Multi‐actuated functionally graded piezoelectric micro‐tools design: A multiphysics topology optimization approach

Micro‐tools offer significant promise in a wide range of applications such as cell manipulation, micro‐surgery, and micro/nanotechnology processes. Such special micro‐tools consist of multi‐flexible structures actuated by two or more piezoceramic devices that must generate output displacements and forces at different specified points of the domain and at different directions. The micro‐tool structure acts as a mechanical transformer by amplifying and changing the direction of the piezoceramics output displacements. The design of these micro‐tools involves minimization of the coupling among movements generated by various piezoceramics. To obtain enhanced micro‐tool performance, the concept of multifunctional and functionally graded materials is extended by tailoring elastic and piezoelectric properties of the piezoceramics while simultaneously optimizing the multi‐flexible structural configuration using multiphysics topology optimization. The design process considers the influence of piezoceramic property gradation and also its polarization sign. The method is implemented considering continuum material distribution with special interpolation of fictitious densities in the design domain. As examples, designs of a single piezoactuator, an XY nano‐positioner actuated by two graded piezoceramics, and a micro‐gripper actuated by three graded piezoceramics are considered. The results show that material gradation plays an important role to improve actuator performance, which may also lead to optimal displacements and coupling ratios with reduced amount of piezoelectric material. The present examples are limited to two‐dimensional models because many of the applications for such micro‐tools are planar devices. Copyright © 2008 John Wiley & Sons, Ltd.     

Recent Advances on 3D Printing Technique for Thermal‐Related Applications

Advances in ink formulation and printing techniques make producing material systems with new and versatile characteristics and functionalities possible. Additive manufacturing or 3D printing enables fabricating complex structures at a faster production rate using different types of materials for various applications. Recently, 3D printing methods are being studied for thermal‐related applications. In this paper, the authors review recent progress of materials and printing techniques for thermal application devices using composite materials.

     

Stress Reduction of 3D Printed Compliance‐Tailored Multilayers

Multilayered multi‐material interfaces are encountered in an array of fields. Here, enhanced mechanical performance of such multi‐material interfaces is demonstrated, focusing on strength and stiffness, by employing bondlayers with spatially‐tuned elastic properties realized via 3D printing. Compliance of the bondlayer is varied along the bondlength with increased compliance at the ends to relieve stress concentrations. Experimental testing to failure of a tri‐layered assembly in a single‐lap joint configuration, including optical strain mapping, reveals that the stress and strain redistribution of the compliance‐tailored bondlayer increases strength by 100% and toughness by 60%, compared to a constant modulus bondlayer, while maintaining the stiffness of the joint with the homogeneous stiff bondlayer. Analyses show that the stress concentrations for both peel and shear stress in the bondlayer have a global minimum when the compliant bond at the lap end comprises ≈10% of the bondlength, and further that increased multilayer performance also holds for long (relative to critical shear transfer length) bondlengths. Damage and failure resistance of multi‐material interfaces can be improved substantially via the compliance‐tailoring demonstrated here, with immediate relevance in additive manufacturing joining applications, and shows promise for generalized joining applications including adhesive bonding.     

Integrated layout design of multi‐component system

A new integrated layout optimization method is proposed here for the design of multi‐component systems. By introducing movable components into the design domain, the components layout and the supporting structural topology are optimized simultaneously. The developed design procedure mainly consists of three parts: (i) Introduction of non‐overlap constraints between components. The finite circle method (FCM) is used to avoid the components overlaps and also overlaps between components and the design domain boundaries. (ii) Layout optimization of the components and supporting structure. Locations and orientations of the components are assumed as geometrical design variables for the optimal placement while topology design variables of the supporting structure are defined by the density points. Meanwhile, embedded meshing techniques are developed to take into account the finite element mesh change caused by the component movements. (iii) Consistent material interpolation scheme between element stiffness and inertial load. The commonly used solid isotropic material with penalization model is improved to avoid the singularity of localized deformation in the presence of design dependent loading when the element stiffness and the involved inertial load are weakened by the element material removal. Finally, to validate the proposed design procedure, a variety of multi‐component system layout design problems are tested and solved on account of inertia loads and gravity center position constraint. Solutions are compared with traditional topology designs without component. Copyright © 2008 John Wiley & Sons, Ltd.     

