Indian Researchers Develop World's Strongest 4D Printed Parts

24/02/2024, 09:34 Indian Researchers Develop World’s Strongest 4D Printed Parts - Manufactur3D
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World’s Strongest 4D Printed
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Conflux Technology Two Indian researchers from the Veer Surendra Sai University of Technology, Burla, Odisha,
advances toward We'd like
have developed two 4Dtoprinted
show prototypes,
you notifications
which for
the the latest claim, are the world’s first &
researchers
Aerospace Certification
news and updates.
AS9100D with Design strongest prototypes built to date.
(https://manufactur3dmag
.com/conflux-aerospace- The prototypes are made from PLA material which is embedded with shape memory alloys
certification-as9100d-
with-design/) (SMA) Ni-Ti and fabricated using FDM 3D printing technology
(https://manufactur3dmag.com/working-fdm-fff-3d-printing-technology/). The Ni-Ti sheet adds
August 26, 2022 2 Mins read
strength to these 4D printed parts. A strength report of these parts shows that these 4D
printed parts have a compressive strength of 150MPa which is closely equivalent to high
strength concrete.
The researchers Bijaya Bikram Samal and Anita Jena under the guidance of Prof. Debadutta
Mishra of the Veer Surendra Sai University of Technology have created prototypes of
biocompatible and biodegradable materials and they actuate when put in hot water.

news and updates.
 Above: Prototype being 4D printed in an FDM 3D printer/Image Credit: Bijaya Bikram Samal
 The first prototype is a simple “self-folding origami structure” with some design considerations,
which successfully actuated to form the final part. The second one is a practically usable
 prototype “3 Jaw robotic gripper” which has been used to pick an object in hot water without
using any bulky motors. The remarkable results obtained from this research can have a
paradigm shift in the way we manufacture products.
What is 4D Printing?

news and updates.
Above: Image shows the differences in one, two, three and four-dimensional objects/Image Credit:
Sculpteo
 4D printing (https://manufactur3dmag.com/understanding-the-concept-of-4d-printing/) relates

to an advanced version of 3D printing where the fourth dimension is Time. This fourth
 dimension refers to the concept of self-assembly wherein the 3D printed object can reshape or
self-assemble itself on the application of an external passive energy like heat, gravity,

magnetics, or simply hot water.
Research
The research was undertaken to find the solutions to some of the underlying problems of the
3D printed parts. The components can change their shape when heat is provided to it which
paves its application to environments where maintenance is very difficult like space and
biomedical engineering where stents can be manufactured using this technology which can save
millions of lives.
It has its application in piping, earthquake-resistant building and structures, soft robotics and
what not. Future products will be self-assembling, We'd like to show
self-healing, you notifications
self-replicating and for the latest
news and updates.
reconfigurable which will provide all materials the ability to cope up with the changing and
challenging environment. In this research PLA based 3D printed parts with embedded Ni-Ti
SMA sheet were fabricated using 4D printing technology.
Methodology
This research focuses on the basic capabilities of the emerging 4D Printing technology. Among
various methods of getting 4D printed components, 3D printing with embedding smart
materials has been utilized in this work. For embedding the SMA sheet into the PLA based 3D
printed objects, the Ni-Ti SMA sheet has to be cut and micro-drilled. Therefore three different
machining operations have been performed using Wire EDM, LASER, and ECM. Optimization of
the three processes has been done based upon which confirmation test is conducted and the
material is prepared. After that 3D printing process is used and the sheet is embedded within it
during the printing hence giving 4D printed components.
Above: 4D printed parts show shape changing capabilities when immersed in hot water/Image
Credit: Bijaya Bikram Samal
From the above images, we can clearly see that the 4D printed prototype, when inserted in a
We'd
tank of hot water quickly, changes its shape. The first rowlike to show
of the imageyou notifications
shows the origamifor the latest
news and updates.
prototype which joined together to form a strong bond. The second row of the image shows a
4D printed prototype which when immersed in hot water changes its shape to form a strong
robotic gripper which can lift heavy items.
A subsequent compression test was also carried out and the results can be seen as below.
Compression test

