Origami by frontal photopolymerization

4D Printing: A Comprehensive Review of Technologies, Materials, Stimuli, Design, and Emerging Applications

4D printing is a groundbreaking technology that seamlessly integrates additive manufacturing with smart materials, enabling the creation of multiscale objects capable of changing shapes and/or functions in a controlled and programmed manner in response to applied energy inputs. Printing technologies, mathematical modeling, responsive materials, stimuli, and structural design constitute the blueprint of 4D printing, all of which have seen rapid advancement in the past decade. These advancements have opened up numerous possibilities for dynamic and adaptive structures, finding potential use in healthcare, textiles, construction, aerospace, robotics, photonics, and electronics. However, current 4D printing primarily focuses on proof-of-concept demonstrations. Further development is necessary to expand the range of accessible materials and address fabrication complexities for widespread adoption. In this paper, we aim to deliver a comprehensive review of the state-of-the-art in 4D printing, probing into shape programming, exploring key aspects of resulting constructs including printing technologies, materials, structural design, morphing mechanisms, and stimuli-responsiveness, and elaborating on prominent applications across various fields. Finally, we discuss perspectives on limitations, challenges, and future developments in the realm of 4D printing. While the potential of this technology is undoubtedly vast, continued research and innovation are essential to unlocking its full capabilities and maximizing its real-world impact.

Recent innovations in interfacial strategies for DLP 3D printing process optimization

Three-dimensional (3D) printing, also known as additive manufacturing, is capable of transforming computer-aided designs into intricate structures directly and on demand. This technology has garnered significant attention in recent years. Among the various approaches, digital light processing (DLP) 3D printing, which utilizes polymers or prepolymers as the ink, has emerged as the leading new technology, driven by high demand across diverse fields such as customized production, healthcare, education, and art design. DLP 3D printing technology employs cured slices as molding units and is recognized for its potential to achieve both high printing speed and resolution. Recent insights into the DLP printing process highlight its inherent interface transformations between liquid and solid states. This review summarizes key aspects of the printing process, speed, precision, and material diversity optimization, from the view of interfacial interactions between solid and liquid phases which are influenced by resin formation, curing surfaces and light source properties. These interactions include those at the liquid resin-UV pattern interface, the cured structure-curing surface interface, the liquid resin-curing surface interface, and the liquid resin-cured structure interface, each contributing to the unique characteristics of the printed results. Finally, this review addresses the current challenges and limitations of DLP 3D printing, providing valuable insights for future improvements and guiding potential innovations in the field.

Low volume shrinkage, alkaline degradable UV nanoimprint lithography resists based on acrylic anhydride

The shrinkage phenomenon of UV-NIL resists during photocuring is still regarded as an important problem hindering the wide application of UV-NIL technology. Herein, we designed four degradable UV-NIL resists with low volume shrinkage rate based on acrylic anhydride. Acrylate provided quick UV curing ability, and the resists were completely cured under a 365 nm UV light for 10 seconds. The anhydride group provided a degradation ability, causing the cured resists to be completely dissolved in an alkaline developer. Introducing rings in the molecular structure could compensate for volume shrinkage by ring-opening, and the volume shrinkage rate of the resists was below 4%. The cured resists showed good thermal stability with a decomposition temperature higher than 150 °C. The UV-NIL resists demonstrated good pattern replication ability, and distinct patterns with 100 nm resolution were obtained. The prepared UV-NIL resists are expected to play a role in the manufacturing of semiconductors, solar cells, displays, sensors, and other devices in the future.

Strain on the upper surface of a perpendicularly peeled soft film

Soft films serve as the primary support materials for flexible devices. These films are frequently peeled perpendicularly during device preparation and application, resulting in large compression on the upper surface of the bending region and significant damage to the device's performance. Accurately assessing this damage is challenging because of the difficulties in calculating the compression in perpendicularly peeled large-deformation films. In this study, we propose a method to calculate the compressive strain on the upper surface of a bending soft film using only its thickness as the key parameter. Furthermore, we demonstrate that the length of the compressive region is directly proportional to the soft film thickness, whereas the maximum strain is inversely proportional to the thickness. These results provide theoretical guidance for applying soft films in flexible devices.

