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Shape memory polymers (SMPs) have gained a presence in additive manufacturing due to their role in 4D printing. They can be printed either in multi-materials for multi-stage shape recovery or in a single material for single-stage shape recovery. When printed in multi-materials, material or material-based design is used as a controlling factor for multi-stage shape recovery. However, when printed in a single material, it is difficult to design multi-stage shape recovery due to the lack of a controlling factor. In this research, we explore the use of geometric thickness as a controlling factor to design smart structures possessing multi-stage shape recovery using a single SMP. L-shaped hinges with a thickness ranging from 0.3–2 mm were designed and printed in four different SMPs. The effect of thickness on SMP’s response time was examined via both experiment and finite element analysis using Ansys transient thermal simulation. A method was developed to accurately measure the response time in millisecond resolution. Temperature distribution and heat transfer in specimens during thermal activation were also simulated and discussed. Finally, a spiral square and an artificial flower consisting of a single SMP were designed and printed with appropriate thickness variation for the demonstration of a controlled multi-stage shape recovery. Experimental results indicated that smart structures printed using single material with controlled thickness parameters are able to achieve controlled shape recovery characteristics similar to those printed with multiple materials and uniform geometric thickness. Hence, the geometric parameter can be used to increase the degree of freedom in designing future smart structures possessing complex shape recovery characteristics.

In 4D printing research, different types of complex structure folding and unfolding have been investigated. However, research on cross-folding of origami structures (defined as a folding structure with at least two overlapping folds) has not been reported. This research focuses on the investigation of cross-folding structures using multi-material components along different axes and different horizontal hinge thickness with single homogeneous material. Tensile tests were conducted to determine the impact of multi-material components and horizontal hinge thickness. In the case of multi-material structures, the hybrid material composition has a significant impact on the overall maximum strain and Young’s modulus properties. In the case of single material structures, the shape recovery speed is inversely proportional to the horizontal hinge thickness, while the flexural or bending strength is proportional to the horizontal hinge thickness. A hinge with a thickness of 0.5 mm could be folded three times prior to fracture whilst a hinge with a thickness of 0.3 mm could be folded only once prior to fracture. A hinge with a thickness of 0.1 mm could not even be folded without cracking. The introduction of a physical hole in the center of the folding/unfolding line provided stress relief and prevented fracture. A complex flower petal shape was used to successfully demonstrate the implementation of overlapping and non-overlapping folding lines using both single material segments and multi-material segments. Design guidelines for establishing cross-folding structures using multi-material components along different axes and different horizontal hinge thicknesses with single or homogeneous material were established. These guidelines can be used to design and implement complex origami structures with overlapping and non-overlapping folding lines. Combined overlapping folding structures could be implemented and allocating specific hole locations in the overall designs could be further explored. In addition, creating a more precise prediction by investigating sets of in between hinge thicknesses and comparing the folding times before fracture, will be the subject of future work.

A new generation of soft functional materials and actuator designs has ushered the development of highly advanced soft grippers as adaptive alternatives to traditional rigid end-effectors for grasping and manipulation applications. While being advantageous over their rigid counterparts, soft gripper capabilities such as contact effort are mostly a consequence of the gripper workspace, which in turn is largely constrained by the gripper design. Moreover, soft grippers designed for highly specific grasping tasks such as scooping grains or wide payloads are usually limited in grasping other payload types or in their manipulation versatility. This article describes a reconfigurable workspace soft (RWS) gripper that exploits compliant structures and pneumatic actuators to reconfigure its workspace to suit a wide range of grasping tasks. To achieve desired kinematics, finite element analysis (FEA) studies are conducted to dictate actuator design and materials used. Various grasping modes and their reconfiguration of the gripper workspace are presented and characterized, including the gripper's capability to reliably scoop granular items with radii as small as 1.5 mm, precisely pick items as thin as 300 μm from flat surfaces, as well as grasp large convex, nonconvex, and deformable items as heavy as 1.4 kg. The RWS gripper can modify and increase its grasping workspace volume by 397%, enabling the widest range of grasping capabilities to date achieved by a single soft gripper.

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