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3D PRINTING AND ADDITIVE MANUFACTURING

Volume 2, Number 4, 2015


ª Mary Ann Liebert, Inc.
DOI: 10.1089/3dp.2015.0039

REVIEW

4D Printing Technology: A Review


Jin Choi,1,2,* O-Chang Kwon,1,3,* Wonjin Jo,1 Heon Ju Lee,1 and Myoung-Woon Moon1
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Abstract

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. In this context, although
similar to 3D printing technology, 4D printing technology adds the fourth dimension of time. 4D printing allows
a printed structure to change its form or function with time in response to stimuli such as pressure, temperature,
wind, water, and light. Recently, rapid advances in printing processes and materials development for 3D
printing have allowed the printing of smart materials or multimaterials designed to change function or shape. In
this review, we first compare the similarities and differences between 3D printing and 4D printing. We then
look into the main factors composing 4D printing technology such as smart materials and designs. Finally, we
summarize the current applications of 4D printing.

Introduction review, we first compare the similarities and differences be-


tween 3D printing and 4D printing. We then discuss the main
Additive manufacturing, more popularly known as 3- factors and recent trends in 4D printing technology such as
dimensional (3D) printing technology, has been developed smart materials and designs. Finally, we discuss the current
for more than 30 years. Recently, 3D printing has been rec- applications of 4D printing.
ognized as a disruptive technology for future advanced 3D printing is defined as an additive manufacturing
manufacturing systems. With a great potential to change method for the fabrication of 3D structures by layering ma-
everything from our daily lives to the global economy, sig- terials depending on a predetermined design. However, there
nificant advances in 3D printing technology have been made is currently a tendency to use 3D printing as a representative
with respect to materials, printers, and processes.1,2 In this term for all additive manufacturing technologies. 3D printing
context, an innovative concept of printing technology known technology is a convergence technology that uses materials,
as 4D printing technology has been developed. The term ‘‘4D designs, and 3D printers for certain applications since it was
printing’’ was introduced by Skylar Tibbits in his TED con- first described in 1984.8 Recently, many countries have de-
ference talk.3 Although similar to 3D printing, 4D printing clared 3D printing technology to be an innovative production
technology involves the fourth dimension of time in addition to manufacturing technology leading the global megatrend for the
the 3D space coordinates. Therefore, one can regard 4D manufacturing industry. Open-source projects such as RepRap
printing as giving the printed structure the ability to change its in the United Kingdom began after the expiration of major 3D
form or function with time (t) under stimuli such as pressure, printing patents owned by Stratasys Inc. and 3D Systems Inc.,
temperature, wind, water, or light. Figure 1 depicts a schematic leading to the sharing of important technical data for printer and
of the 1-, 2-, 3-, and 4D concepts. The concepts of 1-, 2-, and process creation. Such open-source projects also led to the
3D represent line, plane, and 3D space structures, respectively. explosive development and application of 3D printing tech-
For 4D, the concept of changes in the 3D structure (x, y, z) with nology to diverse industries, such as sports, culture, electronics,
respect to time (t) is added, as indicated by curved arrows. The and aerospace. Recently, innovative advances have been made
3D printed structure can change its color, shape, function, or in 3D printing technology with regard to printing processes and
other characteristics in response to stimuli such as temperature, materials. Carbon 3D Inc. recently announced a new con-
water, ultraviolet (UV) rays, or magnetic energy.4–7 In this tinuous liquid interface production method that can print an

1
3D Printing Group, Computational Science Research Center, Korea Institute of Science and Technology, Seoul, Republic of Korea.
2
Department of Multimedia Science, Sookmyung Women’s University, Seoul, Republic of Korea.
3
Department of Mechanical Systems Engineering, Hansung University, Seoul, Republic of Korea.
*These two authors contributed equally to this work.

159
160 CHOI ET AL.

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.