Multi‐Stable Mechanical Structural Materials

Energy absorbing is an important and desirable property in mechanical and civil engineering. Here, a proof‐of‐concept method is presented as a new approach to achieve artificial mechanical materials with tunable compressive behavior for energy absorbing constructed from unit cells with a snap fit structure. The artificial structure undergoes a series of stable configurations derived from the sequential insertion of the plug into the groove of the snap fit. Both, experimental and simulation results manifest the multi‐stable and tunable mechanical properties of the structure. The mechanical energy dissipated by the proposed structure is demonstrated to be dependent on the lead‐in angle of the snap fit and the deflection ratio of the groove, as well as on the coefficient of friction between the plug and the groove of the snap fit. The system designed, herein, exhibits mechanical properties that can be tuned not only by adjusting the geometric parameters, but also by tuning the coefficient of friction between the plug and the groove, allowing the mechanical properties to be tailored post‐fabrication. Furthermore, the proposed model can be extended to the macro‐, micro‐, or nanoscales. These findings provide a simple method to obtain artificial materials with tunable energy absorbing properties, which can be applied in areas such as the design of automobile bumpers and foldable devices that facilitate their transportation.

     

A Novel Design of Multi‐Mechanoresponsive and Mechanically Strong Hydrogels

A newly developed polyacrylamide‐co ‐methyl acrylate/spiropyran (SP) hydrogel crosslinked by SP mechanophore demonstrates multi‐stimuli‐responsive and mechanically strong properties. The hydrogels not only exhibit thermo‐, photo‐, and mechano‐induced color changes, but also achieve super‐strong mechanical properties (tensile stress of 1.45 MPa, tensile strain of ≈600%, and fracture energy of 7300 J m^?2). Due to a reversible structural transformation between spiropyran (a ring‐close) and merocyanine (a ring‐open) states, simple exposure of the hydrogels to white light can reverse color changes and restore mechanical properties. The new design approach for a new mechanoresponsive hydrogel is easily transformative to the development of other mechanophore‐based hydrogels for sensing, imaging, and display applications.     

Pressure‐Responsive Hierarchical Chiral Photonic Aerogels

Pressure‐responsive chiral photonic aerogels are fabricated by combining liquid crystal self‐assembly and ice‐templating processes. The aerogels have a hierarchical structure in which the primary 2D chiral nematic structured walls of cellulose nanocrystals form ribbons that support a secondary 3D cellular network. Owing to the flexibility of the aerogels in solvent, the 3D structure of the aerogel can easily be transformed to a 2D structure by pressure‐induced rearrangement. The aerogels vary from white in color, which arises from light scattering, to a reflective photonic crystal displaying bright iridescent colors that depend on the immersed solvent. A solvent‐sensitive ink that shows quick color response to different solvents is designed using the pressure‐responsive photonic aerogel. This material demonstrates a new response mechanism for the design of smart and mechanoresponsive photonic materials.     

Nature‐Inspired Nacre‐Like Composites Combining Human Tooth‐Matching Elasticity and Hardness with Exceptional Damage Tolerance

Making replacements for the human body similar to natural tissue offers significant advantages but remains a key challenge. This is pertinent for synthetic dental materials, which rarely reproduce the actual properties of human teeth and generally demonstrate relatively poor damage tolerance. Here new bioinspired ceramic–polymer composites with nacre‐mimetic lamellar and brick‐and‐mortar architectures are reported, which resemble, respectively, human dentin and enamel in hardness, stiffness, and strength and exhibit exceptional fracture toughness. These composites are additionally distinguished by outstanding machinability, energy‐dissipating capability under cyclic loading, and diminished abrasion to antagonist teeth. The underlying design principles and toughening mechanisms of these materials are elucidated in terms of their distinct architectures. It is demonstrated that these composites are promising candidates for dental applications, such as new‐generation tooth replacements. Finally, it is believed that this notion of bioinspired design of new materials with unprecedented biologically comparable properties can be extended to a wide range of material systems for improved mechanical performance.     

