Professional Documents
Culture Documents
INTRODUCTION
Technology has always been amazing us with its beautiful inventions in the nature by
making the life of human simpler to a greater extent. Additive manufacturing, more popularly
known as 3-Dimensional (3D) printing technology, has been developed for more than 30 years.
Recently, 3D printing has been recognized as a disruptive technology for future advanced
manufacturing systems. With a great potential to change everything from our daily lives to the
global economy, significant advances in 3D printing technology have been made with respect to
materials, printers, and processes .Now an innovative concept of printing technology known as
4D printing technology has been developed. Although similar to 3D printing, 4D printing
technology involves the fourth dimension of time in addition to the 3D space coordinates.
Therefore, one can regard 4D printing as giving the printed structure the ability to change its
form or function with time (t) under stimuli such as pressure, temperature, wind, water, or light.
1.1 BACKGROUND
The term 4D printing is developed in a collaboration between MIT´s Self-Assembly Lab
and Stratasys education and R&D department. In February 2013, Skylab Tibbits, co-director and
founder of the Self-Assembly Lab located at MIT´s International Design Center, unveiled the
technology “4D printing” during a talk at TED conference held in Long Beach, California.MIT´s
Self-Assembly Lab, 3D printing manufacturer Stratasys and 3D software company Autodesk are
the key players in the development of 4D printing technology.
1.2 OBJECTIVE
Though the knowledge about this technology has not yet reached to common people in the
world still there is a lot of research going on in different labs at universities and research centers,
each one getting different results which demonstrate that this technology could be brought into
reality very soon. Currently 4D-printing requires complex and time-consuming post-processing
steps to mechanically program each component. Also, most commercial printers can only print
4D using a single material, which greatly limits design choices. But a research team led by Jerry
Qi, a mechanical engineering professor at Georgia Institute of Technology, along with scientists
at the Singapore University of Technology and Design, have developed a powerful new 4D
printer that can create self-assembling 4D-structures much more quickly and efficiently.
1|Page
2. 4D PRINTING TECHNOLOGY
FIG. 1. Schematic of 1-, 2-, 3-, and 4D concepts. A 4D structure is a structure (x, y, z) made by 3D
changes over time (t). Arrows indicate the direction of change with respect to time .
2|Page
2.2 PROCESS FOR 4D PRITNING
4d printing similar to current additive manufacturing process (3D printing). The main
difference is the programmable materials or smart materials which are used for making the
product. The4D printing relies predominantly on four factors—
✓ The basic additive manufacturing process, ✓ Types of
stimulus-responsive material, and ✓ Interaction mechanisms.
✓ Smart design.
3|Page
Fig. 1.1 Generic process of CAD to part, showing all 7 stages Step
1: CAD
All AM parts must start from a software model that fully describes the external geometry.
This can involve the use of almost any professional CAD solid modelling software, but the
output must be a 3D solid or surface representation. Reverse engineering equipment (e.g., laser
scanning) can also be used to create this representation.
Step 2: Conversion to STL
Nearly every AM machine accepts the STL file format, which has become a defect
standard, and nearly every CAD system can output such a file format. This file describes the
external closed surfaces of the original CAD model and forms the basis for calculation of the
slices.
4|Page
Step 3: Transfer to AM Machine and STL File Manipulation
The STL file describing the part must be transferred to the AM machine. Here, there may be
some general manipulation of the file so that it is the correct size, position, and orientation for
building.
The AM machine must be properly set up prior to the build process. Such settings would relate to
the build parameters like the material constraints, energy source, layer thickness, timings, etc.
Step 5: Build
Building the part is mainly an automated process and the machines can largely carryon without
supervision. Only superficial monitoring of the machine needs to take place at this time to ensure
no errors have taken place like running out of material, power or software glitches, etc.
Step 6: Removal
Once the AM machine has completed the build, the parts must be removed. This may require
interaction with the machine, which may have safety interlocks ensure for example that the
operating temperatures are sufficiently low or that there are no actively moving parts.
