Conner K. Dunn

Active origami by 4D printing

Recent advances in three dimensional (3D) printing technology that allow multiple materials to be printed within each layer enable the creation of materials and components with precisely controlled heterogeneous microstructures. In addition, active materials, such as shape memory polymers, can be printed to create an active microstructure within a solid. These active materials can subsequently be activated in a controlled manner to change the shape or configuration of the solid in response to an environmental stimulus. This has been termed 4D printing, with the 4th dimension being the time-dependent shape change after the printing. In this paper, we advance the 4D printing concept to the design and fabrication of active origami, where a flat sheet automatically folds into a complicated 3D component. Here we print active composites with shape memory polymer fibers precisely printed in an elastomeric matrix and use them as intelligent active hinges to enable origami folding patterns. We develop a theoretical model to provide guidance in selecting design parameters such as fiber dimensions, hinge length, and programming strains and temperature. Using the model, we design and fabricate several active origami components that assemble from flat polymer sheets, including a box, a pyramid, and two origami airplanes. In addition, we directly print a 3D box with active composite hinges and program it to assume a temporary flat shape that subsequently recovers to the 3D box shape on demand.

Porous polymeric materials by 3D printing of photocurable resin

Porous polymeric materials have a wide range of applications, including as tissue scaffolds, catalyst supports, and membrane filters. This paper presents a new fabrication method to prepare components of porous materials by combining 3D printing with salt leaching. Sacrificial salt particulates and photocurable resin are mixed and used as the ink. 3D objects are then printed in a customized digital light processing printer. Owing to the interconnection of salt particles in the objects, porous polymeric components can be obtained upon salt leaching. Multiple pore sizes can be achieved by using selectively sieved salt powders in the ink formula. This method is very simple to implement for different photocurable resins to create 3D porous objects with complicated shapes. It has the advantage of being self-supporting and can be used to print hollow components, especially parts exhibiting the Droste effect. Shape memory foams by using shape memory polymers and dual-pore scaffolds can also be 3D printed with potential applications in tissue engineering. In addition, the porous components can be used as a template for embedding a conductive material to obtain 3D printed objects that function as flexible conductive components or filling with a second polymer to obtain a composite with a tunable modulus.

Direct Ink Write (DIW) 3D Printed Cellulose Nanocrystal Aerogel Structures

Pure cellulose nanocrystal (CNC) aerogels with controlled 3D structures and inner pore architecture are printed using the direct ink write (DIW) technique. While traditional cellulosic aerogel processing approaches lack the ability to easily fabricate complete aerogel structures, DIW 3D printing followed by freeze drying can overcome this shortcoming and can produce CNC aerogels with minimal structural shrinkage or damage. The resultant products have great potential in applications such as tissue scaffold templates, drug delivery, packaging, etc., due to their inherent sustainability, biocompatibility, and biodegradability. Various 3D structures are successfully printed without support material, and the print quality can be improved with increasing CNC concentration and printing resolution. Dual pore CNC aerogel scaffolds are also successfully printed, where the customizable 3D structure and inner pore architecture can potentially enable advance CNC scaffold designs suited for specific cell integration requirements.

3D Printing of Highly Stretchable, Shape-Memory, and Self-Healing Elastomer toward Novel 4D Printing

The three-dimensional (3D) printing of flexible and stretchable materials with smart functions such as shape memory (SM) and self-healing (SH) is highly desirable for the development of future 4D printing technology for myriad applications, such as soft actuators, deployable smart medical devices, and flexible electronics. Here, we report a novel ink that can be used for the 3D printing of highly stretchable, SM, and SH elastomer via UV-light-assisted direct-ink-write printing. An ink containing urethane diacrylate and a linear semicrystalline polymer is developed for the 3D printing of a semi-interpenetrating polymer network elastomer that can be stretched by up to 600%. The 3D-printed complex structures show interesting functional properties, such as high strain SM and SM -assisted SH capability. We demonstrate that such a 3D-printed SM elastomer has the potential application for biomedical devices, such as vascular repair devices. This research paves a new way for the further development of novel 4D printing, soft robotics, and biomedical devices.

Recyclable 3D printing of vitrimer epoxy

3D printing of polymeric materials for various applications has been quickly developed in recent years. In contrast to thermoplastics, 3D printed thermosets, although desirable, are inherently non-recyclable due to their permanently crosslinked networks. As 3D printing is becoming more popular, it is desirable to develop recycling approaches for 3D printed parts in view of increasing polymer wastes. Here, we present a new thermosetting vitrimer epoxy ink and a 3D printing method that can 3D print epoxy into parts with complicated 3D geometries, which later can be recycled into a new ink for the next round of 3D printing. In the first printing cycle, a high-viscous ink is first slightly cured and is then printed at an elevated temperature into complicated 3D structures, followed by an oven cure using a two-step approach. To be recycled, the printed epoxy parts are fully dissolved in an ethylene glycol solvent in a sealed container at a high temperature. The dissolved polymer solution is reused for the next printing cycle using similar printing conditions. Our experiments demonstrate that the ink can be printed four times and still retains very good printability. In addition, the vitrimer epoxy can be used for pressure-free repairs for the 3D printed parts.