Multi‐Material 3D and 4D Printing: A Survey

Abstract Recent advances in multi‐material 3D and 4D printing (time as the fourth dimension) show that the technology has the potential to extend the design space beyond complex geometries. The potential of these additive manufacturing (AM) technologies allows for functional inclusion in a low‐cost single‐step manufacturing process. Different composite materials and various AM technologies can be used and combined to create customized multi‐functional objects to suit many needs. In this work, several types of 3D and 4D printing technologies are compared and the advantages and disadvantages of each technology are discussed. The various features and applications of 3D and 4D printing technologies used in the fabrication of multi‐material objects are reviewed. Finally, new avenues for the development of multi‐material 3D and 4D printed objects are proposed, which reflect the current deficiencies and future opportunities for inclusion by AM.

[1]  Zhe Yin,et al.  Carbonized Chinese Art Paper-Based High-Performance Wearable Strain Sensor for Human Activity Monitoring , 2019, ACS Applied Electronic Materials.

[2]  Yuki Nakagawa,et al.  Dieless Forming of Carbon Fibre Reinforced Plastic Parts Using 3D Printer , 2014 .

[3]  Adam E Jakus,et al.  Advancing the field of 3D biomaterial printing , 2016, Biomedical materials.

[4]  A. Tavakoli,et al.  The influences of rotational and welding speeds on microstructures and mechanical properties of friction stir welded Al5083 and commercially pure copper sheets lap joints , 2013 .

[5]  Mark S. Mirotznik,et al.  Multi-material additive manufacturing of antennas , 2016, 2016 International Workshop on Antenna Technology (iWAT).

[6]  T. Weller,et al.  A multi-material 3D printing approach for conformal microwave antennas , 2016, 2016 International Workshop on Antenna Technology (iWAT).

[7]  Chao Yuan,et al.  Multi-shape active composites by 3D printing of digital shape memory polymers , 2016, Scientific Reports.

[8]  Yongan Huang,et al.  Electrohydrodynamic Direct-Writing for Flexible Electronic Manufacturing , 2017 .

[9]  A. Fox-Robichaud,et al.  Rapid and inexpensive method for fabrication of multi-material multi-layer microfluidic devices , 2018, Journal of Micromechanics and Microengineering.

[10]  B. Yan,et al.  Manufacturing and 3D printing of continuous carbon fiber prepreg filament , 2018, Journal of Materials Science.

[11]  B. Wardle,et al.  Enhanced Bonding via Additive Manufacturing‐Enabled Surface Tailoring of 3D Printed Continuous‐Fiber Composites , 2018, Advanced Engineering Materials.

[12]  Huiling Duan,et al.  Multimaterial Microfluidic 3D Printing of Textured Composites with Liquid Inclusions , 2018, Advanced science.

[13]  Dae-Eun Kim,et al.  Review of 4D printing materials and their properties , 2017 .

[14]  John Obielodan,et al.  A fabrication methodology for dual-material engineering structures using ultrasonic additive manufacturing , 2014 .

[15]  Maria Isabella Gariboldi,et al.  3D Printed Multimaterial Microfluidic Valve , 2016, PloS one.

[16]  Dichen Li,et al.  Interface and performance of 3D printed continuous carbon fiber reinforced PLA composites , 2016 .

[17]  Amir Hosein Sakhaei,et al.  Multimaterial 3D Printed Soft Actuators Powered by Shape Memory Alloy Wires , 2019, Sensors and Actuators A: Physical.

[18]  Electrophotographic multi-material powder deposition for additive manufacturing , 2018 .

[19]  Wei-Hsin Liao,et al.  Self-expanding/shrinking structures by 4D printing , 2016 .

[20]  G. H. Loh,et al.  An overview of functionally graded additive manufacturing , 2018, Additive Manufacturing.

[21]  F. Akasheh,et al.  Fracture toughness enhancement of carbon fiber–reinforced polymer composites utilizing additive manufacturing fabrication , 2018, Journal of Elastomers & Plastics.

[22]  M. Leu,et al.  Freeze-form extrusion fabrication of functionally graded materials , 2012 .

[23]  Zi-kui Liu,et al.  Functionally graded material of 304L stainless steel and inconel 625 fabricated by directed energy deposition: Characterization and thermodynamic modeling , 2016 .