Once removed from the machine, parts may require an amount of additional cleaning up before
they are ready for use. Parts may be weak at this stage or they may have supporting features that
must be removed. This therefore often requires time and careful, experienced manual
manipulation.
5|Page
2.2.2 SMART MATERIALS
Stimulus-responsive material, often known as smart materials or programmable materials,
is highly dynamic in form and functions. The type of stimuli-responsive materials is the key
element to grant the capability of self transformation and determines the type of stimuli needed to
trigger the change in property and the functionality of the component in 4D printing. The
properties of stimuli responsive materials permit the phenomena of coupling or conversion of
energy between various physical domains; for example, converting thermal energy into
mechanical work. This coupling of energy can be direct or indirect. Direct energy coupling refers
to mechanical response due to field induced eigen strain in the stimulus-responsive materials,
whereas indirect is mechanical response due to field-induced. Change in stiffness or other
properties. The types of stimulus-responsive materials capable of change in physical properties
can be classified into shape-change material and shape memory material. Shape-change material
possessed stimulus-induced behaviour known as shape-change effect (SCE). Shape-change
material transforms instantly and spontaneously in response to its stimulus, and returns to its
original or permanent shape when the stimulus is removed. Shape memory polymers have the
ability to memorize and recover to their trained shape from a temporary shape when stimulus is
applied, known as shape memory effect (SME).
6|Page
the mechanical deformation. Both Rr and Rf have to add up to 100% to be measured as an
effective SMP. The calculation for strain recovery and fixity rate is made up of
Rr=100%×(ε−εrec)/ε and Rf=100%×ε/εload; whereby ε = fixed strain after cooling and
unloading; εrec = strain after recovery; and εload=maximum strain under load . One-way shape
memory effect:
The majority of SMPs have a one-way shape memory effect which is irreversible. When an
external stimulus is applied, the deformation (temporary) shape will become a permanent shape.
A programming step (Fig. 2) is needed for the object to return back to its temporary shape.
Figure 2 describes the process of the one-way shape memory effect where the SMP changes from
its temporary shape (A) back to the permanent original shape (B) under an applied stimulus. In
the programming process, the SMP is first heated above transition temperature to soften the
material, so that a deformation force (e.g., loading) can be applied to the original shape. The
predeformed shape is cooled under the load to a fixed temporary shape. When the unloaded fixed
temporary shape is exposed to stimuli, in this case is heat, the original shape (B) is recovered
(Fig. 3)
Two-way shape memory effect
SMP with two-way shape memory effect has the ability to remember two different shapes when
exposed to stimuli. The material can change from a temporary shape back to its permanent shape
(Fig. 4) and the change is reversible.
Zhou emphasized that this behaviour is neither mechanically nor structurally constrained,
thereby allowing for multiple switching between encoded shapes without applying any external
force. The two-way SME can be found in liquid crystalline elastomers and photo-actuated
deformation polymers . Chen et al. successfully demonstrated the two-way shape memory
behaviour using a polymer laminate prepared from a 1.0 mm-thick active layer of PHAG5000
polyurethane-based shape memory with a 1.0 mm-thick substrate of PBAG600-based
polyurethane. The effect was observed by bending upon heating from 25 to 60 °C and reverse
bending upon cooling from 60 to 25 °C.
7|Page
LIST OF SMART MATERIALS .
8|Page
MATERIALS INPUT OUTPUT RESPONSE APPLICATION
STIMULATION
Personnel sensor
Pyroelectric Temperature Electric signal (open super- market
material door)
Polymer (eg
thin film Humidity change Capacity/resistance Humidity sensors
cellulose), change
ceramic
Force Force
Self-Healing Smart phone chassis
Materials
Dielectric
Elastomers Voltage Strain Robotics
Piezoelectric materials
Those materials capable of generating electric charge in response to applied mechanical stress are
piezoelectric materials. Not all the smart materials do exhibit a shape change but they do carry
significant properties such as electro and magneto theological fluids. Those fluids can change
viscosity upon application of external magnetic or electric field. Naturally occurring crystals like
quartz and sucrose, human bone, ceramics, Polyvinylidene fluoride (PVDF) are known to have
piezoelectric characteristics. Followed by the automotive industry and medical instruments,
global demands for these materials have huge application in industrial and manufacturing sector.