Polyelectrolyte-Mediated Modulation of Spatial Internal Stresses of Hydrogels for Complex 3D Actuators

Hydrogel actuators with complex 3D initial shapes show numerous important applications, but it remains challenging to fabricate such actuators. This article describes a polyelectrolyte-based strategy for modulating small-scale internal stresses within hydrogels to construct complex actuators with tailored 3D initial shapes. Introducing polyelectrolytes into precursor solutions significantly enhances the volume shrinkage of hydrogel networks during polymerization, allowing us to modulate internal stresses. Photopolymerization of these polyelectrolyte-containing solutions through a mask produces mechanically strong hydrogel sheets with large patterned internal stresses. Consequently, these hydrogel sheets attain complex 3D initial shapes at equilibrium, in contrast to the planar initial configuration of 2D actuators. We demonstrate that these 3D actuators can reversibly transform into other 3D shapes (i.e., 3D-to-3D shape transformations) in response to external stimuli. Additionally, we develop a predictive model based on the Flory-Rehner theory to analyze the polyelectrolyte-mediated shrinking behaviors of hydrogel networks during polymerization, allowing precise modulation of shrinkage and internal stress. This polyelectrolyte-boosted shrinking mechanism paves a route to the fabrication of high-performance 3D hydrogel actuators.

3D printing with a 3D printed digital material filament for programming functional gradients

Additive manufacturing, or 3D printing attracts growing attention as a promising method for creating functionally graded materials. Fused deposition modeling (FDM) is widely available, but due to its simple process, creating spatial gradation of diverse properties using FDM is challenging. Here, we present a 3D printed digital material filament that is structured towards 3D printing of functional gradients, utilizing only a readily available FDM printer and filaments. The DM filament consists of multiple base materials combined with specific concentrations and distributions, which are FDM printed. When the DM filament is supplied to the same printer, its constituent materials are homogeneously blended during extrusion, resulting in the desired properties in the final structure. This enables spatial programming of material properties in extreme variations, including mechanical strength, electrical conductivity, and color, which are otherwise impossible to achieve with traditional FDMs. Our approach can be readily adopted to any standard FDM printer, enabling low-cost production of functional gradients.

Determinative scrolling and folding of membranes through shrinking channels

Flat membranes ubiquitously transform into mysterious complex shapes in nature and artificial worlds. Behind the complexity, clear determinative deformation modes have been continuously found to serve as basic application rules but remain unfulfilled. Here, we decipher two elemental deformation modes of thin membranes, spontaneous scrolling and folding as passing through shrinking channels. We validate that these two modes rule the deformation of membranes of a wide thickness range from micrometer to atomic scale. Their occurrence and the determinative fold number quantitatively correlate with the Föppl-von Kármán number and shrinkage ratio. The unveiled determinative deformation modes can guide fabricating foldable designer microrobots and delicate structures of two-dimensional sheets and provide another mechanical principle beyond genetic determinism in biological morphogens.

Impact of Beam Shape on Print Accuracy in Digital Light Processing Additive Manufacture

Photopolymerization-based additive manufacturing requires selectively exposing a feedstock resin to ultraviolet (UV) light, which in digital light processing is achieved either using a digital micromirror device or a digital mask. The minimum tolerances and resolution for a multilayer process are separate for resolution through the Z-axis, looking through the thickness of a printed part, and resolution in the XY-axes, in the plane of the printed layer. The former depends wholly on the rate of attenuation of the incident UV light through the material relative to the mechanical motion of the build layer, while the latter is determined by a two-dimensional pattern of irradiance on the resin formed by the digital micromirror device or the digital mask. The size or the spacing of elements or pixels of this digital mask is frequently given by manufacturers as the "resolution" of the device, however, in practice the achievable resolution is first determined by the beam distribution from each pixel. The beam distribution is, as standard, modeled as a two-parameter Gaussian distribution but the key parameters of peak intensity and standard deviation of the beam are hidden to the user and difficult to measure directly. The ability of models based on the Gaussian distribution to correctly predict the polymerization of printed features in the microscale is also typically poor. In this study, we demonstrate an alternative model of beam distribution based on a heavy-tailed Lorentzian model, which is able to more accurately predict small build areas for both positive and negative features. We show a simple calibration method to derive the key space parameters of the beam distribution from measurements of a single-layer printed model. We propose that the standard Gaussian model is insufficient to accurately predict a print outcome as it neglects higher-order terms, such as beam skew and kurtosis, and in particular failing to account for the relatively heavy tails of the beam distribution. Our results demonstrate how the amendments to the beam distribution can avoid errors in microchannel formation, and better estimates of the true XY-axes resolution of the printer. The results can be used as the basis for voxel-based models of print solidification that allow software prediction of the photopolymerization process.

