Rotary 4D printing of programmable metamaterials on sustainable 4D mandrel

Soleimanzadeh, H, Bodaghi, M ORCID: https://orcid.org/0000-0002-0707-944X, Jamalabadi, M, Rolfe, B and Zolfagharian, A, 2025. Rotary 4D printing of programmable metamaterials on sustainable 4D mandrel. Advanced Materials Technologies. ISSN 2365-709X

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Abstract

This paper presents a novel rotary 4D printing platform capable of producing modular, multi-material, multi-stiffness cylindrical structures directly on a programmable, shape-morphing mandrel. Inspired by bio-inspired re-entrant auxetic geometries, the design incorporates a parametric zigzag pathing strategy to dissipate stress and enhance resilience. The method supports non-planar, continuous-path toolpaths, overcoming the limitations of commercial slicers through a freely available open-source rotary slicing algorithm. Comprehensive numerical and experimental studies to evaluate strain energy distribution, stiffness tunability, and 4D recovery in re-entrant auxetic structures and spiral joints. A data-driven predictive model is introduced to link geometric and material parameters to final shape-morphing behavior, reducing dependence on iterative simulations. The integrated path-planning approach significantly distributes localized Von Mises stress, particularly in hinge regions, while preserving global energy absorption. Using Python scripting within the Grasshopper environment, the complete design-to-G-code algorithm is developed, enabling direct fabrication of non-planar 4D structures, including multi-spiral universal joints with programmable stiffness and multi-degree-of-freedom motion. This work establishes a new paradigm in rotary 4D printing by uniting algorithmic design, stimuli-responsive behavior, and reproducible fabrication within a single open framework. It is concluded by discussing broader implications for sustainable manufacturing, with potential applications in soft robotics, wearable systems, and deployable structures.

Item Type:	Journal article
Publication Title:	Advanced Materials Technologies
Creators:	Soleimanzadeh, H., Bodaghi, M., Jamalabadi, M., Rolfe, B. and Zolfagharian, A.
Publisher:	Wiley
Date:	25 September 2025
ISSN:	2365-709X
Identifiers:	Number Type 10.1002/admt.202501581 DOI 2509204 Other
Rights:	© 2025 The Author(s). Advanced Materials Technologies published by Wiley-VCH GmbH. This is an open access article under the terms of the Creative Commons Attribution-NonCommercial-NoDerivs License, which permits use and distribution in any medium, provided the original work is properly cited, the use is non-commercial and no modifications or adaptations are made.
Divisions:	Schools > School of Science and Technology
Record created by:	Laura Borcherds
Date Added:	07 Oct 2025 15:15
Last Modified:	07 Oct 2025 15:15
URI:	https://irep.ntu.ac.uk/id/eprint/54518

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