Jordan R. Raney

Multistable Architected Materials for Trapping Elastic Strain Energy

3D printing and numerical analysis are combined to design a new class of architected materials that contain bistable beam elements and exhibit controlled trapping of elastic energy. The proposed energy-absorbing structures are reusable. Moreover, the mechanism of energy absorption stems solely from the structural geometry of the printed beam elements, and is therefore both material- and loading-rate independent.

Synthesis and characterization of carbon nanotube-polymer multilayer structures.

We develop lightweight, multilayer materials composed of alternating layers of poly dimethyl siloxane (PDMS) polymer and vertically aligned carbon nanotube (CNT) arrays, and characterize their mechanical response in compression. The CNT arrays used in the assembly are synthesized with graded mechanical properties along their thickness, and their use enables the creation of multilayer structures with low density (0.12-0.28 g/cm(3)). We test the mechanical response of structures composed of different numbers of CNT layers partially embedded in PDMS polymer, under quasi-static and dynamic loading. The resulting materials exhibit a hierarchical, fibrous structure with unique mechanical properties: They can sustain large compressive deformations (up to ∼0.8 strain) with a nearly complete recovery and present strain localization in selected sections of the materials. Energy absorption, as determined by the hysteresis observed in stress-strain curves, is found to be at least 3 orders of magnitude larger than that of natural and synthetic cellular materials of comparable density. Conductive bucky paper is included within the polymer interlayers. This allows the measurement of resistance variation as a function of applied stress, showing strong correlation with the observed strain localization in compression.

Stable propagation of mechanical signals in soft media using stored elastic energy

Significance Advances in nonlinear mechanics have enabled the realization of a variety of nontraditional functions in mechanical systems. Intrinsic dissipation typically limits the utility of these effects, with soft polymeric materials in particular being incompatible with meaningful wave propagation. Here we demonstrate a nonlinear soft system that is able to propagate large-amplitude signals over arbitrary distances without any signal degradation. We make use of bistable beams to store and then release elastic energy along the path of the wave, balancing both dissipative and dispersive effects. The soft and 3D printable system is highly customizable and tunable, enabling the design of mechanical logic that is relevant to soft autonomous systems (e.g., soft robotics). Soft structures with rationally designed architectures capable of large, nonlinear deformation present opportunities for unprecedented, highly tunable devices and machines. However, the highly dissipative nature of soft materials intrinsically limits or prevents certain functions, such as the propagation of mechanical signals. Here we present an architected soft system composed of elastomeric bistable beam elements connected by elastomeric linear springs. The dissipative nature of the polymer readily damps linear waves, preventing propagation of any mechanical signal beyond a short distance, as expected. However, the unique architecture of the system enables propagation of stable, nonlinear solitary transition waves with constant, controllable velocity and pulse geometry over arbitrary distances. Because the high damping of the material removes all other linear, small-amplitude excitations, the desired pulse propagates with high fidelity and controllability. This phenomenon can be used to control signals, as demonstrated by the design of soft mechanical diodes and logic gates.

Hybrid 3D Printing of Soft Electronics

Hybrid 3D printing is a new method for producing soft electronics that combines direct ink writing of conductive and dielectric elastomeric materials with automated pick-and-place of surface mount electronic components within an integrated additive manufacturing platform. Using this approach, insulating matrix and conductive electrode inks are directly printed in specific layouts. Passive and active electrical components are then integrated to produce the desired electronic circuitry by using an empty nozzle (in vacuum-on mode) to pick up individual components, place them onto the substrate, and then deposit them (in vacuum-off mode) in the desired location. The components are then interconnected via printed conductive traces to yield soft electronic devices that may find potential application in wearable electronics, soft robotics, and biomedical devices.

Effect of density variation and non-covalent functionalization on the compressive behavior of carbon nanotube arrays

Arrays of aligned carbon nanotubes (CNTs) have been proposed for different applications, including electrochemical energy storage and shock-absorbing materials. Understanding their mechanical response, in relation to their structural characteristics, is important for tailoring the synthesis method to the different operational conditions of the material. In this paper, we grow vertically aligned CNT arrays using a thermal chemical vapor deposition system, and we study the effects of precursor flow on the structural and mechanical properties of the CNT arrays. We show that the CNT growth process is inhomogeneous along the direction of the precursor flow, resulting in varying bulk density at different points on the growth substrate. We also study the effects of non-covalent functionalization of the CNTs after growth, using surfactant and nanoparticles, to vary the effective bulk density and structural arrangement of the arrays. We find that the stiffness and peak stress of the materials increase approximately linearly with increasing bulk density.

