4D printing with smart materials
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Transcript of 4D printing with smart materials
4D PRINTING WITH
SMART MATERIALSMT5009 – ANALYZING HI-TECH OPPORTUNITIES
Presented by: Imran Ahmad Khan (A0102875E)
Liew Chin Siew (A0098560W)
Loy Yoke Yuan (A0055354H)
Lu Wanheng (A0107258E)
Myint Phone Naing (A0033823M)
Soh Kok Boon Anthony (A0133008W)
1
Outline
• What is 4D Printing?
• Important Technology Aspects of 4D Printing
• SMART Materials’ Properties and Development
• Future Trend Analysis
• Conclusion
2
Outline
• What is 4D Printing?
• Important Technology Aspects of 4D Printing
• SMART Materials’ Properties and Development
• Future Trend Analysis
• Conclusion
3
3D Printing• An additive printing technique for making three dimensional
solid objects from a digital file
• An improvised form of rapid proto-typing.
• Based on the first Patent published in 1984 under
Stereolithography (SLA).
• Selective laser sintering (SLS) and Fused Deposition
Modeling (FDM) are others common technologies beside
SLA
4
Lix 3D pen – US$ 140
Another Dimension?"We're proposing that the fourth dimension is Time and that over time static objects will transform and adapt“
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"The rigid material becomes a structure and the other layer is the force that can start bending and twisting it. Imagine water pipes that can expand to cope with different capacities or flows and save digging up the street.“
Mr Tibbits, MIT's (Interview with BBC - 2013)
SMART Material
which can
transform upon
external stimuli
3D Printer
Introduction Video to 4D Printing
6
• https://www.youtube.com/watch?v=GIEhi_sAkU8
Overview of 4D Object
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Transformative materials without control is useless.
Smart
Materials
Some materials change physical property upon energy input
Materials expand upon heat
Materials bend upon electric energy
Energy Source
Natural energy source such as heat, pressure, etc
Controlled energy source such as current, electromagnetic wave
Arrange transformative material in precise angle, position
3D printer
4D Object
Precise Positioning
Control
Outline
• What is 4D Printing?
• Important Technology Aspects of 4D Printing
• SMART Materials’ Properties and Development
• Future Trend Analysis
• Conclusion
8
Important Aspects of 4D Printing
4D Printing
Simulation Software
Multi materials printer
SMART materials
9
Simulation software for self-assembly and design constraints optimization. Autodesk CATIA Open Source
3D printer with capability to print multiple SMART materials Stratasys ROVA SolidView GeoMagic
Materials that change shape upon external stimuli Shape memory alloy Self healing
materials
Simulation Software
• Cyborg 4D Simulation Software
• Cyborg, a design platform spanning applications from the nano-
scale to the human-scale.
• This software allows for simulated self-assembly and programmable
materials as well as optimization for design constraints and joint
folding.
• The aim is to tightly couple this new cross-disciplinary and cross-
scalar design tool with the real-world material transformation of 4D
printing.
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Source: http://www.autodeskresearch.com/projects/cyborg
Software Cost Reduction with Open
Source Technology
11
Top reasons for adopting Open Source1. Quality2. Lower total cost of
ownership3. Ease of deployment4. Ability to access
source code, add features and fix code yourself
5. Better competitive features and technical capabilities
6. Better IT security
Source: Survey results from Black Duck Software
Multi-Smart Materials Printer
12
4D Printer = 3D Printer with multi-smart
materials printing capability
Currently, no standardized hardware architecture yet.
Connex multi material technology Connex1 - Printing capability of 3
materialsSource: http://www.stratasys.com/3d-printers/design-series/objet260-connex1
Portable desktop printer
Printing capability of five materials
Source: http://ordsolutions.com/our-3d-printers/rova3d/
Multi-Smart Materials Printer
• Complete compatibility with current 3D printers which can
print multi-materials.
