<p>Achieving multi-way actuation in single-material four-dimensional (4D)-printed actuators remains challenging due to limited control over sequential behavior. Prior efforts in non-manual (parameter-encoded) shape programming via fused deposition modeling (FDM) have resulted in only one-way actuation. This study presents, for the first time, multi-way actuation in single-material polylactic acid actuators using FDM-based non-manual programming and instant heat activation. A comprehensive response surface methodology design with 46 runs was implemented to evaluate the effects of printing and geometric parameters, including the active-to-passive layers ratio, printing temperature, infill density, raster angle, printing speed, layer height, and actuator height. The results demonstrate up to four distinct actuations, with maximum ranges of 214.63°, 102.21°, 35.93°, and 110.18° for actuators with one, two, three, and four actuations, respectively. The active-to-passive layers ratio emerged as the most significant factor. While 0% and 25% ratios occasionally yielded multiple actuations, 100% active layers consistently generated multi-way actuation. The number of actuations is primarily driven by the interaction between the active-to-passive ratio and printing temperature, whereas the final bending angle is most influenced by layer height and its interaction with printing speed. The approach’s versatility is showcased through a soft gripper and a starfish-inspired structure, demonstrating sequential, task-oriented transformations and biomimetic motion sequences. These findings broaden the functional scope of 4D printing, offering new potential for programming complex actuation sequences in single-material structures for soft robotics and self-deploying devices.</p>

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Non-manual multi-way shape programming of single-material 4D-printed actuators under instant heat activation

  • Kai Feng Bong,
  • Kim Yeow Tshai,
  • Khameel B. Mustapha,
  • Marwan Nafea

摘要

Achieving multi-way actuation in single-material four-dimensional (4D)-printed actuators remains challenging due to limited control over sequential behavior. Prior efforts in non-manual (parameter-encoded) shape programming via fused deposition modeling (FDM) have resulted in only one-way actuation. This study presents, for the first time, multi-way actuation in single-material polylactic acid actuators using FDM-based non-manual programming and instant heat activation. A comprehensive response surface methodology design with 46 runs was implemented to evaluate the effects of printing and geometric parameters, including the active-to-passive layers ratio, printing temperature, infill density, raster angle, printing speed, layer height, and actuator height. The results demonstrate up to four distinct actuations, with maximum ranges of 214.63°, 102.21°, 35.93°, and 110.18° for actuators with one, two, three, and four actuations, respectively. The active-to-passive layers ratio emerged as the most significant factor. While 0% and 25% ratios occasionally yielded multiple actuations, 100% active layers consistently generated multi-way actuation. The number of actuations is primarily driven by the interaction between the active-to-passive ratio and printing temperature, whereas the final bending angle is most influenced by layer height and its interaction with printing speed. The approach’s versatility is showcased through a soft gripper and a starfish-inspired structure, demonstrating sequential, task-oriented transformations and biomimetic motion sequences. These findings broaden the functional scope of 4D printing, offering new potential for programming complex actuation sequences in single-material structures for soft robotics and self-deploying devices.