Shape-shifting 4D-printed Structures using Ferromagnetic PLA through Microwave actuation
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Date
2024-05
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The Ohio State University
Abstract
Four-dimensional (4D) printing is an expanding field that uses external stimuli to prompt a reaction in a 3D-printed structure. The ability to have a structure autonomously react when in the presence of the chosen stimulant has led to extensive research on the subject and its various stimuli, with applications ranging from the medical field to the aerospace field. This research presents a method of 4D printing that revolves around the combined use of polylactic acid (PLA) and ferromagnetic PLA to create shape-shifting structures that deform when actuated with microwave heating. These structures were fabricated through a fused-deposition modeling (FDM) printer, with the deformation controlled by the infill pattern and material composition of the structure. By layering longitudinal and latitudinal infill patterns either next to each other or on top of each other, in- or out-of-plane bending could be achieved. Also, a numerical model was created through Abaqus CAE to provide a simulation-based approach to match and predict the results of the experimental structures. The results of testing on simple layered bar structures showed that by changing the amount of heater element in the model, out-of-plane bending ranging from 15.5-22.5% of the body’s total length occurred when heated in the microwave for 60 seconds. Simulation results provided numerical values that closely matched the experimental data, getting deformation that was within 5% error of the experimental data. Building off the testing of this simple bar shape, experimental and simulation testing was conducted on a 4D “star” shaped structure that was programmed so that only selected regions would experience deformation. The results of this showed that the deformable regions showed significant deformation, deforming by 30% when heated for 90 seconds, while the non-deforming regions remained still. The simulation results supported this data, getting deformation within 10% error of the experimental data.
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Keywords
Additive Manufacturing, 3D Printing, 4D Printing, Microwave Heating, Finite-Element Analysis, Abaqus Simulation