Shahram Janbaz

Programming the shape-shifting of flat soft matter: from self-rolling/self-twisting materials to self-folding origami

Nature uses various activation mechanisms to program complex transformations in the shape and functionality of living organisms. Inspired by such natural events, we aimed to develop initially flat (i.e. two-dimensional) programmable materials that, when triggered by a stimulus such as temperature, could self-transform their shape into a complex three-dimensional geometry. A two-dimensional starting point enables full access to the surface, e.g. for (nano-)patterning purposes, which is not available in most other manufacturing techniques including additive manufacturing techniques and molding. We used different arrangements of bi- and multi-layers of a shape memory polymer (SMP) and hyperelastic polymers to program four basic modes of shape-shifting including self-rolling, self-twisting (self-helixing), combined self-rolling and self-wrinkling, and wave-like strips. The effects of various programming variables such as the thermomechanical properties of the hyperelastic layer, dimensions of the bi- and multi-layer strips, and activation temperature on the morphology of the resulting three-dimensional objects were studied experimentally and were found to cause as much as 10-fold change in the relevant dimensions. Some of the above-mentioned modes of shape-shifting were then integrated into other two-dimensional constructs to obtain self-twisting DNA-inspired structures, programmed pattern development in cellular solids, self-folding origami, and self-organizing fibers. Furthermore, the possibility of incorporating multiple surface patterns into one single piece of shape-transforming material is demonstrated using ultraviolet-cured photopolymers.

How does tissue regeneration influence the mechanical behavior of additively manufactured porous biomaterials

Although the initial mechanical properties of additively manufactured porous biomaterials are intensively studied during the last few years, almost no information is available regarding the evolution of the mechanical properties of implant-bone complex as the tissue regeneration progresses. In this paper, we studied the effects of tissue regeneration on the static and fatigue behavior of selective laser melted porous titanium structures with three different porosities (i.e. 77, 81, and 85%). The porous structures were filled with four different polymeric materials with mechanical properties in the range of those observed for de novo bone (0.7GPa<E<1.5GPa) to simulate bone tissue regeneration into their pores. The static mechanical properties and fatigue behavior (S-N curves) of as-manufactured and filled porous structures were then determined. The static mechanical properties and fatigue life (including endurance limit) of the porous structures were found to increase by factors 2-7, even when they were filled with polymeric materials with relatively low mechanical properties. The relative increase in the mechanical properties was much higher for the porous structures with lower porosities. Moreover, the increase in the fatigue life was more notable as compared to the increase in the static mechanical properties. Such large values of increase in the mechanical properties with the progress of bone tissue regeneration have implications in terms of mechanical stimulus for bone tissue regeneration.

Rationally designed meta-implants: a combination of auxetic and conventional meta-biomaterials

Rationally designed meta-biomaterials present unprecedented combinations of mechanical, mass transport, and biological properties favorable for tissue regeneration. Here we introduce hybrid meta-biomaterials with rationally-distributed values of negative (auxetic) and positive Poissons ratios, and use them to design meta-implants that unlike conventional implants do not retract from the bone under biomechanical loading. We rationally design and additively manufacture six different types of meta-biomaterials (three auxetic and three conventional), which then serve as the parent materials to six hybrid meta-biomaterials (with or without transitional regions). Both single and hybrid meta-biomaterials are mechanically tested to reveal their full-field strain distribution by digital image correlation. The best-performing hybrid meta-biomaterials are then selected for the design of meta-implants (hip stems), which are tested under simulated-implantation conditions. Full-field strain measurements clearly show that, under biomechanical loading, hybrid meta-implants press onto the bone on both the medial and lateral sides, thereby improving implant–bone contact and potentially implant longevity.

Origami lattices with free-form surface ornaments

We introduce folding strategies to fabricate lattice structures with arbitrarily complex surface (nano-) ornaments. Lattice structures are used in the design of metamaterials to achieve unusual physical, mechanical, or biological properties. The properties of such metamaterials result from the topology of the lattice structures, which are usually three-dimensionally (3D) printed. To incorporate advanced functionalities into metamaterials, the surface of the lattice structures may need to be ornamented with functionality-inducing features, such as nanopatterns or electronic devices. Given our limited access to the internal surfaces of lattice structures, free-form ornamentation is currently impossible. We present lattice structures that are folded from initially flat states and show that they could bear arbitrarily complex surface ornaments at different scales. We identify three categories of space-filling polyhedra as the basic unit cells of the cellular structures and, for each of those, propose a folding pattern. We also demonstrate “sequential self-folding” of flat constructs to 3D lattices. Furthermore, we folded auxetic mechanical metamaterials from flat sheets and measured the deformation-driven change in their negative Poisson’s ratio. Finally, we show how free-form 3D ornaments could be applied on the surface of flat sheets with nanometer resolution. Together, these folding patterns and experimental techniques present a unique platform for the fabrication of metamaterials with unprecedented combination of physical properties and surface-driven functionalities.

Length-scale dependency of biomimetic hard-soft composites

Biomimetic composites are usually made by combining hard and soft phases using, for example, multi-material additive manufacturing (AM). Like other fabrication methods, AM techniques are limited by the resolution of the device, hence, setting a minimum length scale. The effects of this length scale on the performance of hard-soft composites are not well understood. Here, we studied how this length scale affects the fracture toughness behavior of single-edge notched specimens made using random, semi-random, and ordered arrangements of the hard and soft phases with five different ratios of hard to soft phases. Increase in the length scale (40 to 960 μm) was found to cause a four-fold drop in the fracture toughness. The effects of the length scale were also modulated by the arrangement and volumetric ratio of both phases. A decreased size of the crack tip plastic zone, a crack path going through the soft phase, and highly strained areas far from the crack tip were the main mechanisms explaining the drop of the fracture toughness with the length scale.