4D printing for biomedical applications

While three-dimensional (3D) printing excels at fabricating static constructs, it fails to emulate the dynamic behavior of native tissues or the temporal programmability desired for medical devices. Four-dimensional (4D) printing is an advanced additive manufacturing technology capable of fabricating constructs that can undergo pre-programmed changes in shape, property, or functionality when exposed to specific stimuli. In this Perspective, we summarize the advances in materials chemistry, 3D printing strategies, and post-printing methodologies that collectively facilitate the realization of temporal dynamics within 4D-printed soft materials (hydrogels, shape-memory polymers, liquid crystalline elastomers), ceramics, and metals. We also discuss and present insights about the diverse biomedical applications of 4D printing, including tissue engineering and regenerative medicine, drug delivery, in vitro models, and medical devices. Finally, we discuss the current challenges and emphasize the importance of an application-driven design approach to enable the clinical translation and widespread adoption of 4D printing.

Active Materials for Functional Origami

In recent decades, origami has been explored to aid in the design of engineering structures. These structures span multiple scales and have been demonstrated to be used toward various areas such as aerospace, metamaterial, biomedical, robotics, and architectural applications. Conventionally, origami or deployable structures have been actuated by hands, motors, or pneumatic actuators, which can result in heavy or bulky structures. On the other hand, active materials, which reconfigure in response to external stimulus, eliminate the need for external mechanical loads and bulky actuation systems. Thus, in recent years, active materials incorporated with deployable structures have shown promise for remote actuation of light weight, programmable origami. In this review, active materials such as shape memory polymers (SMPs) and alloys (SMAs), hydrogels, liquid crystal elastomers (LCEs), magnetic soft materials (MSMs), and covalent adaptable network (CAN) polymers, their actuation mechanisms, as well as how they have been utilized for active origami and where these structures are applicable is discussed. Additionally, the state-of-the-art fabrication methods to construct active origami are highlighted. The existing structural modeling strategies for origami, the constitutive models used to describe active materials, and the largest challenges and future directions for active origami research are summarized.

Effect of a new support design on the marginal and internal gap of additively manufactured interim crowns using direct light deposition technology

PURPOSE

To investigate the design and location of supporting structures on the marginal and internal gap of interim restorations.

MATERIALS AND METHODS

A mandibular right first molar resin tooth was prepared for a full coverage crown and scanned using a laboratory scanner (3Shape D900). The scanned data were converted into standard tessellation language (STL) format and an indirect prosthesis was designed using computer-aided design (CAD) software (exocad DentalCAD). The STL file was used to fabricate a total of 60 crowns with a 3D printer (EnvisionTEC Vida HD). The crowns were printed using E-Dent C&B MH resin and divided into 4 groups based on four different support structure designs, including supports on the occlusal (0° group), buccal and occlusal (45° group), buccal (90° group), and a new design consisting of horizontal bars placed on all surfaces and line angles (Bar) (n = 15). The silicone replica technique was used to determine the gap discrepancy. Fifty measurements were obtained for each specimen to examine the marginal and internal gaps by using a digital microscope (Olympus SZX16) at ×70 magnification. Additionally, the marginal discrepancy at different locations of the tested crowns, including buccal (B), lingual (L), mesial (M), and distal (D), as well as the maximum and minimum marginal gap intervals among groups, were analyzed. The collected data were analyzed using factorial ANOVA, followed by the Tukey HSD test for multiple comparisons (a = 0.05).

RESULTS

There was a significant difference in marginal and internal gaps among the groups (p < 0.001). The buccal placement supports (90° group) had the least marginal and internal discrepancies (p < 0.001). The new design group showed the highest marginal and internal gap. The marginal discrepancy in different locations of the tested crowns (B, L, M, D) was found to be significantly different among the groups (p < 0.001). The mesial margin of the Bar group had the largest marginal gap, whereas the buccal margin of the 90° group had the lowest marginal gap. The new design had a significantly smaller difference between the maximum and minimum marginal gap intervals than other groups (p < 0.001).

CONCLUSION

The location and design of the supporting structures affected the marginal and internal gaps of an interim crown. The buccal placement of supporting bars (90° printing orientation) showed the smallest mean internal and marginal discrepancies.