Arbitrarily 3D Configurable Hygroscopic Robots with a Covalent–Noncovalent Interpenetrating Network and Self‐Healing Ability

Soft materials that can reversibly transform shape in response to moisture have applications in diverse areas such as soft robotics and biomedicine. However, the design of a structurally transformable or mechanically self‐healing version of such a humidity‐responsive material, which can arbitrarily change shape and reconfigure its 3D structures remains challenging. Here, by drawing inspiration from a covalent–noncovalent network, an elaborately designed biopolyester is developed that features a simple hygroscopic actuation mechanism, straightforward manufacturability at low ambient temperature (≤35 °C), fast and stable response, robust mechanical properties, and excellent self‐healing ability. Diverse functions derived from various 3D shapes that can grasp, swing, close–open, lift, or transport an object are further demonstrated. This strategy of easy‐to‐process 3D structured self‐healing actuators is expected to combine with other actuation mechanisms to extend new possibilities in diverse practical applications.     

Mechanical Properties of a Novel Zero Poisson's Ratio Honeycomb

In this paper, a novel honeycomb is proposed by embedding a rib into every cell of the existing zero Poisson's ratio (ZPR) configuration, semi re‐entrant honeycomb (SRH). Analytical model is developed to investigate the in‐plane mechanical properties of the new honeycomb, and the resulting theoretical expressions are compared with the experimental tests and numerical results obtained from two different finite element (FE) models (3D beam model and 3D solid model), leading to a good correlation. FE analysis, analytical modeling, and experimental tests of the new honeycomb show that it can achieve ZPR effect in two principal directions. For further studies, parameters analyses are carried out to explore the dependence of the in‐plane mechanical properties versus the geometric parameters. The results show that bending is the dominated deformation model when the new honeycomb is compressed along the x‐ direction, while stretch controlled in the y‐ directional compression. It is remarkable that the new proposed honeycomb features superior specific stiffness and more flexible in mechanical properties tailoring compared to the other ZPR honeycombs in the literature. Given these benefits, the new honeycomb may be promising in some practical applications.

     

Sustainable Solid‐State Supercapacitors Made of 3D‐Poly(3,4‐ethylenedioxythiophene) and κ‐Carrageenan Biohydrogel

3D‐Poly(3,4‐ethylenedioxythiophene) (PEDOT) electrodes are prepared using the multi‐step template‐assisted approach. Specifically, poly(lactic acid) nano‐ and microfibers collected on a previously polymerized PEDOT film are used as templates for PEDOT nano‐ and microtubes, respectively. Morphological analysis of the samples indicates that 3D‐PEDOT electrodes obtained using a low density of templates, in which nano‐ and microtubes are clearly identified, exhibit higher porosity, and specific surface than conventional 2D‐PEDOT electrodes. However, a pronounced leveling effect is observed when the density of templates is high. Thus, electrodes with microtubes still present a 3D‐morphology but much less marked than those prepared using a low density of PLA microfibers, whereas the morphology of those with nanotubes is practically identical to that of films. Electrochemical studies prove that solid supercapacitors prepared using 3D‐PEDOT electrodes and κ‐carrageenan biohydrogel as electrolytic medium, exhibit higher ability to exchange charge reversibly and to storage charge than the analogues prepared with 2D‐electrodes. Furthermore, solid devices prepared using 3D‐electrodes and κ‐carrageenan biohydrogel exhibit very similar specific capacitances that those obtained using the same electrodes and a liquid electrolyte (i.e., acetonitrile solution with 0.1 M LiClO₄). These results prove that the success of 3D‐PEDOT electrodes is independent of the electrolytic medium.