[24]  D. Therriault,et al.  Coextrusion of Multifunctional Smart Sensors , 2018, Advanced Engineering Materials.

[25]  M. Rafiee,et al.  Nonlinear forced vibration analysis of clamped functionally graded beams , 2011 .

[26]  Chibum Lee,et al.  A desktop multi-material 3D bio-printing system with open-source hardware and software , 2017 .

[27]  A. Todoroki,et al.  3D Printing of Continuous Carbon Fibre Reinforced Thermo-Plastic (CFRTP) Tensile Test Specimens , 2016 .

[28]  J. Hascoët,et al.  Modeling and control of a direct laser powder deposition process for Functionally Graded Materials (FGM) parts manufacturing , 2013 .

[29]  Wojciech Matusik,et al.  MultiFab , 2015, ACM Trans. Graph..

[30]  Xiaoyu Zheng,et al.  Multi-material Additive Manufacturing of Metamaterials with Giant, Tailorable Negative Poisson’s Ratios , 2018, Scientific Reports.

[31]  D. Dowling,et al.  Additive manufacturing of woven carbon fibre polymer composites , 2018, Composite Structures.

[32]  Yong Chen,et al.  Three-dimensional circuit fabrication using four-dimensional printing and direct ink writing , 2016, 2016 International Symposium on Flexible Automation (ISFA).

[33]  K. Shea,et al.  Integrated Design and Simulation of Tunable, Multi-State Structures Fabricated Monolithically with Multi-Material 3D Printing , 2017, Scientific Reports.

[34]  Ryan B. Wicker,et al.  Multi-material, multi-technology stereolithography , 2012 .

[35]  Lin Li,et al.  Simultaneous wire- and powder-feed direct metal deposition: An investigation of the process characteristics and comparison with single-feed methods , 2006 .

[36]  Wei-Hsin Liao,et al.  Triple shape memory polymers by 4D printing , 2018 .

[37]  Jie Yang,et al.  Thermal bifurcation buckling of piezoelectric carbon nanotube reinforced composite beams , 2013, Comput. Math. Appl..

[38]  Yunzhuo Lu,et al.  Laser 3D printing of CoCrFeMnNi high-entropy alloy , 2019, Materials Letters.

[39]  Anna C. Balazs,et al.  Stimuli-responsive behavior of composites integrating thermo-responsive gels with photo-responsive fibers , 2016 .

[40]  Qiao Sun,et al.  Composite Modeling and Analysis for Fabrication of FDM Prototypes with Locally Controlled Properties , 2002 .

[41]  A. Todoroki,et al.  3D printing of discontinuous and continuous fibre composites using stereolithography , 2018, Additive Manufacturing.

[42]  Garrett W. Melenka,et al.  Evaluation and prediction of the tensile properties of continuous fiber-reinforced 3D printed structures , 2016 .

[43]  S. Kumar,et al.  Development of functionally graded materials by ultrasonic consolidation , 2010 .

[44]  Chi Zhou,et al.  Digital material fabrication using mask‐image‐projection‐based stereolithography , 2013 .

[45]  K. Mori,et al.  3D printing of carbon fibre-reinforced plastic parts , 2017 .

[46]  Michael Schmidt,et al.  Simultaneous laser beam melting of multimaterial polymer parts , 2015 .

[47]  Wenfeng Hao,et al.  Preparation and characterization of 3D printed continuous carbon fiber reinforced thermosetting composites , 2018 .

[48]  N. Oxman,et al.  Digital anisotropy: A variable elasticity rapid prototyping platform , 2012 .

[49]  D. Cho,et al.  Bioprinting of a mechanically enhanced three-dimensional dual cell-laden construct for osteochondral tissue engineering using a multi-head tissue/organ building system , 2012 .

[50]  M. Leu,et al.  Solvent Based 3D Printing of Biopolymer/Bioactive Glass Composite and Hydrogel for Tissue Engineering Applications , 2017 .

[51]  Frédéric Demoly,et al.  Design for 4D printing: A voxel-based modeling and simulation of smart materials , 2019, Materials & Design.

[52]  Ryan B. Wicker,et al.  Multi-material microstereolithography , 2010 .

[53]  A. Todoroki,et al.  Three-dimensional printing of continuous-fiber composites by in-nozzle impregnation , 2016, Scientific Reports.

[54]  K. Liew,et al.  Non-linear dynamic stability of piezoelectric functionally graded carbon nanotube-reinforced composite plates with initial geometric imperfection , 2014 .

