-Smart Materials Printer

12

4D Printer = 3D Printer with multi-smart

materials printing capability

Currently, no standardized hardware architecture yet.

Connex multi material technology Connex1 - Printing capability of 3

materialsSource: http://www.stratasys.com/3d-printers/design-series/objet260-connex1

Portable desktop printer

Printing capability of five materials

Source: http://ordsolutions.com/our-3d-printers/rova3d/

Multi-Smart Materials Printer

• Complete compatibility with current 3D printers which can

print multi-materials.

13

0

5

10

15

2013 2014 2015 2016 2017 2018 2019

$B

illi

on

Year

Market Value Growth

3D printers

Services and materials

List of Smart Materials (I)

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Material Input/Stimulus Output/Response Application

Polymeric gal pH changeSwelling or

contractingArtificial muscle

Electro-rheological

fluidElectric signal Viscosity change

Torsional steering

system damper

Pyroelectric

materialTemperature Electric signal

Personnel sensor

(open super-

market door)

Polymer (eg thin

film cellulose),

ceramic

Humidity changeCapacity/

resistance changeHumidity sensors

Self-Healing

MaterialsForce Force

Smartphone

chassis

Smart metal alloys Temperature Shape Motor actuators

Dielectric

ElastomersVoltage Strain Robotics

List of Smart Materials (II)

Material Input/Stimulus Output/Response Application

Ceramic (eg, La

doped BaTiO3)

Polymer (eg, C-

black filled

poltethylene)

Current (or

Temperate)Resistance

Thermistor

Overcurrent

Protector

Varistor (eg, Bi

doped ZnO)Voltage Resistance Surge Protector

Y2O3 doped ZrO2Change in Oxygen

Partial PressureElectric Signal Oxygen sensor

Piezoelectric

material

Deformation/

Strain electric

signal

Electric Signal

Active noise

control devices,

pressure and

vibration

sensitizing

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Smart Materials

• Smart materials are designed materials that have one or

more properties that can be significantly changed in a

controlled fashion by external stimuli, such as stress,

temperature, moisture, pH, electric or magnetic fields.

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SMART

Materials

Smart Metal

Alloy

Others

(Not covered)

Dielectric

Elastomers

Self-Healing

Polymers

Roadmap of Smart Materials

• R&D activity on transformative materials is still in early

phase.

17

Outline





• Conclusion

18

Self-Healing Materials

• Self-healing material in a historical perspective

• The state of stone bridges and aqueducts from the Roman age is

still quite good, despite the fact that they have been there for

centuries

• The secret is in the ‘mortar’ – based on volcanic ash and lime

• The ancient Romans used in their constructions to glue the bricks

together

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• Lime dissolves in rain

water, and can seep

to cracks. When the

water vaporizes, the

lime deposits inside

the crack

Application to Smartphone

• Self healing smart phone

• LG smartphone, G-Flex, which is curved and has a self-healing

polymer coating on the back: Light scratches disappear before your

eyes

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How do Self Healing Materials Work?

• Synthetic and biological route to healing

• Inspired by nature

• 3 steps self healing process

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1. Activation phase

2. Transportation phase

3. Repair phase

Source:Self-Healing Polymers and Composites by B.J. Blaiszik, S.L.B. Kramer, S.C. Olugebefola, J.S. Moore, N.R. Sottos, and S.R.White

Different Approach to Self-Healing

a) In capsule-based self-healing materials, the healing agent is stored

in capsules until they are ruptured by damage or dissolved.

b) For vascular materials, the healing agent is stored in hollow

channels or fibers until damage ruptures the vasculature and

releases the healing agent.

c) Intrinsic materials contain a latent functionality that triggers self-

healing of damage via thermally reversible reactions, hydrogen

bonding, ionomeric arrangements, or molecular diffusion and

entanglement.

22

Performance Maps of Different Healing

Approach• Development of Self healing polymers

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Source:Self-Healing Polymers and Composites by B.J. Blaiszik, S.L.B. Kramer, S.C. Olugebefola, J.S.

Moore, N.R. Sottos, and S.R.White

Properties of Self-Healing Material

• Material performance as a function of time

• Traditional materials only accumulate damage and fail after a

certain period of use.

• Self healing materials may show some early deterioration, yet its

self healing character makes sure that total failure only occurs after

very long times.