Researchers from University of Warwick in UK have developed new microstereolithography
(MSL) 3D printing technology that can be used to create piezoceramic object. Piezoceramics are
special type of ceramic materials that can create electrical response and responds to external
electrical stimulation by changing shape. These are very useful materials and applicable all
around, sensor in airbag systems, fuel injectors in engines, electric cigarette lighter and electronic
equipment.
9|Page
Fig 5. Natural piezoelectric materials
10 | P a g e
Magnetostrictive Materials
Similar to piezoelectric and electrostrictive materials magnetostrictive materials uses magnetic
energy. They convert magnetic energy into mechanical energy or other way. Iron, terbium, Naval
Ordnance Laboratory (NOL) and dysprosium (D) are most common magnetostrictive materials.
Those materials can be used as transducers and actuators where magnetic energy is used to cause
shape change. The application include telephone 42 receivers, oscillators, sonar scanning,
hearing head, damping systems and positioning equipment. The development of magnetostrictive
material alloys with better features will certainly help the 4D printing technology.
2.2.3 TRIGGER OR INTERACTION MECHANISMS
A major challenge for 4D printing technology is design structure including both hardware
section and software section. In order to design hardware part, special measures needs to be
addressed. Since, this requires complex and advanced material programming, precise
multimaterial printing, designing complex joints for folding, expansion, contraction, curling,
twisting process. Software section is even challenging that cooperates with hardware design.
Sophisticated simulation, material optimization and topology transformation are few of the
challenges for software part. Following explanation demonstrates structural transformation
regarding its joint angle, folding, curling and bending.
Fabrication
As the printer deposits UV curable polymer and cures layer by layer using UV light thereby
creating complete 3D structure, printers are capable of printing multiple composite materials
with various properties such as color pattern, material hardness and transparency allowing
creation of complex, multiple composite parts in single process. Digital materials can be printed
with this process. The properties can be digitally adjusted and altered with the digital material.
The combination of digital material with different proportion and spatial arrangements plays
significant role providing additional flexibility. 4D printed parts are generally composed of rigid
plastic and digital material that reacts upon external energy source. In case of hydrophilic UV
curable polymer, when exposed to water, the structure absorbs and creates hydrogel with upto
150 percentage of original volume. The shape transformation of the structure is linear in this
case, but when the polymer structure is combined with different composite material that reacts
differently with water, complex geometric transformation occurs. Transformation can be
controlled by adjusting pure expandable polymer with digital composite material as per
requirement.
11 | P a g e
Fig 6. Self cubic folding mechanism
If the expanding composite is placed above rigid polymer, the surface will fold downwards and if
placed below, the surface will fold upwards. This folding happens due to downward or upward
force applied to rigid material. With the digital polymer composite, the control of folding the
12 | P a g e
joints becomes much desirable. The time duration of folding depends upon the expandable
material or digital material. If higher expanding composite is used, there will be more folding
force increasing folding time. Similarly, less expanding composite will generate less folding
force thereby decreasing folding time..
Custom Angle Surfaces
In his research, Skyler Tibbits demonstrated custom angle transformation creating truncated
octahedron shape. Similar mechanism as folding strand described previously, series of flat two
dimensional structures were generated with edge joints. The position and spacing of materials at
each joint specifies the desired fold angle hence positioned accordingly.. After the digital model
was sent to be printed, physical model was immersed in water. The transformation process
occurred within certain time with the final desired model having edges aligned perfectly aligned
with neighboring edges. With this technique, a two dimensional polyhedral shape was folded and
self-transformed into precise three dimensional structure. SelfFolding Truncated Octahedron.
