Direct 4D printing by using multimaterial additive manufacturing

4D Printing is a term that was recently developed to describe the integration of 3D printing and active materials technologies to realize printed components that can be switched between multiple configurations via an environmental stimulus, e.g., heat, or moisture. To date, hydrogels and shape memory polymers (SMPs) are the two main active polymers used in 4D printing. SMPs have been used in 4D printing with both commercial and research printing technologies based on photopolymer inkjetting and projection micro stereolithography. However, 4D printing with SMPs generally requires a series of steps, including synthesis/processing by 3D printing, heating, mechanical loading, cooling, and removing the load. Thermomechanical programming often requires special jigs and fixtures to apply mechanical loads and a well-controlled thermal environment. In this paper, we propose a new direct 4D printing approach with shape memory polymers (SMPs) where we integrate the programming steps into the 3D printing process. As a result, the 3D printed component can directly change its shape rapidly upon heating. This second shape largely remains stable in later variations in temperature, such as cooling back to room temperature. Furthermore, a third shape can be programmed by thermomechanical loading, and the material will always recover back to the permanent (second) stable shape upon heating. We also created a theoretical model that incorporates the key elements, including the material behaviors during the processing/programming and deployment phases and 3D printing processing parameters. The model was then used to guide to design complicated shape changes.