These slides use concepts from my (Jeff Funk) course entitled analyzing hi-tech opportunities to analyze whether and how 4D Printing is becoming economically feasible. 4D printing is defined as 3D printing of smart materials whose shape and properties change with the addition of heat or electrical energy. The presentation describes a number of these smart materials, the specific stimuli that lead to changes in shaper or properties, and application examples. Examples include self-healing polymers for smart phones, other materials for space structures, alloys for heat engines, and dielectric elastomers for artificial muscles.

1. 4D PRINTING WITH
SMART MATERIALS
MT5009 – 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

2. Outline
• What is 4D Printing?
• Important Technology Aspects of 4D Printing
• SMART Materials’ Properties and Development
• Future Trend Analysis
• Conclusion
2

3. Outline
• What is 4D Printing?
• Important Technology Aspects of 4D Printing
• SMART Materials’ Properties and Development
• Future Trend Analysis
• Conclusion
3

4. 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

5. Another Dimension?
"We're proposing that the fourth dimension is Time and that
over time static objects will transform and adapt“
5
"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

6. Introduction Video to 4D Printing
6
• https://www.youtube.com/watch?v=GIEhi_sAkU8

7. Overview of 4D Object
7
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

8. Outline
• What is 4D Printing?
• Important Technology Aspects of 4D Printing
• SMART Materials’ Properties and Development
• Future Trend Analysis
• Conclusion
8

9. 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

10. 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.
10
Source: http://www.autodeskresearch.com/projects/cyborg

11. Software Cost Reduction with Open
Source Technology
11
Top reasons for
adopting Open
Source
1. Quality
2. Lower total cost of
ownership
3. Ease of deployment
4. 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

12. 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
materials
Source: 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/

13. Multi-Smart Materials Printer
• Complete compatibility with current 3D printers which can
print multi-materials.
13
0
5
10
15
2013 2014 2015 2016 2017 2018 2019
$Billion
Year
Market Value Growth
3D printers
Services and materials

14. List of Smart Materials (I)
14
Material Input/Stimulus Output/Response Application
Polymeric gal pH change
Swelling or
contracting
Artificial muscle
Electro-rheological
fluid
Electric signal Viscosity change
Torsional steering
system damper
Pyroelectric
material
Temperature Electric signal
Personnel sensor
(open super-
market door)
Polymer (eg thin
film cellulose),
ceramic
Humidity change
Capacity/
resistance change
Humidity sensors
Self-Healing
Materials
Force Force
Smartphone
chassis
Smart metal alloys Temperature Shape Motor actuators
Dielectric
Elastomers
Voltage Strain Robotics

15. 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 ZrO2
Change in Oxygen
Partial Pressure
Electric Signal Oxygen sensor
Piezoelectric
material
Deformation/
Strain electric
signal
Electric Signal
Active noise
control devices,
pressure and
vibration
sensitizing
15

16. 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

17. Roadmap of Smart Materials
• R&D activity on transformative materials is still in early
phase.
17

18. Outline
• What is 4D Printing?
• Important Technology Aspects of 4D Printing
• SMART Materials’ Properties and Development
• Future Trend Analysis
• Conclusion
18

19. 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

20. 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

21. 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

22. 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

23. 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

24. 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.
24

25. Properties of Self-Healing Polymers
• Development of Self healing polymers
25
Polymer
type
Healing
approach
Chemistry/
method
Best healing
efficiency (%)
Healing
conditions
Thermoplastic
Intrinsic
Reversible bond
formation
75 % < 1 min at -30°C
Capsule
based
Interdiffusion (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
Vascular
Thermally reversible
crosslinks
60%
30 min at 115°C
6 h at 40°C
Vascular
Thermoplastic
additives
45% 1h at 160°C
Thermoset
composites
Capsule
based
Microencapsulation
approach
60%
48h at 80°C
24h at Ambient
Vascular
Thermoplastic
additives
80% 1.5h at 80°C

26. 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.

27. 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. 28
How do Smart Metal Alloys Work?

29. 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. 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

31. 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

32. 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

33. Dielectric Elastomer
• Used in conformal speakers.
33

34. 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)
34
Acrylic elastomers showing 300% linear strain
Source: Extending Applications of Dielectric Elastomer Artificial Muscles to Wireless Communication Systems by Seiki Chiba
and Mikio Waki

35. 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

36. 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

37. Level of Improvement - Performance
37
Source: Advances in Dielectric Elastomers for Actuators and Artificial Muscles by Paul Brochu, Qibing Pei

38. 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 by
Ron Pelrine, Roy Kornbluh, Qibing Pei, Scott Stanford, Seajin Oh, Joe Eckerle

39. Further Applications of Smart Materials
39
Healthcare
Robotic
Automotive
Industry
Consumer
Industrial
Manufacturing
Military
Aerospace

40. Healthcare
40
Nano Scale Objects in Biomedical Engineering. E.g Cardiac tube/Stent
http://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 applied
it 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 Alloys
KPI – Precision control
Smart Materials – Dielectric Elastomer / Piezoelectric
KPI – Reliability

41. Consumer
41
Transformative Shoes
http://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 materials
KPI – Response control

42. 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 Alloys
KPI – Reliability, sensitivity

43. 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 Materials
KPI – Integration

44. Outline
• What is 4D Printing?
• Important Technology Aspects of 4D Printing
• SMART Materials’ Properties and Development
• Future Trend Analysis
• Conclusion
44

45. 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:

46. Patent Landscape
46
Patent Mining
Database
Thomson Innovation
Search Keywords
 4D printing
 4D printer
 Self-healing materials
 Self-healing polymers
 Self-healing coatings
Search Timeline
1 January 2004 to 23 June
2013
*
*
*
*

47. 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
Sectors
Expected Year of Impact
2015 2016 2017 2018 2019 2020 2021 2022 2023 2024
Healthcare
Military
Infrastructure
Automobile
Packaging
Aerospace
Manufacturing

48. Breadth of Application
48

49. Impact of Megatrends
49

50. Size of Innovation Ecosystem
50
Stakeholder Influence Assessment

51. Size of Innovation Ecosystem
51
Impact of Key Innovations Landscape
Source: Frost & Sullivan, June 2014:

52. Global Footprint
52
Source: Frost & Sullivan, June 2014:
Global Development and Adoption Scenario
Region Remarks Intensity of
Adoption
North
America
 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
Asia
Pacific
 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

53. Global Footprint
53
Source: Frost & Sullivan, June 2014:
4D Printing-Adoption Scenario

54. Outline
• What is 4D Printing?
• Important Technology Aspects of 4D Printing
• SMART Materials’ Properties and Development
• Future Trend Analysis
• Conclusion
54

55. 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.
55

56. 56
Thank You
Any Question(s)?