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Properties of Self-Healing Polymers

• Development of Self healing polymers

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Polymer

type

Healing

approach

Chemistry/

method

Best healing

efficiency (%)

Healing

conditions

Thermoplastic

IntrinsicReversible bond

formation75 % < 1 min at -30°C

Capsule

basedInterdiffusion (solvent) 78% 4 – 5 min at 60°C

Intrinsic Photo-induced healing 16% 10 min at 100°C

Intrinsic Nanoparticle healing - 2h at Ambient

Thermoset

VascularThermally reversible

crosslinks60%

30 min at 115°C

6 h at 40°C

VascularThermoplastic

additives45% 1h at 160°C

Thermoset

composites

Capsule

based

Microencapsulation

approach60%

48h at 80°C

24h at Ambient

VascularThermoplastic

additives80% 1.5h at 80°C

Potential Application: Space Structures

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• Benefit in environments and conditions

where access for manual repair is

limited or impossible or where damage

may not be detected.

• Self healing polymers, yet to achieve

high healing efficiency , maximum

efficiency 80% achieved by Thermoset

composites in controlled environment.

• How self-healing materials will

perform under long-term

environment exposure remains as

open question. Accelerated

environment testing of self-healing

systems is critically needed.

Smart Metal Alloys

• Nitinol heat engine

invented in the 1970s that

is capable of converting

heat energy to

mechanical or electrical

energy

• Impact: Efficient

conversion of energy over

small temperature

differences at ambient

conditions

27

Source: Ridgway M. Banks (1983), Single wire Nitinol Engine, United States Patent 4,450,686

28

How do Smart Metal Alloys Work?

List of Smart Metal Alloys

29

Source: S. Barbarino, E.I. Saavedra Flores, R.M. Ajaj, I. Dayyani and M.I. Friswell (2014). A review on shape memory alloys with applications to morphing aircraft, Smart Mater. Struct. 23, 063001

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Metal Alloy Properties


Properties of NiTi Alloys

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Potential Application: Morphing Aircraft

• Overcome limitations of current flight

technology by adapting the geometry of

lifting surfaces to pilot input and different

flight conditions characterizing a typical

mission profile

• Improvement to long-term performance,

reliability and response of metal

actuators is required for this to become

a reality

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Dielectric Elastomer

• Used in conformal speakers.

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Dielectric Elastomer

• Highly efficient transduction from electric energy into mechanical

energy – the theoretical transduction efficiency is 80-90%

• High strain rate up to 300 % as shown below.

• High pressure up to 8MPa and power density of 1 W/g (for

comparison, human muscle is 0.2 W/g and an electric motor with

gearbox is 0.05 W/g)

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Acrylic elastomers showing 300% linear strain

Source: Extending Applications of Dielectric Elastomer Artificial Muscles to Wireless Communication Systems by Seiki Chiba and Mikio Waki

Properties of Dielectric Elastomer

• 1mm thick 3M VHB 4910 uniformly strain to ~300% when

a voltage is applied across it.

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Source: Novel Applications of Dielectric Elastomer Actuators by L. Christopher Stocking

Performance of Dielectric Elastomer

• The energy density of dielectric elastomer has reached 3.4J/g, about

21 times that of single crystal piezoelectrics and more than two orders

of magnitude greater than that of most commercial actuators.

• DE have an actuation pressure/density that is bigger than that of

electrostatic actuators and magnetic actuators, and cause strains that

are bigger than that of piezo electric actuators and magneto strictive

actuators.

36

Source: Dielectric Elastomer Artificial Muscle Actuators: Toward Biomimetic Motion by Ron Pelrine, Roy Kornbluh

Level of Improvement - Performance

37

Source: Advances in Dielectric Elastomers for Actuators and Artificial Muscles by Paul Brochu, Qibing Pei

Potential Application: Artificial muscles• Dielectric elastomers require an external

circuit with a high bias voltage source to

polarize them. To be feasible in real life

application, need to drastically reduce

this voltage requirement.

38

Source: Dielectric Elastomer Artificial Muscle Actuators: Toward Biomimetic Motion byRon Pelrine, Roy Kornbluh, Qibing Pei, Scott Stanford, Seajin Oh, Joe Eckerle

Further Applications of Smart Materials

39

Healthcare

Robotic

AutomotiveIndustry

Consumer

IndustrialManufacturing

Military

Aerospace

Healthcare

40

Nano Scale Objects in Biomedical Engineering. E.g Cardiac tube/Stenthttp://www.nhlbi.nih.gov/health/health-topics/topics/stents

4D printed stent to be maneuvered to a spot and then change form

For example, 4D printed stent that is introduced into an artery – and when ultrasound energy is appliedit balloons up to its needed configuration

Electroactive Polymers for Artificial Limbs http://www.technologyreview.com/article/401750/electroactive-polymers/

An applied voltage changes the polymer’s composition or molecular structure so that it expands, contracts or bends

The motion is smoother and more lifelike than movement generated by mechanical devices.