object 100 times faster than existing methods by creating an formable in response to applied stimuli. Lastly, to implement
oxygen depletion zone in liquid resins.9 New or smart ma- 4D structures by combining design with smart materials, new
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terials and multimaterial composites have been also intro- 4D printer concepts should be developed, or existing highly
duced with dramatic improvements in performance. For functional 3D printers should be improved.
certain functional applications, many efforts have focused on
the fabrication of new materials with desired functionality by 4D printing materials
mixing nanomaterials such as graphene, carbon nanotubes,
To construct 3D structures, materials such as plastic, me-
and functionalized nanoparticles or biomaterials with exist-
tal, and ceramics are widely used as 3D printing materials.
ing 3D printing materials.10,11
However, most of these materials are not applicable to 4D
printing because of their lack of reaction to external stimuli.
4D Printing
Recently, more materials with functional properties have
While 3D printing technology has been used to make static been printed using 3D printers by adjusting or modifying
structures from digital data in 3D coordinates, 4D printing process parameters such as nozzle characteristics, tempera-
adds the concept of change in the printed configuration over ture, and printing environment. Therefore, the proper choice
time, dependent on environmental stimuli. The 3D and 4D of materials is important for 4D printing.
printing processes are nearly equivalent, with printing be- Recent developments have yielded several smart materi-
ginning with product design in 3D modeling programs such als for functional 3D printing or 4D printing, including ma-
as computer-aided design followed by printing the design terials that self-assemble in response to temperature, UV rays,
with a 3D printer. Smart design and smart materials are the self-degradation, or water absorption.8,13–19 One recently in-
key differences of 4D printing compared to 3D printing, as troduced 4D printing material utilizes water absorption cap-
4D printed structures may transform in shape or function abilities to produce a 4D printed structure. A research group at
(Table 1). Therefore, the design of 4D printed structures Massachusetts Institute of Technology (MIT) has printed
should be fully preprogrammed in detail by accounting for multimaterials that change shape underwater.16 The group
any anticipated time-dependent deformations of objects.12 used two different materials with different porosities and water
Another core aspect of 4D printing technology is smart ma- absorption capacities to print bimaterial structures. These
terials, which can become more expandable, flexible, or de- structures have a porous water-absorbing material on one side

Table 1. Simple Comparison Between 3D and 4D Printing Technology


3D printing 4D printing
Materials Thermoplastics Self-assembled materials
Metals Multimaterials
Ceramics Designed materials
Biomaterials or nanomaterials Examples: shape memory alloy/polymer,
self-degradation/deformation materials, temperature-
or UV-driven materials
Design 3D digital information (scanning, drawing) 3D digital information for change (deformation)
Printer 3D printer Smart 3D printer
Examples: stereolithography Examples: modified nozzle, binder, and laser
apparatus, material extrusion, Multimaterial 3D printer
and selective laser sintering Examples: solid/liquid, solid/solid, gradient materials,
and nanocomposites
Change As printed Changed after printing in shape, color, function, etc.
Application Jewelry, toys, fashion, entertainment, Dynamically changing configuration for all applications
automobile, aerospace, by 3D printing
defense, and bio/medical devices
4D PRINTING TECHNOLOGY 161

and a rigid waterproof material on the opposite side. After can be triggered by UV irradiation or sunlight.20,21 UV-
printing, the structure was inserted into a water bath, leading to responsive polymer chains that include azo compounds can
water absorption on both sides. The water-absorbing side in- deform as shown in Figure 3. UV light energy induces the
creased in volume because of water absorption, whereas the deformation of the polymer chain structure, triggering a color
other side remained unchanged, resulting in bending toward change from white to purple. This color change is caused by a
the rigid side as shown in Figure 2a. In the water bath, a shift in the polymeric chain from the ordered nematic phase
straight-line structure with programmed hinges could be de- to the disordered phase.22 When maintained in a dark envi-
formed into a 3D configuration over time. This approach, ronment, the color of the printed object returns to the original
which involves combining materials with different porosities white. Instead of color, the shapes or surface patterns of some
or structures into one printed structure, originates from the light-responsive materials have been known to change via
multimaterial printing method. similar mechanisms. These light-responsive materials can be
Multimaterials or functionally graded materials for 3D used in shopping bag packaging, aerospace structures, pho-
printing were reported by Oxman, who mimicked the cellular tovoltaics, and biomedical devices.22 UV-responsive materi-
structure of materials that dynamically change in shape.4 als are available as ME filaments, and promising applications
Oxman introduced a multimaterial printer using cement and of UV-responsive materials exist in areas such as the fashion
concrete foam along with software for variable property and entertainment industries.
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modeling. Porosity was controlled by changing the ratio of Biomaterials are a major class of smart materials for
aluminum to cement. This process has the ability to dy- 4D printing. Functional materials capable of autonomously
namically mix, grade, and vary the ratios of materials to degrading in the body were studied in late 1990 with 3D
produce functional components with continuous gradients. printing technology.23 Because the human body is composed
Such components can be highly optimized for performance, of dynamically and continuously moving systems, each part
efficiently use materials, reduce waste, and possess highly is exposed to a unique environment and must therefore re-
customizable features with added functionalities. spond over time to differences in conditions such as tem-
Temperature-responsive materials such as shape memory perature or body fluid. Therefore, printed body parts or
polymers and alloys are well-known 4D materials because of structures should have dynamic functional behaviors for
their ability to contract or expand in response to changes in use in vivo. In this regard, biocompatible materials should
temperature. When the temperature of a shape memory degrade in the body environment within a certain period
polymer is increased above the critical temperature for shape of time. Temperature-, water-, or UV-responsive reactions
change, the deformed structure returns to its original struc- occur in the aforementioned materials over periods ranging
ture. As shown in Figure 2b, shape memory polymers can be from a few seconds to days in the body, whereas the bio-
utilized as filamentous material in the material extrusion materials may take several years to degrade completely in a
(ME) method to print artificial structures that can be refolded fluid environment. Well-known self-degrading materials are
from their unfolded states simply by changing the tempera- polylactic acid (PLA) and poly-caprolactone (PCL). PLA is
ture. Figure 2c shows a functional 3D robotic device that can the major material for the ME method, and PCL is the major
self-fold from a single planar material into a 3D structure.6 material for the selective laser sintering methods.24,25 Both
These devices have several functions, including temperature- materials have been reported to degrade over a period of
activated self-folding, actuation controlled by an external several years until the polymer chain has completely dis-
magnetic field, and degradation in liquids such as acetone solved in body fluid.25,26
or water. However, these approaches did not consider any time-
Photo- or light-responsive materials can also serve as 4D dependent changes except for degradation. Morrison et al.
printing materials, as a color reaction in a 3D printed object created a supporting structure using the stereolithography