3D gradient printing based on digital light processing

3D gradient printing is a type of fabrication technique that builds three-dimensional objects with gradually changing properties. Gradient digital light processing based 3D printing has garnered considerable attention in recent years. This function-oriented technology precisely manipulates the performance of different positions of materials and prints them as a monolithic structure to realize specific functions. This review presents a conceptual understanding of gradient properties, covering an overview of current techniques and materials that can produce gradient structures, as well as their limitations and challenges. The principle of digital light processing (DLP) technology and feasible strategies for 3D gradient printing to overcome any barriers are also presented. Additionally, this review discusses the promising future of 4D bioprinting systems based on DLP printing.

Oribron: An Origami-Inspired Deformable Rigid Bronchoscope for Radial Support

The structure of a traditional rigid bronchoscope includes proximal, distal, and body, representing an important means to treat hypoxic diseases. However, the body structure is too simple, resulting in the utilization rate of oxygen being usually low. In this work, we reported a deformable rigid bronchoscope (named Oribron) by adding a Waterbomb origami structure to the body. The Waterbomb's backbone is made of films, and the pneumatic actuators are placed inside it to achieve rapid deformation at low pressure. Experiments showed that Waterbomb has a unique deformation mechanism, which can transform from a small-diameter configuration (#1) to a large-diameter configuration (#2), showing excellent radial support capability. When Oribron entered or left the trachea, the Waterbomb remained in #1. When Oribron is working, the Waterbomb transforms from #1 to #2. Since #2 reduces the gap between the bronchoscope and the tracheal wall, it effectively slows down the rate of oxygen loss, thus promoting the absorption of oxygen by the patient. Therefore, we believe that this work will provide a new strategy for the integrated development of origami and medical devices.

Microfabrication of functional polyimide films and microstructures for flexible MEMS applications

Polyimides are widely used in the MEMS and flexible electronics fields due to their combined physicochemical properties, including high thermal stability, mechanical strength, and chemical resistance values. In the past decade, rapid progress has been made in the microfabrication of polyimides. However, enabling technologies, such as laser-induced graphene on polyimide, photosensitive polyimide micropatterning, and 3D polyimide microstructure assembly, have not been reviewed from the perspective of polyimide microfabrication. The aims of this review are to systematically discuss polyimide microfabrication techniques, which cover film formation, material conversion, micropatterning, 3D microfabrication, and their applications. With an emphasis on polyimide-based flexible MEMS devices, we discuss the remaining technological challenges in polyimide fabrication and possible technological innovations in this field.

Three-dimensional ori-kirigami metamaterials with multistability

Ori-kirigami structures offer a good avenue for designing mechanical metamaterials due to their unique advantage of being independent of material properties and scale limitations. Recently, the scientific community has been greatly interested in exploiting the complex energy landscape of ori-kirigami structures to construct multistable systems and play their valuable role in different applications. Here, we present three-dimensional ori-kirigami structures based on generalized waterbomb units, a cylindrical ori-kirigami structure based on waterbomb units, and a conical ori-kirigami structure based on trapezoidal waterbomb units. We investigate the inherent relationships between the unique kinematics and mechanical properties of these three-dimensional ori-kirigami structures and explore their potential usage as mechanical metamaterials that exhibit negative stiffness, snap-through, hysteresis effects, and multistability. What makes the structures even more attractive is their massive folding stroke, where the conical ori-kirigami structure can obtain a huge folding stroke of more than twice its initial height through penetration of its upper and lower boundaries. This study forms the foundation for designing and constructing three-dimensional ori-kirigami metamaterials based on generalized waterbomb units for various engineering applications.

4D-Printed Soft and Stretchable Self-Folding Cuff Electrodes for Small-Nerve Interfacing

Peripheral nerve interfacing (PNI) has a high clinical potential for treating various diseases, such as obesity or diabetes. However, currently existing electrodes present challenges to the interfacing procedure, which limit their clinical application, in particular, when targeting small peripheral nerves (<200 µm). To improve the electrode handling and implantation, a nerve interface that can fold itself to a cuff around a small nerve, triggered by the body moisture during insertion, is fabricated. This folding is achieved by printing a bilayer of a flexible polyurethane printing resin and a highly swelling sodium acrylate hydrogel using photopolymerization. When immersed in an aqueous liquid, the hydrogel swells and folds the electrode softly around the nerve. Furthermore, the electrodes are robust, can be stretched (>20%), and bent to facilitate the implantation due to the use of soft and stretchable printing resins as substrates and a microcracked gold film as conductive layer. The straightforward implantation and extraction of the electrode as well as stimulation and recording capabilities on a small peripheral nerve in vivo are demonstrated. It is believed that such simple and robust to use self-folding electrodes will pave the way for bringing PNI to a broader clinical application.