Smart Materials – Magnetostrictive / Magnetic Shape Memory AlloysKPI – Precision control

Smart Materials – Dielectric Elastomer / Piezoelectric KPI – Reliability

http://www.nhlbi.nih.gov/health/health-topics/topics/stents

http://www.technologyreview.com/article/401750/electroactive-polymers/

Consumer

41

Transformative Shoeshttp://www.smithsonianmag.com/innovation/Objects-That-Change-Shape-On-Their-Own-180951449/?no-ist

Imagine a single shoe for multiple activities:

If you start running, it adapts to being running shoes

If you play basketball, it adapts to support your ankles

If you go on grass, it grows cleats

If it is raining, it becomes waterproof

Adaptive Tyre Compound

4D printed tyre compound which provide adaptive grip on road condition

Smart Materials – Self-healing materialsKPI – Response control

http://www.smithsonianmag.com/innovation/Objects-That-Change-Shape-On-Their-Own-180951449/?no-ist

Industrial Manufacturing

42

Pipe Manufacturing

http://www.youtube.com/watch?v=0gMCZFHv9v8

Current pipe system is very rigid. To cater for higher flow capacity, we have to replace the whole pipe line.

Solution: An adaptive 4D manufacturing capability to produce capacity adaptable pipes

Insulation Wall Manufacturing

Insulation wall that can adapt to outside temperature

Self adaptive wall that maintain heat during winter and less insulation property during summer

Smart Materials – Shape Memory AlloysKPI – Reliability, sensitivity

http://www.youtube.com/watch?v=0gMCZFHv9v8

Robotics

43

More Humanoid Robot

Current robot systems are very rigid due to inherent mechanical property of motors, gears & etc

By precise geometry arranging of multiple transformative materials, we can achieve desired motion, action upon applied energy

End result is more human like robot which can perform more delicate jobs

Possible Smart Materials – Combination of Smart MaterialsKPI – Integration

Outline





• Conclusion

44

Current State of Technology

• 4D printing is a novel advancement to 3D printing technology

• 4D printing is focused on developing materials and newer printing techniques that could reduce the time taken for assembly of parts, in turn improving the overall efficiency of the manufacturing process.

• Parts manufactured using this novel technology would employ different types of SMART materials.

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Source: Frost & Sullivan, June 2014:

Patent Landscape

46

Patent Mining DatabaseThomson Innovation

Search Keywords 4D printing 4D printer Self-healing materials Self-healing polymers Self-healing coatings

Search Timeline1 January 2004 to 23 June 2013

*

**

*

Year of Impact (4D printing)

47


The expected year of widespread/ large-scale adoption of 4D Printing technology has been computed through assessments of

technology advances, industry initiatives, challenges, advances in related industries, and market potential

SectorsExpected Year of Impact

2015 2016 2017 2018 2019 2020 2021 2022 2023 2024

Healthcare

Military

Infrastructure

Automobile

Packaging

Aerospace

Manufacturing

Breadth of Application

48

Impact of Megatrends

49

Size of Innovation Ecosystem

50

Stakeholder Influence Assessment

Size of Innovation Ecosystem

51

Impact of Key Innovations Landscape


Global Footprint

52


Global Development and Adoption Scenario

Region Remarks Intensity of Adoption

NorthAmerica

Various universities in the country have been developing this novel technology.

USA: Maximum R&D activities ongoing for this technology Main focus: Aerospace and defense, automotive, health care,

infrastructure, manufacturing, and packaging Major funding agency: US ARO and DOD

HIGH

Europe Adoption of 4D printing technology or research activities not been greatly evident in this region.

More actively to develop this technology expected in near term MEDIUM

AsiaPacific

Adoption of 4D printing is expected to be somewhat slower in this region compared to the other two regions.

Researchers from Singapore University of Technology have collaborated with the University of Colorado-Boulder for developing a 4D printing technology that incorporates shape memory fibers.

MEDIUM

Global Footprint

53


4D Printing-Adoption Scenario

Outline





• Conclusion

54

Key Conclusion

• Emerging Market Potential • 4D printing technology is expected to significantly increase the efficiency of the

manufacturing process and increase the capability to produce complex parts and products for different industrial sectors. Expected to create a large number of potential applications in diverse industrial sectors (for example, aerospace, defense, automotive, health care, infrastructure, manufacturing, packaging)

• Evolving Ecosystem • 4D printing technology is expected to be adopted by a range of industrial

sectors. Research laboratories, universities, and companies are also expected to increase their 4D printing research activities, further enabling convergence between industries and increasing the breadth of applications of 4D printing technology.

• Technology • 4D printing technology (software, hardware, 4D printing materials) is still in

early phase of S-curve. Dominant hardware/software architecture yet to be established. IP on 4D printing smart materials is building up. 4D technology will be getting increasingly popular as the trends toward its integration with the giant industries like manufacturing and healthcare, have increased.

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Thank You

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