Through their anisotropic cellular mesostructure and differential swelling and shrinking properties, hygroscopic plant structures move in response to changes in the environment without consuming metabolic energy. When the movement is choreographed in sequential time steps, either in individual structures or with a coordinated interplay of various structural elements, complex functionalities such as dispersal and protection of seeds are achieved. Inspired by the multi-phase motion in plant structures, this paper presents a method to physically program the timescale and the sequences of shape-change in 4D-printed hygromorphic structures. Using the FDM 3D-printing method, we have developed multi-layered, multi-material functional bilayers that combine highly hygroscopic active layers (printed with hygroscopic bio-composite materials) with hydrophobic restrictive and blocking layers (printed with PLA and TPC materials). The timescale of motion is programmed through the design of the mesostructured layers and 3D-printing process parameters, including thickness (number of printed active layers), porosity (filling ratio of the active layer), and water permeability (filling ratio of the blocking layer). Through a series of experiments, it is shown that the timescale of motion can be extended by increasing the thickness of the active layer, decreasing the porosity of the active layer, or increasing the filling ratio of the hydrophobic restrictive and blocking layers. Similarly, a lower thickness of the active layer and lower filling ratio of all layers result in a faster motion. As a proof of concept, we demonstrate several prototypes that exhibit sequential motion, including an aperture with overlapping elements where each completes its movement sequentially to avoid collision, and a self-locking mechanism where defined areas of the structure are choreographed to achieve a multi-step self-shaping and locking function. The presented method extends the programmability and the functional capabilities of hygromorphic 4D-printing, allowing for novel applications across fields such as robotics, smart actuators, and adaptive architecture.

Damage-repair is particularly important for the maintenance of the water-storing abilities of succulent plants such as cacti. Comparative morphological, anatomical, and biomechanical analyses of self-repair were performed on artificially wounded branches of Opuntia ficus-indica and Cylindropuntia bigelovii. Macroscopic observations, contrast staining, and lignin-proof staining were used to investigate morphological and anatomical responses after wounding at various time intervals. Two-point bending tests were repeatedly performed on the same branches under unwounded, freshly wounded, and healed conditions by using customized 3D-printed clamping jaws. Morphologically, both species showed a rolling-in of the wound edges, but no mucilage discharge. Anatomically, ligno-suberized peridermal layers developed that covered the wound region, and new parenchyma cells formed, especially in O. ficus-indica. In all samples, the wounding effect directly after damage caused a decrease between 18% and 37% in all the tested mechanical parameters, whereas a positive healing effect after 21 days was only found for C. bigelovii. Based on our data, we hypothesize a high selection pressure on the restoration of structural integrity in the wound area, with a focus on the development of efficient water-retaining mechanisms, whereas the concept of “sufficient is good enough” seems to apply for the restoration of the mechanical properties.

(1) Significance of geometry for bio-inspired hygroscopically actuated bilayer structures is well studied and can be used to fine-tune curvatures in many existent material systems. We developed a material design space to find new material combinations that takes into account unequal effective widths of the layers, as commonly used in fused filament fabrication, and deflections under self-weight. (2) For this purpose, we adapted Timoshenko’s model for the curvature of bilayer strips and used an established hygromorphic 4D-printed bilayer system to validate its ability to predict curvatures in various experiments. (3) The combination of curvature evaluation with simple, linear beam deflection calculations leads to an analytical solution space to study influences of Young’s moduli, swelling strains and densities on deflection under self-weight and curvature under hygroscopic swelling. It shows that the choice of the ratio of Young’s moduli can be crucial for achieving a solution that is stable against production errors. (4) Under the assumption of linear material behavior, the presented development of a material design space allows selection or design of a suited material combination for application-specific, bio-inspired bilayer systems with unequal layer widths.

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