4D Printing of Recyclable Lightweight Architectures Using High Recovery Stress Shape Memory Polymer

High-performance lightweight architectures, such as metallic microlattices with excellent mechanical properties have been 3D printed, but they do not possess shape memory effect (SME), limiting their usages for advanced engineering structures, such as serving as a core in multifunctional lightweight sandwich structures. 3D printable self-healing shape memory polymer (SMP) microlattices could be a solution. However, existing 3D printable thermoset SMPs are limited to either low strength, poor stress memory, or non-recyclability. To address this issue, a new thermoset polymer, integrated with high strength, high recovery stress, perfect shape recovery, good recyclability, and 3D printability using direct light printing, has been developed in this study. Lightweight microlattices with various unit cells and length scales were printed and tested. The results show that the cubic microlattice has mechanical strength comparable to or even greater than that of metallic microlattices, good SME, decent recovery stress, and recyclability, making it the first multifunctional lightweight architecture (MLA) for potential multifunctional lightweight load carrying structural applications.