[55]  Elizabeth Cosgriff-Hernandez,et al.  Fabrication of biomimetic bone grafts with multi-material 3D printing , 2017, Biofabrication.

[56]  Kamran Mumtaz,et al.  Laser melting functionally graded composition of Waspaloy® and Zirconia powders , 2007 .

[57]  B. Derby,et al.  3D printing of materials with spatially non-linearly varying properties , 2018, Materials & Design.

[58]  D. Karalekas,et al.  Study of the mechanical properties of nonwoven fibre mat reinforced photopolymers used in rapid prototyping , 2003 .

[59]  J. Kang,et al.  Multi-phase refining of an AlCoCrFeNi high entropy alloy by hot compression , 2017 .

[60]  Eduardo Saiz,et al.  Multimaterial 3D Printing of Graphene-Based Electrodes for Electrochemical Energy Storage Using Thermoresponsive Inks. , 2017, ACS applied materials & interfaces.

[61]  C. Leyens,et al.  Enhanced manufacturing possibilities using multi-materials in laser metal deposition , 2018, Journal of Laser Applications.

[62]  W. Zhong,et al.  RESEARCH ON RAPID-PROTOTYPING/PART MANUFACTURING (RP&M) FOR THE CONTINUOUS FIBER REINFORCED COMPOSITE , 2001 .

[63]  Martin Wegener,et al.  Adding chemically selective subtraction to multi-material 3D additive manufacturing , 2018, Nature Communications.

[64]  Laiquan Li,et al.  Development of hybrid magnetorheological elastomers by 3D printing , 2018, Polymer.

[65]  J. Lewis,et al.  3D Bioprinting of Vascularized, Heterogeneous Cell‐Laden Tissue Constructs , 2014, Advanced materials.

[66]  Mark S. Mirotznik,et al.  Multi-material additive manufacturing of embedded low-profile antennas , 2015 .

[67]  Takahiko Kato,et al.  Relationship between the microstructure and mechanical properties of an equiatomic AlCoCrFeNi high-entropy alloy fabricated by selective electron beam melting , 2016 .

[68]  L. Velásquez-García,et al.  Miniaturized Diaphragm Vacuum Pump by Multi-Material Additive Manufacturing , 2017, Journal of Microelectromechanical Systems.

[69]  Dichen Li,et al.  3D printing for continuous fiber reinforced thermoplastic composites: mechanism and performance , 2017 .

[70]  M. Domack,et al.  Selective Reinforcement of Aerospace Structures Using Ultrasonic Additive Manufacturing , 2018, Journal of materials engineering and performance (Print).

[71]  Brian Mellor,et al.  Multiple material additive manufacturing – Part 1: a review , 2013 .

[72]  F. Xuan,et al.  Fine-structured CoCrFeNiMn high-entropy alloy matrix composite with 12 wt% TiN particle reinforcements via selective laser melting assisted additive manufacturing , 2019, Materials letters (General ed.).

[73]  Iulia Salaoru,et al.  Development of a direct feed fused deposition modelling technology for multi-material manufacturing , 2016 .

[74]  A. Studart,et al.  Multimaterial magnetically assisted 3D printing of composite materials , 2015, Nature Communications.

[75]  Amir Hosein Sakhaei,et al.  Multimaterial 4D Printing with Tailorable Shape Memory Polymers , 2016, Scientific Reports.

[76]  Amit Bandyopadhyay,et al.  Additive manufacturing of Inconel 718—Copper alloy bimetallic structure using laser engineered net shaping (LENS™) , 2018 .

[77]  Qudus Hamid,et al.  Hetero-cellular prototyping by synchronized multi-material bioprinting for rotary cell culture system , 2016, Biofabrication.

[78]  S. Ahzi,et al.  Synergistic reinforcement of polyamide-based composites by combination of short and continuous carbon fibers via fused filament fabrication , 2019, Composite Structures.

[79]  Skylar Tibbits,et al.  4D Printing: Multi‐Material Shape Change , 2014 .

[80]  Saeed Akbari,et al.  Enhanced multimaterial 4D printing with active hinges , 2018 .

[81]  Sina Naficy,et al.  3D printing of tough hydrogel composites with spatially varying materials properties , 2017 .