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0
5
10
15
2013 2014 2015 2016 2017 2018 2019
$B
illi
on
Year
Market Value Growth
3D printers
Services and materials
List of Smart Materials (I)
14
Material Input/Stimulus Output/Response Application
Polymeric gal pH changeSwelling or
contractingArtificial muscle
Electro-rheological
fluidElectric signal Viscosity change
Torsional steering
system damper
Pyroelectric
materialTemperature Electric signal
Personnel sensor
(open super-
market door)
Polymer (eg thin
film cellulose),
ceramic
Humidity changeCapacity/
resistance changeHumidity sensors
Self-Healing
MaterialsForce Force
Smartphone
chassis
Smart metal alloys Temperature Shape Motor actuators
Dielectric
ElastomersVoltage Strain Robotics
List of Smart Materials (II)
Material Input/Stimulus Output/Response Application
Ceramic (eg, La
doped BaTiO3)
Polymer (eg, C-
black filled
poltethylene)
Current (or
Temperate)Resistance
Thermistor
Overcurrent
Protector
Varistor (eg, Bi
doped ZnO)Voltage Resistance Surge Protector
Y2O3 doped ZrO2Change in Oxygen
Partial PressureElectric Signal Oxygen sensor
Piezoelectric
material
Deformation/
Strain electric
signal
Electric Signal
Active noise
control devices,
pressure and
vibration
sensitizing
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Smart Materials
• Smart materials are designed materials that have one or
more properties that can be significantly changed in a
controlled fashion by external stimuli, such as stress,
temperature, moisture, pH, electric or magnetic fields.
16
SMART
Materials
Smart Metal
Alloy
Others
(Not covered)
Dielectric
Elastomers
Self-Healing
Polymers
Roadmap of Smart Materials
• R&D activity on transformative materials is still in early
phase.
17
Outline
• What is 4D Printing?
• Important Technology Aspects of 4D Printing
• SMART Materials’ Properties and Development
• Future Trend Analysis
• Conclusion
18
Self-Healing Materials
• Self-healing material in a historical perspective
• The state of stone bridges and aqueducts from the Roman age is
still quite good, despite the fact that they have been there for
centuries
• The secret is in the ‘mortar’ – based on volcanic ash and lime
• The ancient Romans used in their constructions to glue the bricks
together
19
• Lime dissolves in rain
water, and can seep
to cracks. When the
water vaporizes, the
lime deposits inside
the crack
Application to Smartphone
• Self healing smart phone
• LG smartphone, G-Flex, which is curved and has a self-healing
polymer coating on the back: Light scratches disappear before your
eyes
20
How do Self Healing Materials Work?
• Synthetic and biological route to healing
• Inspired by nature
• 3 steps self healing process
21
1. Activation phase
2. Transportation phase
3. Repair phase
Source:Self-Healing Polymers and Composites by B.J. Blaiszik, S.L.B. Kramer, S.C. Olugebefola, J.S. Moore, N.R. Sottos, and S.R.White
Different Approach to Self-Healing
a) In capsule-based self-healing materials, the healing agent is stored
in capsules until they are ruptured by damage or dissolved.
b) For vascular materials, the healing agent is stored in hollow
channels or fibers until damage ruptures the vasculature and
releases the healing agent.
c) Intrinsic materials contain a latent functionality that triggers self-
healing of damage via thermally reversible reactions, hydrogen
bonding, ionomeric arrangements, or molecular diffusion and
entanglement.
22
Performance Maps of Different Healing
Approach• Development of Self healing polymers
23
Source:Self-Healing Polymers and Composites by B.J. Blaiszik, S.L.B. Kramer, S.C. Olugebefola, J.S.
Moore, N.R. Sottos, and S.R.White
Properties of Self-Healing Material
• Material performance as a function of time
• Traditional materials only accumulate damage and fail after a
certain period of use.
• Self healing materials may show some early deterioration, yet its
self healing character makes sure that total failure only occurs after
very long times.
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Properties of Self-Healing Polymers
• Development of Self healing polymers
25
Polymer
type
Healing
approach
Chemistry/
method
Best healing
efficiency (%)
Healing
conditions
Thermoplastic
IntrinsicReversible bond
formation75 % < 1 min at -30°C
Capsule
basedInterdiffusion (solvent) 78% 4 – 5 min at 60°C
Intrinsic Photo-induced healing 16% 10 min at 100°C
Intrinsic Nanoparticle healing - 2h at Ambient
Thermoset
VascularThermally reversible
crosslinks60%
30 min at 115°C
6 h at 40°C
VascularThermoplastic
additives45% 1h at 160°C
Thermoset
composites
Capsule
based
Microencapsulation
approach60%
48h at 80°C
24h at Ambient
VascularThermoplastic
additives80% 1.5h at 80°C
Potential Application: Space Structures
26
• Benefit in environments and conditions
where access for manual repair is
limited or impossible or where damage
may not be detected.
• Self healing polymers, yet to achieve
high healing efficiency , maximum
efficiency 80% achieved by Thermoset
composites in controlled environment.
• How self-healing materials will
perform under long-term
environment exposure remains as
open question. Accelerated
environment testing of self-healing
systems is critically needed.