FIG. 2. Examples of 4D printing technology. (a) Transformation of a structure from 1D to 3D with water absorption materials,
printed by Massachusetts Institute of Technology (MIT). Reprinted with permission from Tibbits.14 Copyright ª 2014 John Wiley
& Sons, Ltd. (b) Temperature-responsive design of artificial hands by Korea Institute of Science and Technology. (c) Functional
3D device fabricated by MIT. Reprinted with permission from Miyashita et al.6 Copyright ª 2015, IEEE.
162 CHOI ET AL.

FIG. 3. Printing examples using a photoresponsive material: (a) cat, (b) flower, and (c) schematic description of changes
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in the polymer microstructure in response to light.

(SL) apparatus method with liquid PCL for infants with se- airway size by expanding as the patient grew for 3 years as
vere tracheobronchomalacia to prevent airway collapse dur- shown in Figure 4. After 3 years, the materials were com-
ing normal breathing.27 PCL is known as a biodegradable and pletely removed from the body and the fully grown airways
biocompatible material.28 While Morrison et al. printed the were able to function unaided.29,30 This example demon-
supporting structure with a customized design for patients strates that, in combination with 3D printing technology
less than 1 year old, the splint accommodated changes in and designs for changes in shape and material properties,

FIG. 4. (a) Digital Imaging and Communications in Medicine images of a patient’s computed tomography scan used to
generate a 3D model of the patient’s airway via segmentation in Mimics. (b) Stereolithography representation of a
tracheobronchial splint demonstrating the bounded design parameters of the device. (c) Final 3D printed poly-caprolactone
tracheobronchial splint. (d) Mechanism of action of the tracheobronchial splint in treating tracheobronchial collapse in
tracheobronchomalacia. Reprinted with permission from Morrison et al.27 Copyright ª 2015, The American Association for
the Advancement of Science.
4D PRINTING TECHNOLOGY 163

FIG. 5. 4D printing with a shape memory polymer. (a) Schematic of the folding mechanism and (b) representative images
for folding by heat. Reprinted with permission from Ge et al.39 Copyright ª 2013, AIP Publishing LLC.
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4D biomaterials are extremely useful and promising for Smart design


medicine.
4D printing can be useful for a wide variety of healthcare In addition to smart materials, one of the core techniques
applications, ranging from nanoparticle design to tissue for 4D printing is the design of materials for structural
engineering to the manufacture of self-assembling human- change. Although the smart material itself plays a pivotal role
scale biomaterials.31–33 Organovo Holdings Inc., U.S.A., in transforming a printed object into another shape or con-
has been involved in several bioprinting projects focused on figuration, sophisticated design based on a rigorous under-
the development of functional human tissues.34 This com- standing of mechanisms, predicted behaviors, and required
pany is developing an artificial human liver using 4D parameters should be performed to achieve controllable re-
printing technology. The potential of this technology to sults.37,38 The powerful advantage of 3D printing technology
create programmable biological materials with changeable is the capability to create complex 3D shapes with varied
shapes and properties can be a foundation for enabling smart material distributions through spatial arrangement. By de-
pharmacology, personalized medicine, and programmable signing the orientation and location of smart materials such as
cells and tissues that can precisely target treatments for shape memory polymer fibers within composite materials, we
diseases.35,36 can facilitate morphological changes in response to external