Shape Morphing by Topological Patterns and Profiles in Laser-Cut Liquid Crystal Elastomer Kirigami

Programming shape changes in soft materials requires precise control of the directionality and magnitude of their mechanical response. Among ordered soft materials, liquid crystal elastomers (LCEs) exhibit remarkable and programmable shape shifting when their molecular order changes. In this work, we synthesized, remotely programmed, and modeled reversible and complex morphing in monolithic LCE kirigami encoded with predesigned topological patterns in its microstructure. We obtained a rich variety of out-of-plane shape transformations, including auxetic structures and undulating morphologies, by combining different topological microstructures and kirigami geometries. The spatiotemporal shape-shifting behaviors are well recapitulated by elastodynamics simulations, revealing that the complex shape changes arise from integrating the custom-cut geometry with local director profiles defined by topological defects inscribed in the material. Different functionalities, such as a bioinspired fluttering butterfly, a flower bud, dual-rotation light mills, and dual-mode locomotion, are further realized. Our proposed LCE kirigami with topological patterns opens opportunities for the future development of multifunctional devices for soft robotics, flexible electronics, and biomedicine.

3D printing of hollow geometries using blocking liquid substitution stereolithography

Micrometer scale arbitrary hollow geometries within a solid are needed for a variety of applications including microfluidics, thermal management and metamaterials. A major challenge to 3D printing hollow geometries using stereolithography is the ability to retain empty spaces in between the solidified regions. In order to prevent unwanted polymerization of the trapped resin in the hollow spaces-known as print-through-significant constraints are generally imposed on the primary process parameters such as resin formulation, exposure conditions and layer thickness. Here, we report on a stereolithography process which substitutes the trapped resin with a UV blocking liquid to mitigate print-through. We investigate the mechanism of the developed process and determine guidelines for the formulation of the blocking liquid. The reported method decouples the relationship between the primary process parameters and their effect on print-through. Without having to optimize the primary process parameters to reduce print-through, hollow heights that exceed the limits of conventional stereolithography can be realized. We demonstrate fabrication of a variety of complex hollow geometries with cross-sectional features ranging from tens of micrometer to hundreds of micrometers in size. With the framework presented, this method may be employed for 3D printing functional hollow geometries for a variety of applications, and with improved freedom over the printing process (e.g. material choices, speed and resulting properties of the printed parts).

Three-dimensional printing of smart constructs using stimuli-responsive biomaterials: A future direction of precision medicine

Three-dimensional (3D) printing, which is a valuable technique for the fabrication of tissue-engineered constructs and biomedical devices with complex architectures, has brought about considerable progress in regenerative medicine, drug delivery, and diagnosis of diseases. However, because of the static and inanimate properties of conventional 3D-printed structures, it is difficult to use them in therapies for active and precise medicine, such as improved tissue regeneration, targeted or controlled drug delivery, and advanced pathophysiological monitoring. The integration of stimuli-responsive biomaterials into 3D printing provides a potential strategy for designing and building smart constructs that exhibit programmed functions and controllable changes in properties in response to exogenous and autogenous stimuli. These features make 3D-printed smart constructs the next generation of tissue-engineered products. In this review, we introduce the prevalent 3D printing techniques (with an emphasis on the differences between 3D printing and bioprinting, and biomaterials and bioink), the working principle of each technique, and the advantages of using 3D printing for the fabrication of smart constructs. Stimuli-responsive biomaterials that are widely used for 3D printing of smart constructs are categorized, followed by a summary of their applications in tissue regeneration, drug delivery, and biosensors. Finally, the challenges and future perspectives of 3D-printed smart constructs are discussed.

