Ice floating on water is a great manifestation of negative thermal expansion (NTE) in nature. The limited examples of natural materials possessing NTE have stimulated research on engineered structures. Previous studies on NTE structures were mostly focused on theoretical design with limited experimental demonstration in two-dimensional planar geometries. In this work, aided with multimaterial projection microstereolithography, we experimentally fabricate lightweight multimaterial lattices that exhibit significant negative thermal expansion in three directions and over a temperature range of 170 degrees. Such NTE is induced by the structural interaction of material components with distinct thermal expansion coefficients. The NTE can be tuned over a large range by varying the thermal expansion coefficient difference between constituent beams and geometrical arrangements. Our experimental results match qualitatively with a simple scaling law and quantitatively with computational models.

Multistable shape-reconfigurable architected materials encompassing living hinges and enabling combinations of high strength, high volumetric change, and complex shape-morphing patterns are introduced. Analytical and numerical investigations, validated by experiments, are performed to characterize the mechanical behavior of the proposed materials. The proposed architected materials can be constructed from virtually any base material, at any length scale and dimensionality.

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Early examples of computers were almost exclusively based on mechanical devices. Although electronic computers became dominant in the past 60 years, recent advancements in three-dimensional micro-additive manufacturing technology provide new fabrication techniques for complex microstructures which have rekindled research interest in mechanical computations. Here we propose a new digital mechanical computation approach based on additively-manufacturable micro-mechanical logic gates. The proposed mechanical logic gates (i.e., NOT, AND, OR, NAND, and NOR gates) utilize multi-stable micro-flexures that buckle to perform Boolean computations based purely on mechanical forces and displacements with no electronic components. A key benefit of the proposed approach is that such systems can be additively fabricated as embedded parts of microarchitected metamaterials that are capable of interacting mechanically with their surrounding environment while processing and storing digital data internally without requiring electric power.

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In this paper, we demonstrate how the principles of the freedom, actuation, and constraint topologies (FACT) approach may be applied to the synthesis, analysis, and optimization of microstructural architectures that possess extreme or unusual thermal expansion properties (e.g., zero or large negative-thermal expansion coefficients). FACT provides designers with a comprehensive library of geometric shapes, which may be used to visualize the regions wherein various microstructural elements can be placed for achieving desired bulk material properties. In this way, designers can rapidly consider and compare a multiplicity of microstructural concepts that satisfy the desired design requirements before selecting the final concept. A complementary analytical tool is also provided to help designers rapidly calculate and optimize the desired thermal properties of the microstructural concepts that are generated using FACT. As a case study, this tool is used to calculate the negative-thermal expansion coefficient of a microstructural architecture synthesized using FACT. The result of this calculation is verified using a finite element analysis (FEA) package called ale3d.

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