The advantage of this process includes efficiencies of printing flat shape with quick printing time
and minimal resources used. If the final model were to be printed directly, it would have taken
longer time consuming more support materials. On the long run, this technology can be effective
for logistics operation where flat surface material can be created, shipped and self-transformed
into three dimensional structure when required
13 | P a g e
explained with the example of concentric circles made of expanding polymers separated by rigid
or less expanding polymer. The position of expanding polymer above or below rigid polymer in
each circle with the ring being neutral, creates mountain and valley folds. When the design print
is placed in water, after certain time period, the structure transforms itself from two dimensional
crease to doubly curved structure.
14 | P a g e
Fig 10. (a) Schematic of the folding mechanism and (b) representative images for folding by heat.
They also fabricated a self-folding and self-opening box with two-layer printed active composites
as hinges connecting six inactive plates of a stiff plastic as shown in Figure 7a. Using this model,
Ge et al. could actuate the hinges created from composites with polymer fibers, making the
hinges fold to a prescribed angle. Finally, the group created a number of active origami
components, including a box, a pyramid, and two origami airplanes based on different design
parameters. They demonstrated that the folding of the printed composite hinges depended on the
material properties of the polymers (including the shape memory behavior of the fibers), the
lamina and laminate architecture, and the thermo mechanical loading profile.
Fig 11.(a) Folding processes of cubes printed with a composite material with a hinge made of shape
memory polymer. Reprinted with permission (b) Folding processes of cubes printed with a single shape
memory material. (c) Hinge design of a heat-induced folding cube made from a single material
15 | P a g e
3. APPLICATION AREA AND FUTURE DEVELOPMENT
4D printing technology has the potential to change the current business environment. Future
advancement of this mechanism depends and remains focused on variety of capabilities. For
example, current process that allows 4D printed structure to expand when exposed to water and when
structure is allowed to dry, it tends to unfold and regain its original shape. However, when similar
process is repeated again and again, the material degrades over time and process is not infinitely
repeatable. To control directionality and reversibility process, further research and development need
to be conducted. This development points towards changing future of education and science. With the
study of existing self-changing structures and models, new experiment with new material properties
and functional behaviors can be tested. The self-changing ability of material leads to range of
applications in various industries. It is essential for any business to reduce manufacturing cost and
increase profit to stay in fierce competitive environment. The concept of 4D printing technology
along with 3D printing provides platform for new business ideas that can adapt and compete current
market trend by lowering capital requirement, time efficient, less space for holding inventory and
increasing efficiency of the business. 4D printing promotes maintaining sustainable environment as
the self-transforming capability of 4D printed item allows after use disposition, changing back to
original shape.
3.1 MEDICAL FIELD
University of Michigan developed a 3D printed stint that gets absorbed into the body over
time. For the patient with weak cartilage in walls of bronchial tubes, the stint was used to open
airways for two or three years, which is enough time for bronchial cartilage to form back to the
shape. This biomedical splint which was printed using 3D printing technology changes shape and
conforms over time as the body moves or grows. There has been a successful implant of those 4D
printed structure, which needs to be biocompatible with patient’s immune system and able to adapt
the external surrounding tissues within the body. The process started with virtual model of trachea
through CT scan of patient and designing model of virtual stint with medical imaging software called
Mimics. Polycaprolactone (PCL), a biomaterial was used to print the stint with the help of Formiga
P100 3D printer. (Mearian, 2016) Most likely, upcoming future of 4D printing technology will
include all types of implants and reconstructive surgery. Beyond helping patients with respiratory
issues, researchers are exploring their use to correct human skeletal deformation such as facial
reconstruction, rebuilding ears.
16 | P a g e
fig 12. (a) Computational image-based design of 3D-printed tracheobronchial splints . (b) 4d printed stent
that is introduced into an artery.
