Design of a 4D Printing System using Thermal Sensitive Smart Materials and Photoactivated Shape Changing Polymers

4D printing is an emerging additive manufacturing technology that combines 3D printing with smart materials. Current 3D printing technology can print objects with a multitude of materials; however, these objects are usually static, geometrically permanent, and not suitable for multi-functional use. The 4D printed objects can change their shape over time when exposed to different external stimuli such as heat, pressure, magnetic fields, or moisture. In this research, heat and light reactive smart materials are explored as a 4D printing materials. Synthetization of a material that actuates when exposed to stimulus can be a very difficult process, and merging that same material with the ability to be 3D printed can be further difficult. A common 3D printing thermoplastic, poly(lactic) acid (PLA), is used as a shape memory material that is 3D printed using a fused deposition machine (FDM) and combined with nylon fabric for the exploration of smart textiles. The research shows that post printed PLA possesses shape memory properties depending on the thickness of the 3D printed material and the activation temperature. PLA can be thermomechanically trained into temporary shapes and return to its original shape when exposed to high temperatures. PLA can be 3D printed onto nylon fabrics for the creation of the smart textiles. Additionally, a photoisomerable shape changing material is explored because light activation is wireless, controllable, focusable, abundant, causes rapid shape change of the smart material, and induces reversible shape change in the material. This study supports the fundamental research to generate knowledge needed for synthesis of a novel azobenzene shape changing polymer (SCP) and integrating this smart material into objects printed with a 4D printing process using syringe printing. Multiple versions of azobenzene SCP are synthesized that actuate when exposed to 365 nm and 455 nm light. Two SCPs, MeOABHx and DR1Hx, are selected for the 4D printing research because of their ability to photoisomerize at room temperature and 3D printability. The physical properties of these polymers are characterized, photomechanical bending tests are performed, and the photo-generated stress is measured using a dynamic mechanical analyzer (DMA). The SCPs are deposited onto a passive layer to create bilayer films in order to actuate. The photomechanical efficiency of bilayer films is evaluated depending on the thickness of the passive layer film, type of azobenzene SCP, wavelength of the light source, intensity of the light source, and distance between the light and films. 4D printing can be used to streamline the design and manufacturing process of actuating parts. Complex heavy parts can be removed from actuation systems such as onboard power storage, motors, sensors, and processors by embedding these capabilities into the material themselves. This reduces the amount of required parts, the amount of materials, and reduces the cost of producing these parts. 4D printed products possess the properties of programmability, reaction and adaption to their environment, and automation. Therefore, they can find wider applications including foldable unmanned aerial vehicles, artificial muscles, grippers, biomedical drug delivery systems, stents, and minimally invasive surgeries.Ph.D., Engineering Management -- Drexel University, 201