Grace X. Gu

Three-Dimensional-Printing of Bio-Inspired Composites

Optimized for millions of years, natural materials often outperform synthetic materials due to their hierarchical structures and multifunctional abilities. They usually feature a complex architecture that consists of simple building blocks. Indeed, many natural materials such as bone, nacre, hair, and spider silk, have outstanding material properties, making them applicable to engineering applications that may require both mechanical resilience and environmental compatibility. However, such natural materials are very difficult to harvest in bulk, and may be toxic in the way they occur naturally, and therefore, it is critical to use alternative methods to fabricate materials that have material functions similar to material function as their natural counterparts for large-scale applications. Recent progress in additive manufacturing, especially the ability to print multiple materials at upper micrometer resolution, has given researchers an excellent instrument to design and reconstruct natural-inspired materials. The most advanced 3D-printer can now be used to manufacture samples to emulate their geometry and material composition with high fidelity. Its capabilities, in combination with computational modeling, have provided us even more opportunities for designing, optimizing, and testing the function of composite materials, in order to achieve composites of high mechanical resilience and reliability. In this review article, we focus on the advanced material properties of several multifunctional biological materials and discuss how the advanced 3D-printing techniques can be used to mimic their architectures and functions. Lastly, we discuss the limitations of 3D-printing, suggest possible future developments, and discuss applications using bio-inspired materials as a tool in bioengineering and other fields.

Hierarchically Enhanced Impact Resistance of Bioinspired Composites

An order of magnitude tougher than nacre, conch shells are known for being one of the toughest body armors in nature. However, the complexity of the conch shell architecture creates a barrier to emulating its cross-lamellar structure in synthetic materials. Here, a 3D biomimetic conch shell prototype is presented, which can replicate the crack arresting mechanisms embedded in the natural architecture. Through an integrated approach combining simulation, additive manufacturing, and drop tower testing, the function of hierarchy in conch shells multiscale microarchitectures is explicated. The results show that adding the second level of cross-lamellar hierarchy can boost impact performance by 70% and 85% compared to a single-level hierarchy and the stiff constituent, respectively. The overarching mechanism responsible for the impact resistance of conch shell is the generation of pathways for crack deviation, which can be generalized to the design of future protective apparatus such as helmets and body armor.

Printing nature: Unraveling the role of nacre's mineral bridges

Creating materials with strength and toughness has been a long-sought goal. Conventional engineering materials often face a trade-off between strength and toughness, prompting researchers seeking to overcome these limitations to explore more sophisticated materials, such as composites. This paradigm shift in material design is spurred by nature, which exhibits a plethora of heterogeneous materials that offer outstanding material properties, and many natural materials are widely regarded as examples of high-performing hybrid materials. A classic example is nacre, also known as mother-of-pearl, which boasts a combination of high stiffness, strength, and fracture toughness. Various microstructural features contribute to the toughness of nacre, including mineral bridges (MBs), nano-asperities, and waviness of the constituent platelets. Recent research in biomimicry suggests that MBs contribute to the high strength and toughness observed in nacre and nacre-inspired materials. However, previous work in this area did not allow for complete control over the length scale of the bridges and had limitations on the volume fraction of mineral content. In this work, we present a systematic investigation elucidating the effects of structural parameters, such as volume fraction of mineral phase and density of MBs, on the mechanical response of nacre-inspired additive manufactured composites. Our results demonstrate that it is possible to tune the composite properties by tuning sizes and content of structural features (e.g. MBs and mineral content) in a heterogeneous material. Looking forward, this systematic approach enables materials-by-design of complex architectures to tackle demanding engineering challenges in the future.

Bioinspired hierarchical composite design using machine learning: simulation, additive manufacturing, and experiment

Biomimicry, adapting and implementing natures designs provides an adequate first-order solution to achieving superior mechanical properties. However, the design space is too vast even using biomimetic designs as prototypes for optimization. Here, we propose a new approach to design hierarchical materials using machine learning, trained with a database of hundreds of thousands of structures from finite element analysis, together with a self-learning algorithm for discovering high-performing materials where inferior designs are phased out for superior candidates. Results show that our approach can create microstructural patterns that lead to tougher and stronger materials, which are validated through additive manufacturing and testing. We further show that machine learning can be used as an alternative method of coarse-graining – analyzing and designing materials without the use of full microstructural data. This novel paradigm of smart additive manufacturing can aid in the discovery and fabrication of new material designs boasting orders of magnitude increase in computational efficacy over conventional methods.