A Review of 4D Printing Technology and Future Trends: September 2018
A Review of 4D Printing Technology and Future Trends: September 2018
A Review of 4D Printing Technology and Future Trends: September 2018
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Nkosilathi Nkomo
National University of Science and Technology, Bulawayo
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Department of Fibre and Polymer Materials Engineering, National University of Science and Technology, P.O Box AC
939, Ascot, Bulawayo, Zimbabwe
Abstract
3D printing has gained immerse popularity since its introduction and finds application in areas such as prototyping,
engineering and medical field largely due to its advantage of being able to quickly and inexpensively transform
computer 3D files into physical objects. 3D printing has the capability of printing geometrically fixed structures which
are static and not suited for multifunctional use. 4D printing was developed when researchers combined smart
materials and 3D printing. 4D printing uses the fourth dimension of time to create shape morphing 3D printed objects
when exposed to stimuli after using conversional 3D printing technology such as fused deposition modelling (FDM)
and selective laser sintering (SLS). 4D printed materials respond to stimuli such as pH, humidity and temperature to
activate the 3D printed components without the use of electronics or motors. There has been a lot of research done
on smart materials capable of sensing external stimuli and responding to it. In this paper 4D printing is reviewed
according to activation stimuli and the uses of this technology are explored. 4D printing has the prospective to
simplify the design and manufacturing of different products and has the vast potential to create parts that self-
actuate to react to their environment. Applications of 4D printing are in areas such as biomedical devices, security,
fabrication of patterned surfaces for optics and structures with multi directional properties.
1. Introduction
3D printing is a well-known additive manufacturing technology that allows researchers, manufacturers, and
private users to fabricate custom 3D objects using computer software such as computer aided design (CAD) [1]. Due to
the highly customizable nature of 3D printing it has found use in a number of fields such as fabrication of fashion
jewellery [2], polymer printed textiles [3], supercapacitors, mechanical metamaterials and sensors, bio-hybrid robotics
[4] and tissue scaffolds. Several additive manufacturing technologies have been developed for processing pure polymers
and polymer nanocomposites [5] such as stereolithographic (SL), digital light projection (DLP), direct inkjet and
extrusion-based printing as well as liquid deposition modelling (LDM). They enable less expensive free form fabrication
of complex, customized and multi-scale 3D geometries for application in a vast range of fields, from tissue engineering
scaffolds [6]to strain and skin like sensors.
The introduction of smart materials which are responsive to external stimuli has found use in shape recovery, sensors
and actuators [7]. 3D printing technology has been used to make static structures from digital data in 3D coordinates,
4D printing adds the concept of change in the printed configuration over time, dependent on environmental stimuli.
Shape morphing systems can be found in many areas including smart textiles [8], autonomous robotics, biomedical
devices, drug delivery and tissue engineering. The natural analogues of such systems are exemplified by nastic plant
motions, where a variety of organs such as tendrils, bracts, leaves and flowers respond to environmental stimuli such
as humidity, light or touch by carrying internal turgor, which leads to dynamic conformations governed by tissue
composition and microstructural anisotropy of cell walls. 4D printing is inspired by these botanical systems. 4D printing
has the economic, environmental, geopolitical, and strategic implications of additive manufacturing while providing
new and unprecedented capabilities in transforming digital information of the virtual world into physical objects of the
material world. The fourth dimension in 4D printing refers to the ability for material objects to change form and function
after they are produced, thereby intelligent materials become a key issue in this technology. This paper reviews the
development and capabilities of the 4D printing technology and investigates its applications and suggests its future
impact.
The materials shown in table 1.0 can be exploited and used in 3d printing as smart materials to yield objects that can
morph over time giving 4D printed objects.
3.0 Motivations
4D printing opens new fields for application in which a structure can be activated for self-assembly,
reconfiguration, and replication through environmental free energies. There are several advantages brought about by
this technology such as significant volume reduction for storage, and transformations that can be achieved with a flat
pack 4D printed structures. Another example is instead of directly creating complex structures using 3D printing, simple
components from smart materials can be 3D printed first and then self-assembled to reach the final complex shape
[19]. The potential applications of 4D printing can be broadly classified into three main categories which include self-
assembly, multi-functionality and self-repair. The ability of 4D printed structures to self-assemble and self-repair opens
new opportunities of application, such as the fabrication of minimally invasive surgery devices that can be placed in
human body through a little surgical incision and then assembled at the required position for surgical operations [20].
3.1 Self assembly
A future application can be on a large scale and in a harsh environment. Individual parts can be printed with
small 3D printers and then self-assembled into larger structures, such as space antennae and satellites [21]. This
capability can be exploited for the creation of transportation systems for complex parts to the International space
station. Further applications include self-assembling buildings, this is especially useful in war zones or in outer space
where the elements can come together to give a fully formed building with minimum work force [22]. There is also the
added advantage that some limitations in construction can be eliminated by the use of 4D printing. Rigid materials can
be can be 3D printed along with smart materials to create specific areas of a part that act as joints and hinges for
bending. Raviv et al argue that construction must be made smarter and solve problems of wasting large amounts of
energy, materials, money and time for building. These issues can be solved using design programs and software to
embed information into the materials that makes the material and construction more accurate [23]. Self-assembly may
not be efficient for every purpose, which implies different sectors and applications must be identified that benefit most
from self-assembly [24].