     

High‐Throughput Continuous Production of Shear‐Exfoliated 2D Layered Materials using Compressible Flows

2D nanomaterials are finding numerous applications in next‐generation electronics, consumer goods, energy generation and storage, and healthcare. The rapid rise of utility and applications for 2D nanomaterials necessitates developing means for their mass production. This study details a new compressible flow exfoliation method for producing 2D nanomaterials using a multiphase flow of 2D layered materials suspended in a high‐pressure gas undergoing expansion. The expanded gas–solid mixture is sprayed in a suitable solvent, where a significant portion (up to 10% yield) of the initial hexagonal boron nitride material is found to be exfoliated with a mean thickness of 4.2 nm. The exfoliation is attributed to the high shear rates ( > 10⁵ s^?1) generated by supersonic flow of compressible gases inside narrow orifices and converging‐diverging channels. This method has significant advantages over current 2D material exfoliation methods, such as chemical intercalation and exfoliation, as well as liquid phase shear exfoliation, with the most obvious benefit being the fast, continuous nature of the process. Other advantages include environmentally friendly processing, reduced occurrence of defects, and the versatility to be applied to any 2D layered material using any gaseous medium. Scaling this process to industrial production has a strong possibility of reducing the cost of creating 2D nanomaterials.     

3D‐Printed Biomimetic Super‐Hydrophobic Structure for Microdroplet Manipulation and Oil/Water Separation

Biomimetic functional surfaces are attracting increasing attention for various technological applications, especially the superhydrophobic surfaces inspired by plant leaves. However, the replication of the complex hierarchical microstructures is limited by the traditional fabrication techniques. In this paper, superhydrophobic micro‐scale artificial hairs with eggbeater heads inspired by Salvinia molesta leaf was fabricated by the Immersed surface accumulation three dimensional (3D) printing process. Multi‐walled carbon nanotubes were added to the photocurable resins to enhance the surface roughness and mechanical strength of the microstructures. The 3D printed eggbeater surface reveals interesting properties in terms of superhydrophobilicity and petal effect. The results show that a hydrophilic material can macroscopically behave as hydrophobic if a surface has proper microstructured features. The controllable adhesive force (from 23 μN to 55 μN) can be easily tuned with different number of eggbeater arms for potential applications such as micro hand for droplet manipulation. Furthermore, a new energy‐efficient oil/water separation solution based on our biomimetic structures was demonstrated. The results show that the 3D‐printed eggbeater structure could have numerous applications, including water droplet manipulation, 3D cell culture, micro reactor, oil spill clean‐up, and oil/water separation.     

Biomaterial‐Based “Structured Opals” with Programmable Combination of Diffractive Optical Elements and Photonic Bandgap Effects

Naturally occurring iridescent systems produce brilliant color displays through multiscale, hierarchical assembly of structures that combine reflective, diffractive, diffusive, or absorbing domains. The fabrication of biopolymer‐based, hierarchical 3D photonic crystals through the use of a topographical templating strategy that allows combined optical effects derived from the interplay of predesigned 2D and 3D geometries is reported here. This biomaterials‐based approach generates 2D diffractive optics composed of 3D nanophotonic lattices that allow simultaneous control over the reflection (through the 3D photonic bandgap) and the transmission (through 2D diffractive structuring) of light with the additional utility of being constituted by a biocompatible, implantable, edible commodity textile material. The use of biopolymers allows additional degrees of freedom in photonic bandgap design through directed protein conformation modulation. Demonstrator structures are presented to illustrate the lattice multifunctionality, including tunable diffractive properties, increased angle of view of photonic crystals, color‐mixing, and sensing applications.     

Folding at the Microscale: Enabling Multifunctional 3D Origami‐Architected Metamaterials

Mechanical metamaterials inspired by the Japanese art of paper folding have gained considerable attention because of their potential to yield deployable and highly tunable assemblies. The inherent foldability of origami structures enlarges the material design space with remarkable properties such as auxeticity and high deformation recoverability and deployability, the latter being key in applications where spatial constraints are pivotal. This work integrates the results of the design, 3D direct laser writing fabrication, and in situ scanning electron microscopic mechanical characterization of microscale origami metamaterials, based on the multimodal assembly of Miura‐Ori tubes. The origami‐architected metamaterials, achieved by means of microfabrication, display remarkable mechanical properties: stiffness and Poisson’s ratio tunable anisotropy, large degree of shape recoverability, multistability, and even reversible auxeticity whereby the metamaterial switches Poisson’s ratio sign during deformation. The findings here reported underscore the scalable and multifunctional nature of origami designs, and pave the way toward harnessing the power of origami engineering at small scales.     