Smart Metal Alloys
• Nitinol heat engine
invented in the 1970s that
is capable of converting
heat energy to
mechanical or electrical
energy
• Impact: Efficient
conversion of energy over
small temperature
differences at ambient
conditions
27
Source: Ridgway M. Banks (1983), Single wire Nitinol Engine, United States Patent 4,450,686
28
How do Smart Metal Alloys Work?
List of Smart Metal Alloys
29
Source: S. Barbarino, E.I. Saavedra Flores, R.M. Ajaj, I. Dayyani and M.I. Friswell (2014). A review on shape memory alloys with applications to morphing aircraft, Smart Mater. Struct. 23, 063001
30
Metal Alloy Properties
Source: S. Barbarino, E.I. Saavedra Flores, R.M. Ajaj, I. Dayyani and M.I. Friswell (2014). A review on shape memory alloys with applications to morphing aircraft, Smart Mater. Struct. 23, 063001
Properties of NiTi Alloys
31
Source: S. Barbarino, E.I. Saavedra Flores, R.M. Ajaj, I. Dayyani and M.I. Friswell (2014). A review on shape memory alloys with applications to morphing aircraft, Smart Mater. Struct. 23, 063001
Potential Application: Morphing Aircraft
• Overcome limitations of current flight
technology by adapting the geometry of
lifting surfaces to pilot input and different
flight conditions characterizing a typical
mission profile
• Improvement to long-term performance,
reliability and response of metal
actuators is required for this to become
a reality
32
Dielectric Elastomer
• Used in conformal speakers.
33
Dielectric Elastomer
• Highly efficient transduction from electric energy into mechanical
energy – the theoretical transduction efficiency is 80-90%
• High strain rate up to 300 % as shown below.
• High pressure up to 8MPa and power density of 1 W/g (for
comparison, human muscle is 0.2 W/g and an electric motor with
gearbox is 0.05 W/g)
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Acrylic elastomers showing 300% linear strain
Source: Extending Applications of Dielectric Elastomer Artificial Muscles to Wireless Communication Systems by Seiki Chiba and Mikio Waki
Properties of Dielectric Elastomer
• 1mm thick 3M VHB 4910 uniformly strain to ~300% when
a voltage is applied across it.
35
Source: Novel Applications of Dielectric Elastomer Actuators by L. Christopher Stocking
Performance of Dielectric Elastomer
• The energy density of dielectric elastomer has reached 3.4J/g, about
21 times that of single crystal piezoelectrics and more than two orders
of magnitude greater than that of most commercial actuators.
• DE have an actuation pressure/density that is bigger than that of
electrostatic actuators and magnetic actuators, and cause strains that
are bigger than that of piezo electric actuators and magneto strictive
actuators.
36
Source: Dielectric Elastomer Artificial Muscle Actuators: Toward Biomimetic Motion by Ron Pelrine, Roy Kornbluh
Level of Improvement - Performance
37
Source: Advances in Dielectric Elastomers for Actuators and Artificial Muscles by Paul Brochu, Qibing Pei
Potential Application: Artificial muscles• Dielectric elastomers require an external
circuit with a high bias voltage source to
polarize them. To be feasible in real life
application, need to drastically reduce
this voltage requirement.
38
Source: Dielectric Elastomer Artificial Muscle Actuators: Toward Biomimetic Motion byRon Pelrine, Roy Kornbluh, Qibing Pei, Scott Stanford, Seajin Oh, Joe Eckerle
Further Applications of Smart Materials
39
Healthcare
Robotic
AutomotiveIndustry
Consumer
IndustrialManufacturing
Military
Aerospace
Healthcare
40
Nano Scale Objects in Biomedical Engineering. E.g Cardiac tube/Stenthttp://www.nhlbi.nih.gov/health/health-topics/topics/stents
4D printed stent to be maneuvered to a spot and then change form
For example, 4D printed stent that is introduced into an artery – and when ultrasound energy is appliedit balloons up to its needed configuration
Electroactive Polymers for Artificial Limbs http://www.technologyreview.com/article/401750/electroactive-polymers/
An applied voltage changes the polymer’s composition or molecular structure so that it expands, contracts or bends
The motion is smoother and more lifelike than movement generated by mechanical devices.