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Fig 1: Transformation of a structure from 1D to 3D with water absorption materials printed by Massachusetts Institute
of Technology [31]
Ge et al developed a model that took into account different design options to fabricate composite hinge structures.
Their research focused on characterizing hinge behaviour with respect to hinge bending angle as a function of
geometrical parameters, thermomechanical loading parameters and programming parameters [32]. Ge et al reported
a paradigm of 4D printing to create printed active composites directly printing shape memory polymer fibres in an
elastomeric matrix to enable shape change of the composite. SMPs could recover their original shape and size when
heated above their glass transition temperatures. They experimentally proved this by producing the folding box shown
in Fig 2 and also 4D printed a pyramid and an origami airplane [33]. Tibbits and his colleagues experimentally
demonstrated how 4D printed objects could perform self-assemblies. A strip of hydrophilic polymer that expands by
150% when it encounters water was printed over a corresponding strip of rigid material, which causes the primitive to
fold.
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Fig 3: Photo responsive materials based on carbon black and polyurethane extruded from a FDM printer to form a 3D
printed object with photo responsive shape memory effect. The shape recovery of cubic frame under 87mW/cm 2 of
light source [34]
Figure 4 shows the printing of a 3D printed structure with multiple SMPs. Multi-material grippers that have the potential
to function as micro grippers [35] that can grab objects or drug delivery devices [36], [37] and the release the objects.
Fig 4 shows different sized multi-material grippers with different designs. Fig 4b shows the 3D printed gripper as printed
in its open state and functionality if grabbing objects is triggered upon heating. Fig 4c shows a time lapse image of the
gripper grabbing an object. By controlling the dynamic properties of the different SMPs it is possible to design the time
dependent sequential shape recovery [38].
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Fig 5: Shape memory based electrical device a) conductive ink printed on the shape memory construct b) fabricated
temperature sensor in its off state (top) and on state (bottom) [40]
They used a heated bath for the photopolymer where a projection Sintering Laser (SL) process was used to create the
structures and inkjet printing was used to print the conductive inks. Basing on this proof of concept, 4D printing
technology can be used in the fabrication of soft robotics, medical devices, sensors, and wearable electronics [41].
4.1 Light activated SMPS
Light is an effective activation technique for SMPs due to its abundant nature, it being wireless and controllable.
Light activated SMPs have been used in areas of self-assembly structures, complex folding methods, and transformative
surface deformations.
5.0 Composites in 4D printing
Ge et al used a multi-material 3D printer to print an active composite material [15]. The printed active
composite (PAC) consisted of a glassy polymer fibre embedded in an elastomeric resin. The glass fibres exhibited a shape
memory effect with a shape fixity ratio of approximately 80% whereas the elastomeric resin was not capable of shape
shifting and had a shape fixing ratio of 0. This bilayer laminate comprising a pure elastomer lamina and a PAC lamina
with a prescribed fibre structure which includes the shape, size and orientation was printed, heated, stretched, cooled
and realised. Upon release of the deformation stress, the laminate turned into a complex temporary shape due to the
mismatch in the shape fixity ratio between the elastomer lamina and the shape memorizing PAC lamina. Depending on
the fibre properties complex 3D configurations can be produced including bent, coiled, twisted, and folded shapes. This
PAC laminate can be integrated with other structures or functional components to create active devices. For an example
the PAC laminate could be used to enable active origami as a means to creating 3D structures.
6.0 Future of 3D printing and trends
4D printing technologies may require multi-material and multiple nozzles which is currently a limitation with
3D printing technology. Exploring different types of printing smart materials will give 4D printed parts that are lighter,
stronger, react to different types of stimuli and give different property changes. 4D printing can find use in textiles and
camouflage technology by altering not just the shape but also the colour and texture of the surface of the text. Textiles
could react to different stimuli from the weather elements and morph allowing better ventilation or insulation to the
wearer increasing the comfort [42].
Self-healing polymers have the possibility of increasing the life span of the 3D printed parts as any damage that occurs
on the material can be self-repaired [43].
7.0 Conclusion
Additive manufacturing is still a growing industry still in its infancy. New materials, printing methods, software’s
and machines are constantly being developed and improved. Recently 4D printing has been gaining attention because
4D printed structures have the capability to change in form or function over time in response to stimuli such as pressure,
temperature, wind, water, and light. 4D printing technology uses smart materials, designs to forecast change processes
and smart printing can be applied to various fields from simple shape changes to bio printing for organisms. Using multi-
material 3D printing and smart materials, 4D printing has been developed. This new technology provides a feasible
method to fabricate a compact deployable structure. Smart materials are the cornerstone for 4D printing.
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Smart materials can allow the self-assembly of structures which are 3D printed and when exposed to
external stimuli morph into the desired shape saving on time and costs of fabrication
Use of smart materials also allows self-healing polymers. The use of self-healing hydrogels can allow
pipes to self-repair if they develop a leak.
Smart materials can serve the function of sensing and actuation directly into a material rendering
external electromechanically systems unnecessary. This decreases the number of parts in a structure
which require electronics and electro mechanic actuators.
4D printing has various potential end uses not only utilising the shape change property but other properties such as
the colour and texture of the polymer. This could be useful in smart textiles which would react to different stimuli
from the weather elements and morph allowing better ventilation or insulation to the wearer by change in colour and
texture of the fabric increasing comfort and functionality.
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