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4D-Printed Tool for Compressing a Shape Memory Polyurethane Foam during Programming.

Dilip Chalissery¹, Thorsten Pretsch¹

¹Fraunhofer Institute for Applied Polymer Research IAP, Geiselbergstraße 69, 14476 Potsdam, Germany.

|May 25, 2024

Summary

This summary is machine-generated.

Researchers used four-dimensional (4D) printing to create a thermoresponsive tool that precisely compresses shape memory polymer (SMP) foams. This novel approach enables controlled deformation of cylindrical SMPs, overcoming previous limitations in programming these advanced materials.

Keywords:

4D printing polyurethane programmable material programming tool shape memory polymer shape memory polymer foam

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Area of Science:

Materials Science
Polymer Science
Additive Manufacturing

Background:

Controlled deformation of shape memory polymers (SMPs), especially cylindrical ones, presents significant challenges.
Existing force application methods lack precision for homogeneous compression of cylinder-like SMP samples.

Purpose of the Study:

To develop a material-based solution for controlled deformation of SMPs using four-dimensional (4D) printing.
To enable homogeneous compression of cylindrical SMP foam samples through a novel tooling approach.

Main Methods:

Utilized fused filament fabrication (FFF) to 4D-print a thermoresponsive tool from polyether urethane (PEU).
Employed differential scanning calorimetry (DSC) to determine the glass transition temperature (Tg) of PEU and melting behavior of polyester urethane urea (PEUU).
Integrated a laser-cut PEUU foam cylinder within the 4D-printed tool for compression and shape fixing via thermal cycling.

Main Results:

The 4D-printed PEU tool successfully compressed the PEUU foam sample upon heating to 75°C, transferring internal stresses.
The compressed foam shape was fixed upon cooling to -15°C and maintained its programmed shape for 900 days at 23°C.
Reheating to 75°C successfully recovered the original shape of the PEUU foam, demonstrating shape memory recovery.

Conclusions:

4D printing offers a viable material approach to create custom thermoresponsive tools for precise SMP programming.
This technique overcomes limitations in deforming cylindrical SMPs, paving the way for complex shape programming.
Future applications include diverse 4D-printed tool geometries for programming various SMPs and other programmable materials.