Above: 4D printed sample before and after compression test/Image Credit: Bijaya Bikram Samal

The image shows the sample part before and after compression test. It compressive strength of
the parts is easily visible in the image by the deformation of the metallic strip. It is a visual
indication of the strength of the 4D printed parts.

news and updates.
Above: Compression test result graph/Image Credit: Bijaya Bikram Samal
In the above image of the compression test report, you can clearly see that the compressive
strength of the Indian 4D printed prototype is moreWe'd like to show
than 150MPa you
which notifications
is quite fortothe latest
high close
news and updates.
any high strength concrete. This suggests that the prototype can take high loads when used as
a mechanical component in any mechanical systems.
Why is this research unique?
A lot of research on 4D printing is being carried out across various universities of the world but
let us explain why this research is unique:
Firstly, an increasing number of researchers are carrying out research on 4D printing around the
world but none of their prototypes exhibit a high strength product which can be used as a
mechanical component.
Secondly, none of them have a practical application.
Thirdly, no research has ever used shape memory alloy with PLA material for 4D Printing.
 And lastly, no other research has claimed their 4D Printed prototype as fully bio-degradable
and bio-compatible. Both the prototypes in this new research are bio-degradable and bio-

compatible so that can be used further in making user-friendly and user-safe prosthetics and
 stents.

Major challenges in 4D Printing
No simulation software and API: There is an absence of a simulation software which can
clearly show how the 4D printed part will behave when it comes in contact with an external
stimulus like heat, gravity, magnetics, etc. Such a unique software can help in overcoming a big
hurdle. This will not only quicken the pace of research but also save a lot of costly resources. It
will help in optimising the complete process.
There is no separate API (Application Programming Interfaces) which will enable the designers
We'd
to define the characteristics of the materials they are like
made to show you notifications for the latest
from.
news and updates.
High initial cost: 4D printing demands heavy initial monetary resources. As compared to the
western countries where there is a dearth of funding for research. In the Asia Pacific region, and
especially in India, research is mostly seen as an activity for large corporations and funding is
always in short supply.
4D printing, no doubt, has high initial cost compared to 3D printing but given the fact that it also
provides better functionalities, high productivity, reliability & high product life, it actually offers a
better trade-off than 3D printing.
Moreover, products made using this technology unlike 3D Printed objects are not static and
hence can have unprecedented applications in all fields of science and engineering.
Future Implications
This is just a beginning to understand the capabilities of 4D printing which will enable the
 design of a completely new system. This is an emerging technology having a lot of possible
 future applications like as follows:
 Soft Robotics: Robotic grippers, like the ones created in this research, for use in industries can
have a significant impact on the functionality.

Aerospace and Aviation
Space: In environments and conditions where access for manual repair is limited, conditions
which are hostile like space it can be used for self-healing of materials. 4D printing with origami
and kirigami will enable us to make anything in 2D shape easily carry it to space then add hot
water or provide heat by electrical resistance to it and it will transform into a 3D object of your
use.
Morphing Aircrafts: Since birds are the source of inspiration for airplane development, airplanes
should, supposedly, look more like birds in order toWe'd likemore
become to show you
energy notifications
efficient. for the latest
However,
news and updates.
airplanes today look quite different from birds in many aspects as through experiments and
comparison between airplanes and birds, researchers have found that airplanes can achieve
better efficiency if they can “behave” more like birds in flight, and morphing technology makes it
possible.
It can be only possible by 4D printing technology as this provides a very good chance for us to
make things that can change its shape and size according to a specific stimulus.
Healthcare
Stents: This technology can be used in healthcare for advanced nanoscale stents and drug
delivery system. The 4D printed stent can be maneuvered to a spot and then made to change
form by application for a stimulus. For example, 4D printed stent that is introduced into an
artery and when ultrasound energy is applied it balloons up to its needed configuration
Better Prosthetics: Electroactive components for artificial limbs. An applied voltage changes

the configuration of the 4D printed part so that it expands, contracts or bends. The motion is
 smoother and more lifelike than movement generated by mechanical devices.
 Consumer Goods

