Multi-stage responsive 4D printed smart structure through varying geometric thickness of shape memory polymer

Shape memory polymers (SMPs) have gained a presence in additive manufacturing due to their role in 4D printing. They can be printed either in multi-materials for multi-stage shape recovery or in a single material for single-stage shape recovery. When printed in multi-materials, material or material-based design is used as a controlling factor for multi-stage shape recovery. However, when printed in a single material, it is difficult to design multi-stage shape recovery due to the lack of a controlling factor. In this research, we explore the use of geometric thickness as a controlling factor to design smart structures possessing multi-stage shape recovery using a single SMP. L-shaped hinges with a thickness ranging from 0.3-2 mm were designed and printed in four different SMPs. The effect of thickness on SMP's response time was examined via both experiment and finite element analysis using Ansys transient thermal simulation. A method was developed to accurately measure the response time in millisecond resolution. Temperature distribution and heat transfer in specimens during thermal activation were also simulated and discussed. Finally, a spiral square and an artificial flower consisting of a single SMP were designed and printed with appropriate thickness variation for the demonstration of a controlled multi-stage shape recovery. Experimental results indicated that smart structures printed using single material with controlled thickness parameters are able to achieve controlled shape recovery characteristics similar to those printed with multiple materials and uniform geometric thickness. Hence, the geometric parameter can be used to increase the degree of freedom in designing future smart structures possessing complex shape recovery characteristics.