FIG. 6. (a) Left: rendered illustration of the primitive folding. This design is composed of bars and disks. The disks in the
center act as stoppers. By adjusting the distances between the stoppers, it is possible to set the final folding angle. Right:
video frames of the fabricated primitive folding in water over time. (b) Fabricating a time-varying curve. From left to right
and top to bottom, the curve deforms over time into a different shape. Reprinted with permission from Raviv et al.40
Copyright ª 2014, rights managed by Nature Publishing Group.
164 CHOI ET AL.

stimuli. For example, Ge et al. investigated the design vari- of the ring, They were able to adjust the stretching length of
ables that are important for creating a laminated architec- the structure (Figure 6b). In the folding primitive, the rigid
ture.39 They examined various fiber orientations and volume disks in the center acted as stoppers. By adjusting the dis-
fractions as well as the magnitude of the curvature as a tances between the stoppers, the desired folding angle could
function of the composite geometry, applied mechanical be created.
load, and thermal history. A two-layer laminate consisting of The importance of smart design in 4D printed objects is clear
one lamina layer with fibers at a prescribed orientation and in the fabrication of self-assembling origami, where a flat sheet
one layer of pure matrix material was constructed (Figure 5a). automatically folds into a complicated 3D component.5 Ge
When the samples were heated, the printed two-layer lami- et al. extended the concept of self-assembling origami by using
nates transformed into bent, coiled, and twisted strips; folded spatial variations in the material composites to control shape
shapes; and complex contoured shapes with nonuniform and deformation in an origami structure.39 They also fabricated a
spatially varying curvatures depending on each sample’s self-folding and self-opening box with two-layer printed active
prescribed fiber architecture (Figure 5b). composites as hinges connecting six inactive plates of a stiff
Raviv et al. fabricated self-evolving structures with a variety plastic as shown in Figure 7a. Ge et al. developed a theoretical
of highly specific joint designs for folding, curling, twisting, model that considered design parameters and the complex
linear expansion, and shrinkage as well as other transforma- thermomechanics of the composite hinge structures to fab-
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tions in the presence of water.40 They used a computational ricate various active origami structures.5 More specifically,
design approach to characterize topology transformations of the group focused on characterizing hinge behavior with re-
the various self-evolving structures. As a design step, the group spect to the hinge bending angle as a function of geometric
modeled three primitives: a linear stretching primitive, a ring parameters (hinge length and laminate/lamina configuration),
stretching primitive, and a folding primitive. Two different thermomechanical loading parameters (stretching strain),
models were created for stretching, and another model was and programming parameters (deformations and heating/
created for folding. The length of the linear stretching primitive cooling temperatures).41 Using this model, Ge et al. could
could be controlled over time. By adjusting the ratio of ex- actuate the hinges created from composites with polymer
panding material in the middle to the rigid disks as shown in fibers, making the hinges fold to a prescribed angle. Finally,
Figure 6a, they were able to change the length of stretching the group created a number of active origami components,
and the percentage of linear expansion in the joint. The ring including a box, a pyramid, and two origami airplanes based
stretching primitive was based on expansion of the ring-like on different design parameters. They demonstrated that the
shape into a bar. Because the inner and outer rings were folding of the printed composite hinges depended on the
printed with different materials, the inner ring expanded and material properties of the polymers (including the shape
forced the structure to deform into a bar shape once the memory behavior of the fibers), the lamina and laminate ar-
structure was submerged in water. By controlling the radius chitecture, and the thermomechanical loading profile.

FIG. 7. (a) Folding processes of cubes printed with a composite material with a hinge made of shape memory polymer.
Reprinted with permission from Ge et al.39 Copyright ª 2013, AIP Publishing LLC. (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.
4D PRINTING TECHNOLOGY 165