Transformative Shoes or Garments:
Imagine a single shoe which can be used 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 walk on
grass, it grows cleats, and if it is raining, it becomes waterproof.
Adaptable Tyre Compound: These tyres will be all water tyre which can change according to
different road conditions.
Piping: Current pipe system is very rigid. To cater for higher flow capacity, we have to replace
the whole pipeline. An adaptive 4D manufacturing We'd like to
capability to produce
show you notifications
capacity for the latest
adaptable
news and updates.
pipes pipping with a variable diameter as per demand can significantly increase the flow
efficiency.
This technology provides a lot of flexibility and customization to a product in a very short
manufacturing lead time with the dynamic characteristics of changing its structure, functionality
and adaptable to the environment that can be utilized to achieve maximum efficiency in any field
of its usage.
The research paper will soon be published in reputed international journals.
About Researchers:
Prof. Debadutta Mishra:
He is a professor at the Department of Production Engineering, Veer Surendra Sai University of

Technology, Burla. He is also the Dean (Students Welfare) at the institution. He has about 27
 years of experience in academia and research. He has completed many research projects funded
 by UGC, DST and other reputed organizations. He has many publications in reputed journals
and conferences. He is also the head of Idea and Innovation club of the institution, which has
 made significant developments under his able guidance in different fields of engineering.

He did his Ph.D. from Sambalpur University, Odisha, M.Tech from National Institute of
Technology, Rourkela and B.Tech from College of Engineering and Technology, Odisha.
Bijaya Bikram Samal:
He is presently a Ph.D. scholar working on 4D printing and micro manufacturing at Indian

Institute of Technology, Kharagpur. He is an M.Tech Gold medalist from the first engineering
college of Odisha i.e Veer Surendra Sai University of Technology (Formerly University College of
Engineering) Burla during which he worked on novel 4D Printing technology to make two
We'd
important prototypes. He did his B.Tech from the Biju like to
Patnaik show you
University notificationsOdisha
of Technology, for the latest
during which he worked on making a low-cost FDM 3D printer.
news and updates.
Anita Jena:
She is presently a Ph.D. scholar working on micro machines at Indian Institute of Technology,
Kharagpur. She did her M.Tech from the Veer Surendra Sai University of Technology, Burla,
Odisha during which she actively worked on many smart materials especially shape memory
alloys and had developed an engine, which uses SMA to produce power from waste hot water.
She completed her B.Tech from the Biju Patnaik University of Technology, Odisha during which
she worked on making a low-cost FDM 3D Printer.
(Disclaimer: We inform the readers that the views, thoughts, figures, and opinions expressed in
the article belong solely to the researchers, and not necessarily to Manufactur3D)
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24/02/2024, 09:34 Indian Researchers Develop World’s Strongest 4D Printed Parts - Manufactur3D

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 4D printing (https://manufactur3dmag.com/understanding-the-concept-of-4d-printing/) relates

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Above: Compression test result graph/Image Credit: Bijaya Bikram Samal

Why is this research unique?

Secondly, none of them have a practical application.

 future applications like as follows:

Aerospace and Aviation

 smoother and more lifelike than movement generated by mechanical devices.

The research paper will soon be published in reputed international journals.

Prof. Debadutta Mishra:

He is a professor at the Department of Production Engineering, Veer Surendra Sai University of

Bijaya Bikram Samal:

He is presently a Ph.D. scholar working on 4D printing and micro manufacturing at Indian

 Indian Scientists (https://manufactur3dmag.com/tag/indian-scientists/)

We'd like to show you notifications for the latest

HP Unveils HP Metal Jet – The World’s most Advanced Metals 3D Printing

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