[82]  James J. Yoo,et al.  Bioprinting technology and its applications. , 2014, European journal of cardio-thoracic surgery : official journal of the European Association for Cardio-thoracic Surgery.

[83]  D. Sameoto,et al.  Printing with mechanically interlocked extrudates using a custom bi-extruder for fused deposition modelling , 2018, Rapid Prototyping Journal.

[84]  Thomas S. Lumpe,et al.  Tensile properties of multi-material interfaces in 3D printed parts , 2019, Materials & Design.

[85]  Wai Yee Yeong,et al.  Additively manufactured multi-material free-form structure with printed electronics , 2018 .

[86]  Mohsen Ziaee,et al.  Binder jetting: A review of process, materials, and methods , 2019, Additive Manufacturing.

[87]  Enoch Asuako Larson,et al.  Laser additive manufacturing of FeCrCoMnNi high-entropy alloy: Effect of heat treatment on microstructure, residual stress and mechanical property , 2019, Journal of Alloys and Compounds.

[88]  Martin L. Dunn,et al.  Sequential Self-Folding Structures by 3D Printed Digital Shape Memory Polymers , 2015, Scientific Reports.

[89]  Wai Yee Yeong,et al.  Performance evaluation of ProJet multi-material jetting 3D printer , 2017 .

[90]  A. Bandyopadhyay,et al.  Additive manufacturing of multi-material structures , 2018, Materials Science and Engineering: R: Reports.

[91]  D. Bartholomeusz,et al.  Xurography: rapid prototyping of microstructures using a cutting plotter , 2005, Journal of Microelectromechanical Systems.

[92]  M. Toursangsaraki,et al.  A Review of Multi-material and Composite Parts Production by Modified Additive Manufacturing Methods , 2018, 1808.01861.

[93]  Y. Zhao,et al.  AlCoCuFeNi high-entropy alloy with tailored microstructure and outstanding compressive properties fabricated via selective laser melting with heat treatment , 2019, Materials Science and Engineering: A.

[94]  Xiaoyong Tian,et al.  Programmable morphing composites with embedded continuous fibers by 4D printing , 2018, Materials & Design.

[95]  Dominique Grevey,et al.  Laser-assisted direct manufacturing of functionally graded 3D objects , 2005 .

[96]  A. Johnson,et al.  Multimaterial polyacrylamide: fabrication with electrohydrodynamic jet printing, applications, and modeling , 2014, Biofabrication.

[97]  Yingguang Li,et al.  Rapid prototyping of continuous carbon fiber reinforced polylactic acid composites by 3D printing , 2016 .

[98]  Yang Gao,et al.  Simultaneous additive and subtractive three-dimensional nanofabrication using integrated two-photon polymerization and multiphoton ablation , 2012, Light: Science & Applications.

[99]  Daan Witters,et al.  Evaluating 3D printing to solve the sample-to-device interface for LRS and POC diagnostics: example of an interlock meter-mix device for metering and lysing clinical urine samples. , 2016, Lab on a chip.

[100]  Yongan Huang,et al.  Addressable multi-nozzle electrohydrodynamic jet printing with high consistency by multi-level voltage method , 2015 .

[101]  A. R. Damanpack,et al.  Adaptive metamaterials by functionally graded 4D printing , 2017 .

[102]  T. Shun,et al.  Nanostructured High‐Entropy Alloys with Multiple Principal Elements: Novel Alloy Design Concepts and Outcomes , 2004 .

[103]  Sung-Hoon Ahn,et al.  From 3D to 4D printing – design, material and fabrication for multi-functional multi-materials , 2017 .

[104]  Wim E Hennink,et al.  25th Anniversary Article: Engineering Hydrogels for Biofabrication , 2013, Advanced materials.

[105]  Lin Li,et al.  A novel hybrid magnetorheological elastomer developed by 3D printing , 2017 .

[106]  Martine Dubé,et al.  Three‐Dimensional Printing of Multifunctional Nanocomposites: Manufacturing Techniques and Applications , 2016, Advanced materials.

[107]  M. Longana,et al.  An investigation into 3D printing of fibre reinforced thermoplastic composites , 2018, Additive Manufacturing.

[108]  B. Wardle,et al.  Strength and Performance Enhancement of Multilayers by Spatial Tailoring of Adherend Compliance and Morphology via Multimaterial Jetting Additive Manufacturing , 2018, Scientific Reports.