17 | P a g e
3.3 MILITARY AND AUTOMOBILE APPLICATIONS
Programmable matter will have vast application areas in military sector. US army and Navy are
developing three dimensional printed spare parts in the field and developing programmable elements
that form into full building with all the necessary components such as electricity, plumbing and other
technical structures. As the technology allows the materials to change its shape, military equipment,
cars and fabrics could enable them to alter its camouflage. Military advancements with 4D printing
technology would develop coating material in automobile that changes its structure to cope with
humid environment and corrosion. Similarly, transformation of tires depending upon road and
weather condition. In 2013, US Army Research Office granted $855,000 to researchers at three
universities, Harvard's School of Engineering and Applied Science, The University of Illinois and
The University of Pittsburgh Swanson School of Engineering.In automobile industries this
technology helps in printing body parts so that they can change their shape with external conditions.
For example with variation in speed the front portion will get airfoil shape it reduces load on the car.
BMW Company used 4d printing technology for printing body parts.
Fig 14. (a) Camouflage military vehicle fig 14. (b) BMW NEXT 100 4d printed car parts
18 | P a g e
Along with the time saving, it could help people get rid of complex assembling process and mistakes.
3.5 FASHION
The idea of clothes and trainers adjusting their shape and function in response to external
environment and comforting the user, sounds fascinating. Fitting perfectly upon pressure being
applied or gears becoming water proof itself when raining. Massachusetts based design studio
Nervous System have developed 4D printed wearable which is composed of thousands of unique
interlocking component and the dress responds to the wearer's body. It is to fold the dress and
reduces the space required. It can act like insulation for environment conditions like hot and cold.
Experiments involving 4D printing have been few and limited to the date as there are only few
major players actively in the field of research. 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.
19 | P a g e
perspectives. To convey the whole relevant studies,we organize the important concepts as the
following sub-sections by considering four of main advancements in wind turbine blades
including adaptability, bend-twist coupling shape-shifting, flexibility and plant leaf-mimetic
wind blade.
Fig 16. (a) Pipe manufacturing Fig 16. b) Pre-bending deformation in flexible
wind turbine blades to ensure tower clearance
20 | P a g e
4. ANALYSIS OF 4D PRINTING TECHNOLOGY
21 | P a g e
4.2 4d printing Market Analysis
Upon analyzing the trends in 4D printing market on the basis of programmable matter,end user
industry and future scope, 4D printing market is expected to be commercialized by 2019. As the
printing technology is in its initial developing phase, the global market is expected to grow with
compound annual growth of 42.5% between 2019 and 2025 reaching USD 537.8 million as
shown in Figure 22. As North America expected to hold the majority market size, market
development will be driven by the necessity to reduce manufacturing cost, logistic problems and
secure sustainable development. Similar to 3D printing technology, 4D printing industry will
have major impact into aerospace, military and defense, healthcare, automotive, clothing and
construction sector.
22 | P a g e
5. CONCLUSION
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
Scurve. 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.
23 | P a g e
6. REFERENCES
➢ https://www.asme.org/engineering-topics/articles/manufacturing-design/4d-printing-
Advances-additive-manufacturing
➢ Thomas A. Campbell, Skylar Tibbits, Banning Garret “The Next wave: 4D printing”
programming the material world Atlantic Council
➢ https://en.wikipedia.org/wiki/Four-dimensional_printing
➢ http://manufacturing.materialise.com/stereolithography
➢ http://www.nhlbi.nih.gov/health/healthtopics/topics/ stents
➢ http://www.technologyreview.com/article/401750/electroactive -polymers/
➢ http://www.youtube.com/watch?v=0gMCZFHv9v8
➢ https://www.theseus.fi/bitstream/handle/10024/130325/thesis_dilip.sequence=1
Technical considerations of 4d printing
➢ Plant leaf-mimetic smart wind turbine blades by 4D printing
https://www.sciencedirect.com/science/article/pii/S0960148118306207
24 | P a g e