Direct ink write multi-material printing of PDMS-BTO composites with MWCNT electrodes for flexible force sensors

With recent advances of additive manufacturing (AM) technology, direct ink write (DIW) printing has allowed to incorporate multi-material printing of various materials with freedom of design and complex geometric shapes to complete functional sensors in a one-step fabrication. This paper introduces the use of DIW 3D printing of polydimethylsiloxane (PDMS) with barium titanate (BTO) filler as stretchable composites with tunable piezoelectric properties that can be used for force sensors applications. To improve the bonding between stretchable piezoelectric composites and electrodes, multi-walled carbon nanotubes (MWCNT) was included in the fabrication of electrodes at a fixed ratio of 11 wt. %. The alignment of the BTO dipoles was achieved through corona poling method, which applies an electric charge on the surface layer of the functional material, aligning the dipoles in the desired direction and thus gaining the piezoelectricity. Different BTO mixing ratios (10-50 wt. %) were evaluated in order to obtain tunable piezoelectric properties and compare the sensitivity with respect their elastic properties. Tensile testing and piezoelectric testing were carried out to characterize mechanical and piezoelectric properties. Results showed that fabricated PDMS with 50 wt. % BTO gave the highest piezoelectric coefficient (d33) of 11.5 pC/N and with an output voltage of 385 mV under compression loading of >200 lbF. This demonstrates feasibility of using multi-material DIW printing to fabricate piezoelectric force sensors with integrated electrodes in one-step without compromising the flexibility of the material.

Advances in additive manufacturing of shape memory polymer composites

Purpose A review on additive manufacturing (AM) of shape memory polymer composites (SMPCs) is put forward to highlight the progress made up to date, conduct a critical review and show the limitations and possible improvements in the different research areas within the different AM techniques. The purpose of this study is to identify academic and industrial opportunities. Design/methodology/approach This paper introduces the reader to three-dimensional (3 D) and four-dimensional printing of shape memory polymers (SMPs). Specifically, this review centres on manufacturing technologies based on material extrusion, photopolymerization, powder-based and lamination manufacturing processes. AM of SMPC was classified according to the nature of the filler material: particle dispersed, i.e. carbon, metallic and ceramic and long fibre reinforced materials, i.e. carbon fibres. This paper makes a distinction for multi-material printing with SMPs, as multi-functionality and exciting applications can be proposed through this method. Manufacturing strategies and technologies for SMPC are addressed in this review and opportunities in the research are highlighted. Findings This paper denotes the existing limitations in the current AM technologies and proposes several directions that will contribute to better use and improvements in the production of additive manufactured SMPC. With advances in AM technologies, gradient changes in material properties can open diverse applications of SMPC. Because of multi-material printing, co-manufacturing sensors to 3D printed smart structures can bring this technology a step closer to obtain full control of the shape memory effect and its characteristics. This paper discusses the novel developments in device and functional part design using SMPC, which should be aided with simple first stage design models followed by complex simulations for iterative and optimized design. A change in paradigm for designing complex structures is still to be made from engineers to exploit the full potential of additive manufactured SMPC structures. Originality/value Advances in AM have opened the gateway to the potential design and fabrication of functional parts with SMPs and their composites. There have been many publications and reviews conducted in this area; yet, many mainly focus on SMPs and reserve a small section to SMPC. This paper presents a comprehensive review directed solely on the AM of SMPC while highlighting the research opportunities.

3D Multi-Material Printing of an Anthropomorphic, Personalized Replacement Hand for Use in Neuroprosthetics Using 3D Scanning and Computer-Aided Design: First Proof-of-Technical-Concept Study

Background: This paper presents a novel approach for a hand prosthesis consisting of a flexible, anthropomorphic, 3D-printed replacement hand combined with a commercially available motorized orthosis that allows gripping. Methods: A 3D light scanner was used to produce a personalized replacement hand. The wrist of the replacement hand was printed of rigid material; the rest of the hand was printed of flexible material. A standard arm liner was used to enable the user’s arm stump to be connected to the replacement hand. With computer-aided design, two different concepts were developed for the scanned hand model: In the first concept, the replacement hand was attached to the arm liner with a screw. The second concept involved attaching with a commercially available fastening system; furthermore, a skeleton was designed that was located within the flexible part of the replacement hand. Results: 3D-multi-material printing of the two different hands was unproblematic and inexpensive. The printed hands had approximately the weight of the real hand. When testing the replacement hands with the orthosis it was possible to prove a convincing everyday functionality. For example, it was possible to grip and lift a 1-L water bottle. In addition, a pen could be held, making writing possible. Conclusions: This first proof-of-concept study encourages further testing with users.

Hexagon-Twist Frequency Reconfigurable Antennas via Multi-Material Printed Thermo-Responsive Origami Structures

The origami structure has caused a great interest in the field of engineering, and it has fantastic applications in the deployable and reconfigurable structures. Owing to the unique multi-stable states, here a typical hexagon-twist origami structure is fabricated via multi-material printing technology. The printed structure has multi-stable features and the stiffness of the deformable structure is dramatically reduced under thermal triggering. Such behavior causes an increase in the structural degree of freedom, allowing for self-deployment via releasing the prestored energy in the elastic crease. The response time and reaction time of the self-deployment process are also studied and illustrate the higher energy barrier of the folded state, the longer self-deployment time. Utilizing such unique features and design principles, a prototype of frequency reconfigurable origami antenna of nine diverse operating modes is subsequently designed and assembled with the hexagon-twist origami structure as the dielectric substrate. The antenna implements the cross-band from two different frequency bands, enabling to realize frequency reconfigurable under thermal condition.

An Overview of Additive Manufacturing of Polymers and Associated Composites

Additive manufacturing is rapidly evolving and opening new possibilities for many industries. This article gives an overview of the current status of additive manufacturing with polymers and polymer composites. Various types of reinforcements in polymers and architectured cellular material printing including the auxetic metamaterials and the triply periodic minimal surface structures are discussed. Finally, applications, current challenges, and future directions are highlighted here.