Nonlinear viscoelasticity of freestanding and polymer-anchored vertically aligned carbon nanotube foams

Vertical arrays of carbon nanotubes (VACNTs) show unique mechanical behavior in compression, with a highly nonlinear response similar to that of open cell foams and the ability to recover large deformations. Here, we study the viscoelastic response of both freestanding VACNT arrays and sandwich structures composed of a VACNT array partially embedded between two layers of poly(dimethylsiloxane) (PDMS) and bucky paper. The VACNTs tested are similar to 2 mm thick foams grown via an injection chemical vapor deposition method. Both freestanding and sandwich structures exhibit a time-dependent behavior under compression. A power-law function of time is used to describe the main features observed in creep and stress-relaxation tests. The power-law exponents show nonlinear viscoelastic behavior in which the rate of creep is dependent upon the stress level and the rate of stress relaxation is dependent upon the strain level. The results show a marginal effect of the thin PDMS/bucky paper layers on the viscoelastic responses. At high strain levels (epsilon - 0.8), the peak stress for the anchored CNTs reaches similar to 45 MPa, whereas it is only similar to 15MPa for freestanding CNTs, suggesting a large effect of PDMS on the structural response of the sandwich structures

Lightweight 3D cellular composites inspired by balsa

Additive manufacturing technologies offer new ways to fabricate cellular materials with composite cell walls, mimicking the structure and mechanical properties of woods. However, materials limitations and a lack of design tools have confined the usefulness of 3D printed cellular materials. We develop new carbon fiber reinforced, epoxy inks for 3D printing which result in printed materials with longitudinal Youngs modulus up to 57 GPa (exceeding the longitudinal modulus of wood cell wall material). To guide the design of hierarchical cellular materials, we developed a parameterized, multi-scale, finite element model. Computational homogenization based on finite element simulations at multiple length scales is employed to obtain the elastic properties of the material at multiple length scales. Parameters affecting the elastic response of cellular composites, such as the volume fraction, orientation distribution, and aspect ratio of fibers within the cell walls as well as the cell geometry and relative density are included in the model. To validate the model, experiments are conducted on both solid carbon fiber/epoxy composites and cellular structures made from them, showing excellent agreement with computational multi-scale model predictions, both at the cell-wall and at the cellular-structure levels. Using the model, cellular structures are designed and experimentally shown to achieve a specific stiffness nearly as high as that observed in balsa wood. The good agreement between the multi-scale model predictions and experimental data provides confidence in the practical utility of this model as a tool for designing novel 3D cellular composites with unprecedented specific elastic properties.

Elastic Vector Solitons in Soft Architected Materials

We demonstrate experimentally, numerically, and analytically that soft architected materials can support the propagation of elastic vector solitons. More specifically, we focus on structures comprising a network of squares connected by thin and highly deformable ligaments and investigate the propagation of planar nonlinear elastic waves. We find that for sufficiently large amplitudes two components-one translational and one rotational-are coupled together and copropagate without dispersion. Our results not only show that soft architected materials offer a new and rich platform to study the propagation of nonlinear waves, but also open avenues for the design of a new generation of smart systems that take advantage of nonlinearities to control and manipulate the propagation of large amplitude vibrations.

Rotational 3D printing of damage-tolerant composites with programmable mechanics

Significance Natural composites exhibit hierarchical and spatially varying structural features that give rise to high stiffness and strength as well as damage tolerance. Here, we report a rotational 3D printing method that enables exquisite control of fiber orientation within engineered composites. Our approach broadens their design, microstructural complexity, and performance space by enabling site-specific optimization of fiber arrangements within short carbon fiber–epoxy composites. Using this approach, we have created composites with programmable strain distribution and failure as well as enhanced damage tolerance. Natural composites exhibit exceptional mechanical performance that often arises from complex fiber arrangements within continuous matrices. Inspired by these natural systems, we developed a rotational 3D printing method that enables spatially controlled orientation of short fibers in polymer matrices solely by varying the nozzle rotation speed relative to the printing speed. Using this method, we fabricated carbon fiber–epoxy composites composed of volume elements (voxels) with programmably defined fiber arrangements, including adjacent regions with orthogonally and helically oriented fibers that lead to nonuniform strain and failure as well as those with purely helical fiber orientations akin to natural composites that exhibit enhanced damage tolerance. Our approach broadens the design, microstructural complexity, and performance space for fiber-reinforced composites through site-specific optimization of their fiber orientation, strain, failure, and damage tolerance.

Architected Lattices with High Stiffness and Toughness via Multicore–Shell 3D Printing

The ability to create architected materials that possess both high stiffness and toughness remains an elusive goal, since these properties are often mutually exclusive. Natural materials, such as bone, overcome such limitations by combining different toughening mechanisms across multiple length scales. Here, a new method for creating architected lattices composed of core-shell struts that are both stiff and tough is reported. Specifically, these lattices contain orthotropic struts with flexible epoxy core-brittle epoxy shell motifs in the absence and presence of an elastomeric silicone interfacial layer, which are fabricated by a multicore-shell, 3D printing technique. It is found that architected lattices produced with a flexible core-elastomeric interface-brittle shell motif exhibit both high stiffness and toughness.