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Lalegani Dezaki, M 
ORCID: https://orcid.org/0000-0001-5680-1550,
2024.
Mechanical design, 4D printing, and programming of smart composite actuators.
PhD, Nottingham Trent University.
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Abstract
The rise of four-dimensional (4D) printing addressed the growing need for rapid and replicable prototyping of bespoke structures with intricate geometries. Smart materials explore advancements in the creation and control of soft, responsive, strong, and functional actuators designed for safe interaction with delicate environments. The mechanical design, programming, and 4D printing of stimuli-responsive shape memory polymers (SMPs) for smart composite actuators are the main areas of interest in this work. The activation of smart actuators can be done via temperature, electricity, magnetic fields, and pneumatic air in this study. This thesis aims to develop a method for designing and constructing smart composite actuators with customized geometrical, functional, and control properties. It leverages existing 4D printing techniques to fabricate actuators from SMPs and shape memory polymer composites (SMPCs).
The research investigates and controls the actuation of these 3D dynamic structures by manipulating the stimuli components. The study describes 4D-printed composite actuators with functionalities including remote programmability, precise controllability, shape manipulation, and shape locking. This work presents a novel approach to developing 4D-printed shape memory composite actuators using fused deposition modelling (FDM). This thesis delves into the selection of suitable materials for 4D printing smart composite actuators. It achieves this through a comprehensive review of existing 4D printing technologies, smart actuator designs, and identifying materials that excel in both printability and functionality. Also, the thesis specifically evaluates actuators, focusing on their material properties, fabrication methods, and responsiveness to various stimuli. This thesis also examines how FDM 4D printing is used to fabricate smart composite actuators. These actuators hold the potential for integration into various applications based on requirements.
Shape memory magneto-electroactive composite actuators are developed accordingly. These composite smart actuators offer remote programmability, enabling control over shape morphing and subsequent shape locking. It achieves this by utilizing 4D-printed SMPs/SMPCs as hinges, enabling the transformation of a planar sheet into a 3D structure. 4D-printed SMPC structures offer cost-effective, multi-stable designs that can be remotely programmed at high temperatures. These structures exhibit the capacity to repeatedly transition between predetermined temporary and permanent configurations. This prevents material waste and enables several designs in a single construction. Understanding magnetic response, SMPC mechanics, and the manufacturing concept form the basis of the strategy. Switchable multi-stable structures have the advantage of lowering material waste, effort, and energy consumption while boosting productivity in industries like packing.
Composite shape memory meta-laminar jamming (MLJ) actuators fabricated using negative air pressure and SMPs are developed as well. These MLJ actuators exhibit enhanced stiffness at both room and high temperatures when activated with negative air pressure. Additionally, they possess remote programmability and shape-locking functionalities. MLJ actuators have an advantage over traditional LJ actuators in that the actuator can be stimulated without a constant negative air pressure. The actuator is able to lift and hold objects with a variety of weights and shapes without the need for power input. This actuator has proven its adaptability in hypothetical uses by serving as both a gripper and an end-effector.
The final objectives of this thesis centre around the development of a fabrication method for 4D-printed SMPC actuators exhibiting high mechanical properties and dynamic responses. This groundbreaking method can be applied universally to all types of SMPC actuators, resulting in superior strength and durability. To achieve this, the research focuses on developing FDM 4D printing of SMPCs for continuous fibre-reinforced composite (CFRC) actuators. This approach paves the way for the development of robust shape memory smart composite actuators. The ability to modify the polymer matrix allows for actuation via diverse stimuli, exceeding the limitations of traditional SMPs in terms of strength. These results show how versatile 4D-printed CFRCs may be in a range of domains, including mechanical and biological sciences as well as human-material interaction. By minimising material use and waste, the approach promotes sustainability by creating goods that are lightweight and reusable.
This dissertation explores the synergy between mechanical design, 3D/4D printing, and the unique properties of SMPs/SMPCs. By leveraging FDM 4D printing with SMPCs, it presents novel composite actuators/structures with significantly expanded functionalities. By showcasing 4D printing's potential for practical uses, this study advances the field of smart actuators.
| Item Type: | Thesis |
|---|---|
| Creators: | Lalegani Dezaki, M. |
| Contributors: | Name Role NTU ID ORCID Zolfagharian, A. Thesis supervisor SST3ZOLFAA UNSPECIFIED |
| Date: | September 2024 |
| Rights: | The author holds the copyright in this work. You may copy up to 5% of this work for private study, or personal, non-commercial research. Any re-use of the information contained within this document should be fully referenced, quoting the author, title, university, degree level and pagination. Queries or requests for any other use, or if a more substantial copy is required, should be directed to the author. |
| Divisions: | Schools > School of Science and Technology |
| Record created by: | Melissa Cornwell |
| Date Added: | 28 Jan 2025 15:56 |
| Last Modified: | 28 Jan 2025 15:56 |
| URI: | https://irep.ntu.ac.uk/id/eprint/52937 |
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