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4D printing (4DP) is an evolutionary step of 3D printing, which includes the fourth dimension, in this case the time. In different time steps the printed structure shows different shapes, influenced by external stimuli like light, temperature, pH value, electric or magnetic field. The advantage of 4DP is the solution of technical problems without the need for complex internal energy supply via cables or pipes. Previous approaches to 4D printing with magnetoresponsive materials only use materials with limited usability (e.g. hydrogels) and complex programming during the manufacturing process (e.g. using magnets on the nozzle). The 4D printing using unmagnetized particles and the later magnetization allows the use of a standard 3D printer and has the advantage of being easily reproducible and relatively inexpensive for further application. Therefore, a magnetoresponsive feedstock filament is produced which shows elastic and magnetic properties. In a first step, pellets are produced by compounding polymer with magnetic particles. In a second step, those pellets are extruded in form of filament. This filament is printed using a conventional printing system for Material Extrusion (MEX-TRB/P). Various prototypes have been printed, deformed and magnetized, which is called programming. In comparison to shape memory polymers (SMP) the repeatability of the movement is better. The results show the possibilities of application and function of magnetoresponsive materials. In addition, an understanding of the behaviour of this novel material is achieved.
In 4D printing an additively manufactured component is given the ability to change its shape or function under the influence of an external stimulus. To achieve this, special smart materials are used that are able to react to external stimuli in a specific way. So far, a number of different stimuli have already been investigated and initial applications have been impressively demonstrated, such as self-folding bodies and simple grippers. However, a methodical specification for the selection of the stimuli and their implementation was not yet in the foreground of the development.
The focus of this work is therefore to develop a methodical approach with which the technology of 4DP can be used in a solution- and application-oriented manner. The developed approach is based on the conventional design methodology for product development to solve given problems in a structured way. This method is extended by specific approaches under consideration of the 4D printing and smart materials.
To illustrate the developed method, it is implemented in practice using a problem definition in the form of an application example. In this example, which represents the recovery of an object from a difficult-to-access environment, the individual functions of positioning, gripping and extraction are implemented using 4D printing. The material extrusion process is used for additive manufacturing of all components of the example. Finally, the functions are successfully tested. The developed approach offers an innovative and methodical approach to systematically solve technical complex problems using 4DP and smart materials.
In 4D printing, an additively manufactured component is given the ability to change its shape or function in an intended and useful manner over time. The technology of 4D printing is still in an early stage of development. Nevertheless, interesting research and initial applications exist in the literature. In this work, a novel methodical approach is presented that helps transfer existing 4D printing research results and knowledge into solving application tasks systematically. Moreover, two different smart materials are analyzed, used, and combined following the presented methodical approach to solving the given task in the form of recovering an object from a poorly accessible space. This is implemented by self-positioning, grabbing, and extracting the target object. The first smart material used to realize these tasks is a shape-memory polymer, while the second is a polymer-based magnetic composite. In addition to the presentation and detailed implementation of the methodical approach, the potentials and behavior of the two smart materials are further examined and narrowed down as a result of the investigation. The results show that the developed methodical approach contributes to moving 4D printing closer toward a viable alternative to existing technologies due to its problem-oriented nature.
Additive manufacturing (AM) and in particular the application of 3D multi material printing offers completely new production technologies thanks to the degree of freedom in design and the simultaneous processing of several materials in one component. Today's CAD systems for product development are volume-based and therefore cannot adequately implement the multi-material approach. Voxel-based CAD systems offer the advantage that a component can be divided into many voxels and different materials and functions can be assigned to these voxels. In this contribution two voxel-based CAD systems will be analyzed in order to simplify the AM on voxel level with different materials. Thus, a number of suitable criteria for evaluating voxel-based CAD systems are being developed and applied. The results of a technical-economic comparison show the differences between the voxel-based systems and disclose their disadvantages compared to conventional CAD systems. In order to overcome these disadvantages, a new method is therefore presented as an approach that enables the voxelization of a component in a simple way based on a conventional CAD model. The process chain of this new method is demonstrated using a typical component from product design. The results of this implementation of the new method are illustrated and analyzed.
Additive manufacturing offers completely new production technologies thanks to the layered structure and the simultaneous processing of several materials. In order to exploit the potential of this new technology, it is already necessary in product development to consider the components no longer as monolithic blocks, but as a structure of many layers and individual elements (voxels). Therefore, this paper will examine the current state of voxel-based CAD systems and the subsequent 3D multi-material printing of the designed components. Different voxel-based CAD systems are used and analyzed for component design and a sample component is additively manufactured. The results show that simple components can be designed using voxel-based CAD systems. With the application of 3D multi-material printing, different materials and thus functions can be assigned to the designed voxel-based CAD-model.