4D Printing Elastic Composites for Strain-Tailored Multistable Shape Morphing

Three-dimensional (3D) morphing structures with multistable shapes that can be quantitatively and reversibly altered are highly desired in many potential applications ranging from soft robots to wearable electronics. In this study, we present a 4D printing method for fabricating multistable shape-morphing structures that can be quantitatively controlled by the applied strains. The structures are printed by a two-nozzle 3D printer that can spatially distribute phase change wax microparticles (MPs) in the elastomer matrix. The wax MPs can retain the residual strain after the prestrained elastomer composite is relaxed because of the solid-liquid phase change. Thanks to high design freedom of the 3D printing, spatial distribution of the wax MPs can be programmed, leading to an anisotropic stress field in the elastomer composite. This causes the out-of-plane deformations such as curling, folding, and buckling. These deformations are multistable and can be reprogrammed because of the reversible phase change of the wax MPs. What's more, characteristics of deformations such as curvatures and folding angles are linearly dependent on the applied strains, suggesting that these deformations are quantitatively controllable. Finally, the applications of the strained-tailored multistable shape morphing 3D structures in the assembly of 3D electronics and adaptive wearable sensors were demonstrated.