Architected Design and Fabrication of Soft Mechanical Metamaterials
This study proposes a systematic design approach to 3D print soft mechanical metamaterials by tuning material flow behavior and using optimal toolpaths and print parameters. Planar printing tool paths, utilized in layer‐by‐layer printing such as fused deposition modeling (FDM) and prevalently used i...
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| Main Authors: | , , , , , , , , |
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| Format: | Article |
| Language: | English |
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Wiley
2025-04-01
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| Series: | Advanced Intelligent Systems |
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| Online Access: | https://doi.org/10.1002/aisy.202400514 |
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| author | Thileepan Stalin Aby Raj Plamootil Mathai Naresh Kumar Thanigaivel Elgar Kanhere Saikrishna Dontu Gumawang Hiramandala Aaron Chooi Arturo Castillo Ugalde Pablo Valdivia Y Alvarado |
| author_facet | Thileepan Stalin Aby Raj Plamootil Mathai Naresh Kumar Thanigaivel Elgar Kanhere Saikrishna Dontu Gumawang Hiramandala Aaron Chooi Arturo Castillo Ugalde Pablo Valdivia Y Alvarado |
| author_sort | Thileepan Stalin |
| collection | DOAJ |
| description | This study proposes a systematic design approach to 3D print soft mechanical metamaterials by tuning material flow behavior and using optimal toolpaths and print parameters. Planar printing tool paths, utilized in layer‐by‐layer printing such as fused deposition modeling (FDM) and prevalently used in most slicing algorithms, severely limit the realization of complex topologies required in metamaterials. Utilizing parametric design principles, the proposed approach employs discrete and continuous 3D freeform tool paths for supported and unsupported direct ink writing (DIW) of elastomeric structures. The resulting textured, soft topologies significantly enhance the performance of various mechanisms in soft robotics and impact energy‐absorbing wearable devices. Various bioinspired structures such as cilia, webs, leaf‐like structures, and lattices are explored using extrusion‐based silicone 3D printing, achieving features with high aspect ratios (L/D ≤ 12) without support. These complex structures are challenging to 3D print using conventional planar toolpaths. To demonstrate the enhanced functionalities enabled by these new topologies, cilia arrays added to suction cups increased the pull‐off forces by 18%. Additionally, 3D‐printed elastomeric lattice slabs used as energy‐absorbing structures reduced the maximum impact peak forces by 85%. Further functionalities, including magnetic, thermochromic, and signal transmission properties, are also showcased using functional soft mechanical metamaterials. |
| format | Article |
| id | doaj-art-39de1eaba00941ffbc943a4604507bed |
| institution | DOAJ |
| issn | 2640-4567 |
| language | English |
| publishDate | 2025-04-01 |
| publisher | Wiley |
| record_format | Article |
| series | Advanced Intelligent Systems |
| spelling | doaj-art-39de1eaba00941ffbc943a4604507bed2025-08-20T03:08:42ZengWileyAdvanced Intelligent Systems2640-45672025-04-0174n/an/a10.1002/aisy.202400514Architected Design and Fabrication of Soft Mechanical MetamaterialsThileepan Stalin0Aby Raj Plamootil Mathai1Naresh Kumar Thanigaivel2Elgar Kanhere3Saikrishna Dontu4Gumawang Hiramandala5Aaron Chooi6Arturo Castillo Ugalde7Pablo Valdivia Y Alvarado8Engineering Product Development (EPD) Singapore University of Technology and Design Singapore 487372 SingaporeEngineering Product Development (EPD) Singapore University of Technology and Design Singapore 487372 SingaporeEngineering Product Development (EPD) Singapore University of Technology and Design Singapore 487372 SingaporeDigital Manufacturing and Design (DManD) Centre Singapore University of Technology and Design Singapore 487372 SingaporeDigital Manufacturing and Design (DManD) Centre Singapore University of Technology and Design Singapore 487372 SingaporeDigital Manufacturing and Design (DManD) Centre Singapore University of Technology and Design Singapore 487372 SingaporeEngineering Product Development (EPD) Singapore University of Technology and Design Singapore 487372 SingaporeEngineering Product Development (EPD) Singapore University of Technology and Design Singapore 487372 SingaporeEngineering Product Development (EPD) Singapore University of Technology and Design Singapore 487372 SingaporeThis study proposes a systematic design approach to 3D print soft mechanical metamaterials by tuning material flow behavior and using optimal toolpaths and print parameters. Planar printing tool paths, utilized in layer‐by‐layer printing such as fused deposition modeling (FDM) and prevalently used in most slicing algorithms, severely limit the realization of complex topologies required in metamaterials. Utilizing parametric design principles, the proposed approach employs discrete and continuous 3D freeform tool paths for supported and unsupported direct ink writing (DIW) of elastomeric structures. The resulting textured, soft topologies significantly enhance the performance of various mechanisms in soft robotics and impact energy‐absorbing wearable devices. Various bioinspired structures such as cilia, webs, leaf‐like structures, and lattices are explored using extrusion‐based silicone 3D printing, achieving features with high aspect ratios (L/D ≤ 12) without support. These complex structures are challenging to 3D print using conventional planar toolpaths. To demonstrate the enhanced functionalities enabled by these new topologies, cilia arrays added to suction cups increased the pull‐off forces by 18%. Additionally, 3D‐printed elastomeric lattice slabs used as energy‐absorbing structures reduced the maximum impact peak forces by 85%. Further functionalities, including magnetic, thermochromic, and signal transmission properties, are also showcased using functional soft mechanical metamaterials.https://doi.org/10.1002/aisy.202400514architected designsbioinspired structuresmultimaterial additive manufacturingsoft mechanical metamaterialssoft robots |
| spellingShingle | Thileepan Stalin Aby Raj Plamootil Mathai Naresh Kumar Thanigaivel Elgar Kanhere Saikrishna Dontu Gumawang Hiramandala Aaron Chooi Arturo Castillo Ugalde Pablo Valdivia Y Alvarado Architected Design and Fabrication of Soft Mechanical Metamaterials Advanced Intelligent Systems architected designs bioinspired structures multimaterial additive manufacturing soft mechanical metamaterials soft robots |
| title | Architected Design and Fabrication of Soft Mechanical Metamaterials |
| title_full | Architected Design and Fabrication of Soft Mechanical Metamaterials |
| title_fullStr | Architected Design and Fabrication of Soft Mechanical Metamaterials |
| title_full_unstemmed | Architected Design and Fabrication of Soft Mechanical Metamaterials |
| title_short | Architected Design and Fabrication of Soft Mechanical Metamaterials |
| title_sort | architected design and fabrication of soft mechanical metamaterials |
| topic | architected designs bioinspired structures multimaterial additive manufacturing soft mechanical metamaterials soft robots |
| url | https://doi.org/10.1002/aisy.202400514 |
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