Designing 3d-Printed Deployable Structures With Shape Memory Polymers

The aim of this project was to get a better understanding of the shape memory behaviour of 3D-printed polymers, and the different parameters which affect this, with the ultimate goal to apply shape memory in product design. This project started with a literature study on shape memory polymers and 3D-printing. The material properties, different types of shape memory and different actuation methods were investigated, as well as different 3D-printing techniques and using shape memory polymers in 3D-printing. Existing applications and concepts using shape memory polymers, as well as recent studies in applying these materials were also investigated. In parallel to the literature study, testing was done on the influence of different parameters on the shape memory behaviour of one of the most common FDM 3D-printing materials: PLA. Through an iterative process, a test sample was designed which was used to test parameters related to material (different types of PLA), manufacturing (printing settings), and design (geometry and orientation of models). Knowledge gained through the literature research and testing was combined to create design guidelines for manufacturing shape memory objects using 3D-printing. To demonstrate how the shape memory capabilities of 3D-printed PLA could be applied in product design, A product concept was developed. With a vision as a starting point, ideation and concept development was started by first having a brainstorm session with different people to learn how people not involved with the project envisioned shape memory in product design. Moving on from this, useful results from this session were taken into an ideation phase, where a multitude of different ideas were thought up. From these ideas, four were chosen to be developed into concepts, of which one was chosen to be further developed into a physical prototype. The chosen concept was a wake-up light which uses the heat of the lightbulb inside the lamp to heat the shape memory material and initiate shape recovery, which resulted in the lamp gradually giving off more light. This would wake up the user in a natural way. The concept, which was given the name ‘’DAWN’’, was developed into a physical demonstrator, and the shape memory parts were printed based on the established guidelines. This also served as a test for the guidelines to see how they could be applied in the design process. After testing several printed prototype parts, a final design for the demonstrator was created and produced. At the end of the project, the process and results were evaluated and recommendations were given for further research into 3D-printing shape memory objects.Integrated Product Desig