We have printed a hexahedral planar structure using ME signs were accomplished.44 Espalin et al. introduced the use
3D printer with a thermal polyurethane (TPU), which is a of professional-grade ME systems for discrete multimaterial
shape memory polymer filament. While all of the parts can fabrication.24 A multimaterial, multitechnology ME system
be printed with TPU, we designed hinges with different was developed and constructed to enable the production of
thicknesses to allow for the proper deformation and bending parts using either discrete multimaterials or build process
of each arm as shown in Figure 7b and c. We also connected variations (variable layer thickness and road width). Two
the six faces by inserting TPU lines through predesigned legacy ME machines were modified and installed onto a single
holes to improve shrinkage strain as temperature was in- manufacturing system to allow strategic, spatially controlled
creased. thermoplastic deposition of multiple materials with multiple
extrusion nozzles during the same build. This automated
process was enabled by a build platform attached to a pneu-
Printers for 4D printing
matic slide that moved the platform between the two ME
In general, conventional 3D printing materials such as systems, an overall control system, a central PC, a custom
PLA or acrylonitrile butadiene styrene (ABS) are optimized program (FDMotion), and a graphic user interface. Contour
for the printing parameters (e.g., temperature and nozzle and raster road widths are parameters that can be selected
design) that are already preset in each 3D printer. Smart from a certain range using the ME part preparation software,
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materials with specific functionalities or multicomponent and these road widths are controlled by the ME machine
materials may cause problems in current 3D printers, as these during the manufacturing process by feeding more or less
materials may become agglomerated, clogged, or resolved material through the nozzle for a given extrusion head speed.
during the printing process. Therefore, several techniques
have been adopted for 4D printers. We used a printer with a Summary and Perspective
coated nozzle tip that was adapted for stable printing of TPU
with the ME method. This printer also has a heating bed for The rapid development of materials, design, and printers
proper heat circulation during the printing process. Because for 3D printing gave birth to the 4D printing concept. Re-
TPU has a high thermal expansion coefficient and com- cently, 4D printing has been gaining attention because 4D
presses in the nozzle when heated, the printing nozzle easily printed structures have the capability to change in form or
becomes clogged. In addition, the molten TPU may flow over function over time in response to stimuli such as pressure,
cold end regions, leading to poor adhesion between layers or temperature, wind, water, and light. 4D printing technology,
pores in the printed line. To suppress the overflow of molten which uses smart materials, designs to forecast change
materials and to reduce friction, the TPU printer nozzle is processes, and smart printing, can be applied to various
coated with polytetrafluoroethylene and has a barrel that is fields from simple changes to bioprintings for organisms.45
1.2–1.5 times longer than the typical nozzles used for PLA or The U.S. Army has already tried to adapt this technology to
ABS. In addition, the heating device is placed close to the produce camouflage textiles that help soldiers hide in cer-
nozzle to minimize heat loss. tain environments by bending the light reflected from the
The printing of multimaterial components is a key factor clothing.46 4D printing can also be used to create systems
for the 4D printing of structures with adaptability and desired for the International Space Station that can be transported
functionalities. Multimaterial printers may allow printed easier than existing systems produced with conventional
structures to have colors, shapes, or electronic properties that methods.
change in response to UV rays, light, heat, or water. Multi- Because 4D printing and 3D printing are different from
material printers can print bimaterial structures or function- conventional manufacturing technology, these new technol-
ally graded structures by mixing two or three different ogies can reduce the manufacturing time and human labor
materials within one printed structure. Several printers have required to assemble machines or goods. Furthermore, 4D
already been developed for multimaterial printing. Lopes printing can reduce the time and labor required for logistics,
et al. performed discrete multimaterial fabrication and pro- transportation charges, and the volume of goods that must be
duced functional electroactive polymer actuators via non- transported. Finally, 4D printing can address the consumer
heated ME. Lopes et al. also produced biomedical scaffolds need for personal designs or options on consumer goods
and 3D structural electronics via a hybrid manufacturing sys- items such as smart phones or watches.
tem that integrated SL and direct print (DP) technologies to
fabricate 3D structures with embedded electronic circuits.42,43 Acknowledgments
A hybrid SL/DP system was designed and developed using a This work was supported by a Korea Institute of Science
3D Systems SL 250/50 machine and an nScrypt micro- and Technology internal project. The authors acknowledge
dispensing pump integrated with the SL machine via orthog- support from the Ministry of Culture, Sports and Tourism and
onally aligned linear translation stages. the Korea Creative Content Agency in the Culture Technol-
A corresponding manufacturing process was also developed ogy Research & Development Program. The authors also
using this system to fabricate 2D and 3D monolithic structures acknowledge support from the Center for Advanced Meta-
with embedded electronic circuits. The process involved part Materials (CAMM) funded by the Ministry of Science, ICT,
design, process planning, integrated manufacturing (including and Future Planning as a Global Frontier Project (CAMM-
multiple starts and stops of both SL and DP and multiple No. 2014063701).
intermediate processes), and postprocessing. SL provided
substrate/mechanical structure manufacturing, and intercon-
Author Disclosure Statement
nections were achieved using DP of conductive inks. Simple
functional demonstrations involving 2D and 3D circuit de- No competing financial interests exist.
166 CHOI ET AL.

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E-mail: mwmoon@kist.re.kr
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