Smart Materials – Magnetostrictive / Magnetic Shape Memory AlloysKPI – Precision control
Smart Materials – Dielectric Elastomer / Piezoelectric KPI – Reliability
Consumer
41
Transformative Shoeshttp://www.smithsonianmag.com/innovation/Objects-That-Change-Shape-On-Their-Own-180951449/?no-ist
Imagine a single shoe for multiple activities:
If you start running, it adapts to being running shoes
If you play basketball, it adapts to support your ankles
If you go on grass, it grows cleats
If it is raining, it becomes waterproof
Adaptive Tyre Compound
4D printed tyre compound which provide adaptive grip on road condition
Smart Materials – Self-healing materialsKPI – Response control
Industrial Manufacturing
42
Pipe Manufacturing
http://www.youtube.com/watch?v=0gMCZFHv9v8
Current pipe system is very rigid. To cater for higher flow capacity, we have to replace the whole pipe line.
Solution: An adaptive 4D manufacturing capability to produce capacity adaptable pipes
Insulation Wall Manufacturing
Insulation wall that can adapt to outside temperature
Self adaptive wall that maintain heat during winter and less insulation property during summer
Smart Materials – Shape Memory AlloysKPI – Reliability, sensitivity
Robotics
43
More Humanoid Robot
Current robot systems are very rigid due to inherent mechanical property of motors, gears & etc
By precise geometry arranging of multiple transformative materials, we can achieve desired motion, action upon applied energy
End result is more human like robot which can perform more delicate jobs
Possible Smart Materials – Combination of Smart MaterialsKPI – Integration
Outline
• What is 4D Printing?
• Important Technology Aspects of 4D Printing
• SMART Materials’ Properties and Development
• Future Trend Analysis
• Conclusion
44
Current State of Technology
• 4D printing is a novel advancement to 3D printing technology
• 4D printing is focused on developing materials and newer printing techniques that could reduce the time taken for assembly of parts, in turn improving the overall efficiency of the manufacturing process.
• Parts manufactured using this novel technology would employ different types of SMART materials.
45
Source: Frost & Sullivan, June 2014:
Patent Landscape
46
Patent Mining DatabaseThomson Innovation
Search Keywords 4D printing 4D printer Self-healing materials Self-healing polymers Self-healing coatings
Search Timeline1 January 2004 to 23 June 2013
*
**
*
Year of Impact (4D printing)
47
Source: Frost & Sullivan, June 2014:
The expected year of widespread/ large-scale adoption of 4D Printing technology has been computed through assessments of
technology advances, industry initiatives, challenges, advances in related industries, and market potential
SectorsExpected Year of Impact
2015 2016 2017 2018 2019 2020 2021 2022 2023 2024
Healthcare
Military
Infrastructure
Automobile
Packaging
Aerospace
Manufacturing
Breadth of Application
48
Impact of Megatrends
49
Size of Innovation Ecosystem
50
Stakeholder Influence Assessment
Size of Innovation Ecosystem
51
Impact of Key Innovations Landscape
Source: Frost & Sullivan, June 2014:
Global Footprint
52
Source: Frost & Sullivan, June 2014:
Global Development and Adoption Scenario
Region Remarks Intensity of Adoption
NorthAmerica
Various universities in the country have been developing this novel technology.
USA: Maximum R&D activities ongoing for this technology Main focus: Aerospace and defense, automotive, health care,
infrastructure, manufacturing, and packaging Major funding agency: US ARO and DOD
HIGH
Europe Adoption of 4D printing technology or research activities not been greatly evident in this region.
More actively to develop this technology expected in near term MEDIUM
AsiaPacific
Adoption of 4D printing is expected to be somewhat slower in this region compared to the other two regions.
Researchers from Singapore University of Technology have collaborated with the University of Colorado-Boulder for developing a 4D printing technology that incorporates shape memory fibers.
MEDIUM
Global Footprint
53
Source: Frost & Sullivan, June 2014:
4D Printing-Adoption Scenario
Outline
• What is 4D Printing?
• Important Technology Aspects of 4D Printing
• SMART Materials’ Properties and Development
• Future Trend Analysis
• Conclusion
54
Key Conclusion
• Emerging Market Potential • 4D printing technology is expected to significantly increase the efficiency of the
manufacturing process and increase the capability to produce complex parts and products for different industrial sectors. Expected to create a large number of potential applications in diverse industrial sectors (for example, aerospace, defense, automotive, health care, infrastructure, manufacturing, packaging)
• Evolving Ecosystem • 4D printing technology is expected to be adopted by a range of industrial
sectors. Research laboratories, universities, and companies are also expected to increase their 4D printing research activities, further enabling convergence between industries and increasing the breadth of applications of 4D printing technology.
• Technology • 4D printing technology (software, hardware, 4D printing materials) is still in
early phase of S-curve. Dominant hardware/software architecture yet to be established. IP on 4D printing smart materials is building up. 4D technology will be getting increasingly popular as the trends toward its integration with the giant industries like manufacturing and healthcare, have increased.
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