We combine materials engineering and digital processing to design and print cellulose-based continuous stiffness gradients.

In response to the global challenge of reducing carbon emissions and energy consumption from regulating indoor climates, we investigate the applicability of biobased cellulosic materials and bioinspired 4D-printing for weather-responsive adaptive shading in building facades. Cellulose is an abundantly available natural material resource that exhibits hygromorphic actuation potential when used in 4D-printing to emulate motile plant structures in bioinspired bilayers. Three key aspects are addressed: (i) examining the motion response of 4D-printed hygromorphic bilayers to both temperature and relative humidity, (ii) verifying the responsiveness of self-shaping shading elements in lab-generated conditions as well as under daily and seasonal weather conditions for over a year, and (iii) deploying the adaptive shading system for testing in a real building facade by upscaling the 4D-printing manufacturing process. This study demonstrates that hygromorphic bilayers can be utilized for weather-responsive facades and that the presented system is architecturally scalable in quantity. Bioinspired 4D-printing and biobased cellulosic materials offer a resource-efficient and energy-autonomous solution for adaptive shading, with potential contributions towards indoor climate regulation and climate change mitigation.

This paper presents a material programming approach for designing 4D‐printed self‐shaping material systems based on biological role models. Plants have inspired numerous adaptive systems that move without using any operating energy; however, these systems are typically designed and fabricated in the form of simplified bilayers. This work introduces computational design methods for 4D‐printing bio‐inspired behaviors with compounded mechanisms. To emulate the anisotropic arrangement of motile plant structures, material systems are tailored at the mesoscale using extrusion‐based 3D‐printing. The methodology is demonstrated by transferring the principle of force generation by a twining plant (Dioscorea bulbifera) to the application of a self‐tightening splint. Through the tensioning of its stem helix, D. bulbifera exhibits a squeezing force on its support to provide stability against gravity. The functional strategies of D. bulbifera are abstracted and translated to customized 4D‐printed material systems. The squeezing forces of these bio‐inspired motion mechanisms are then evaluated. Finally, the function of self‐tightening is prototyped in a wrist‐forearm splint—a common orthotic device for alignment. The presented approach enables the transfer of novel and expanded biomimetic design strategies to 4D‐printed motion mechanisms, further opening the design space to new types of adaptive creations for wearable assistive technologies and beyond.

Insight into mechanics of biomimetic self-shaping wood leads to revolutionizing manufacturing of curved structural timber.

Through their anisotropic cellular mesostructure and differential swelling and shrinking properties, hygroscopic plant structures move in response to changes in the environment without consuming metabolic energy. When the movement is choreographed in sequential time steps, either in individual structures or with a coordinated interplay of various structural elements, complex functionalities such as dispersal and protection of seeds are achieved. Inspired by the multi-phase motion in plant structures, this paper presents a method to physically program the timescale and the sequences of shape-change in 4D-printed hygromorphic structures. Using the FDM 3D-printing method, we have developed multi-layered, multi-material functional bilayers that combine highly hygroscopic active layers (printed with hygroscopic bio-composite materials) with hydrophobic restrictive and blocking layers (printed with PLA and TPC materials). The timescale of motion is programmed through the design of the mesostructured layers and 3D-printing process parameters, including thickness (number of printed active layers), porosity (filling ratio of the active layer), and water permeability (filling ratio of the blocking layer). Through a series of experiments, it is shown that the timescale of motion can be extended by increasing the thickness of the active layer, decreasing the porosity of the active layer, or increasing the filling ratio of the hydrophobic restrictive and blocking layers. Similarly, a lower thickness of the active layer and lower filling ratio of all layers result in a faster motion. As a proof of concept, we demonstrate several prototypes that exhibit sequential motion, including an aperture with overlapping elements where each completes its movement sequentially to avoid collision, and a self-locking mechanism where defined areas of the structure are choreographed to achieve a multi-step self-shaping and locking function. The presented method extends the programmability and the functional capabilities of hygromorphic 4D-printing, allowing for novel applications across fields such as robotics, smart actuators, and adaptive architecture.