Scale‐related topology optimization of cellular materials and structures

The integrated optimization of lightweight cellular materials and structures are discussed in this paper. By analysing the basic features of such a two‐scale problem, it is shown that the optimal solution strongly depends upon the scale effect modelling of the periodic microstructure of material unit cell (MUC), i.e. the so‐called representative volume element (RVE). However, with the asymptotic homogenization method used widely in actual topology optimization procedure, effective material properties predicted can give rise to limit values depending upon only volume fractions of solid phases, properties and spatial distribution of constituents in the microstructure regardless of scale effect. From this consideration, we propose the design element (DE) concept being able to deal with conventional designs of materials and structures in a unified way. By changing the scale and aspect ratio of the DE, scale‐related effects of materials and structures are well revealed and distinguished in the final results of optimal design patterns. To illustrate the proposed approach, numerical design problems of 2D layered structures with cellular core are investigated. Copyright © 2006 John Wiley & Sons, Ltd.     

Ultra‐Light and Scalable Composite Lattice Materials

Architected lattice materials are some of the stiffest and strongest materials at ultra‐light density (<10 mg cm^?3), but scalable manufacturing with high‐performance constituent materials remains a challenge that limits their widespread adoption in load‐bearing applications. We show mesoscale, ultra‐light (5.8 mg cm^?3) fiber‐reinforced polymer composite lattice structures that are reversibly assembled from building blocks manufactured with a best‐practice high‐precision, high‐repeatability, and high‐throughput process: injection molding. Chopped glass fiber‐reinforced polymer (polyetherimide) lattice materials produced with this method display absolute stiffness (8.41 MPa) and strength (19 kPa) typically associated with metallic hollow strut microlattices at similar mass density. Additional benefits such as strain recovery, discrete damage repair with recovery of original stiffness and strength, and ease of modeling are demonstrated.

     

Super‐Elastic Magnetic Structural Color Hydrogels

Structural color hydrogels are promising candidates as scaffold materials for tissue engineering and for matrix cell culture and manipulation, while their super‐elastic features are still lacking due to the irreconcilable interfere of the precursor and the self‐assembly unit. This hinders many of their practical biomedical applications where elasticity is required. Herein, hydrophilic and size‐controllable Fe₃O₄@poly(4‐styrenesulfonic acid‐co‐maleic acid) (PSSMA)@SiO₂ magnetic response photonic crystals are fabricated as the assembly units of the structural color hydrogels by orderly packing of core–shell colloidal nanocrystal clusters via a two‐step facile synthesis approach. These units are capable of responding instantaneously to an external magnetic field with resistance to interference of ions, thus, by integrating super‐elastic hydrogels, super‐elastic magnetic structural color hydrogels can be achieved. The structural color arises from the dynamic ordering of the magnetic nanoparticles through the contactless control of external magnetic field, allowing regional polymerization of hydrogels via changing orientation and strength of external magnetic field. These regionally polymerized super‐elastic magnetic structural color hydrogels can work as anti‐counterfeiting labels with super‐elastic identification, which may be widely used in the future.     

Ultrahigh‐Water‐Content,Superelastic, and Shape‐Memory Nanofiber‐Assembled Hydrogels Exhibiting Pressure‐Responsive Conductivity

High‐water‐content hydrogels that are both mechanically robust and conductive could have wide applications in fields ranging from bioengineering and electronic devices to medicine; however, creating such materials has proven to be extremely challenging. This study presents a scalable methodology to prepare superelastic, cellular‐structured nanofibrous hydrogels (NFHs) by combining alginate and flexible SiO₂ nanofibers. This approach causes naturally abundant and sustainable alginate to assemble into 3D elastic bulk NFHs with tunable water content and desirable shapes on a large scale. The resultant NFHs exhibit the integrated properties of ultrahigh water content (99.8 wt%), complete recovery from 80% strain, zero Poisson's ratio, shape‐memory behavior, injectability, and elastic‐responsive conductivity, which can detect dynamic pressure in a wide range (>50 Pa) with robust sensitivity (0.24 kPa^?1) and durability (100 cycles). The fabrication of such fascinating materials may provide new insights into the design and development of multifunctional hydrogels for various applications.