Hollow CoFe-based hybrid composites derived from unique S-modulated coordinated transition bimetal complexes for efficient oxygen evolution from water splitting under alkaline conditions

The oxygen evolution reaction (OER) is an important reaction in water splitting. However, the high cost and slow-rate catalysts hinder commercial applications. Although an important process for manufacturing of hollow structures, it is difficult to construct complicated hollow structures with an excellent and regulable shape for multi-component materials. In this study, we demonstrate that sulfur-Co,Fe bimetallic nitrogen carbon hollow composite hybrids (x-S-CoFe@NC) can be synthesized by regulating the amount of sulfur and using the hydrothermal method. For OER, 32-S-CoFe@NC exhibits excellent electrocatalytic activity with a low overpotential of 232 mV, which is higher than those of 0-S-CoFe@NC (270 mV), 23-S-CoFe@NC (247 mV), and RuO₂ (243 mV) catalysts at 10 mA cm^-2. In addition, with air as the cathode, a rechargeable Zn-air battery with outstanding long-life cycling stability for 80 hours based on 32-CoFe@NC + Pt/C is proposed. The advanced technique described here supplies a new route for preparing hollow transition bimetal carbon hybrids with an adjustable composite arrangement for electrocatalysis and water splitting.

Assembly of complex 3D structures and electronics on curved surfaces

Electronic devices with engineered three-dimensional (3D) architectures are indispensable for frictional-force sensing, wide-field optical imaging, and flow velocity measurement. Recent advances in mechanically guided assembly established deterministic routes to 3D structures in high-performance materials, through controlled rolling/folding/buckling deformations. The resulting 3D structures are, however, mostly formed on planar substrates and cannot be transferred directly onto another curved substrate. Here, we introduce an ordered assembly strategy to allow transformation of 2D thin films into sophisticated 3D structures on diverse curved surfaces. The strategy leverages predefined mechanical loadings that deform curved elastomer substrates into flat/cylindrical configurations, followed by an additional uniaxial/biaxial prestretch to drive buckling-guided assembly. Release of predefined loadings results in an ordered assembly that can be accurately captured by mechanics modeling, as illustrated by dozens of complex 3D structures assembled on curved substrates. Demonstrated applications include tunable dipole antennas, flow sensors inside a tube, and integrated electronic systems capable of conformal integration with the heart.

Recent advances in bioprinting using silk protein-based bioinks

3D printing has experienced swift growth for biological applications in the field of regenerative medicine and tissue engineering. Essential features of bioprinting include determining the appropriate bioink, printing speed mechanics, and print resolution while also maintaining cytocompatibility. However, the scarcity of bioinks that provide printing and print properties and cell support remains a limitation. Silk Fibroin (SF) displays exceptional features and versatility for inks and shows the potential to print complex structures with tunable mechanical properties, degradation rates, and cytocompatibility. Here we summarize recent advances and needs with the use of SF protein from Bombyx mori silkworm as a bioink, including crosslinking methods for extrusion bioprinting using SF and the maintenance of cell viability during and post bioprinting. Additionally, we discuss how encapsulated cells within these SF-based 3D bioprinted constructs are differentiated into various lineages such as skin, cartilage, and bone to expedite tissue regeneration. We then shift the focus towards SF-based 3D printing applications, including magnetically decorated hydrogels, in situ bioprinting, and a next-generation 4D bioprinting approach. Future perspectives on improvements in printing strategies and the use of multicomponent bioinks to improve print fidelity are also discussed.

Digital Light Processing 3D Printing of Tough Supramolecular Hydrogels with Sophisticated Architectures as Impact-Absorption Elements

Processing tough hydrogels into sophisticated architectures is crucial for their applications as structural elements. However, Digital Light Processing (DLP) printing of tough hydrogels is challenging because of the low-speed gelation and toughening process. Described here is a simple yet versatile system suitable for DLP printing to form tough hydrogel architectures. The aqueous precursor consists of commercial photoinitiator, acrylic acid, and zirconium ion (Zr⁴⁺ ), readily forming tough metallo-supramolecular hydrogel under digital light because of in situ formation of carboxyl-Zr⁴⁺ coordination complexes. The high-stiffness and antiswelling properties of as-printed gel enable high-efficiency printing to form high-fidelity constructs. Furthermore, swelling-induced morphing of the gel is also achieved by encoding structure gradients during the printing with grayscale digital light. Mechanical properties of the printed hydrogels are further improved after incubation in water due to the variation of local pH and rearrangement of coordination complex. The swelling-enhanced stiffness affords the printed hydrogel with shape fixation ability after manual deformations, and thereby provides an additional avenue to form more complex configurations. These printed hydrogels are used to devise an impact-absorption element or a high-sensitivity pressure sensor as proof-of-concept examples. This work should merit engineering of other tough gels and extend their scope of applications in diverse fields.

A Review of Multi-Material 3D Printing of Functional Materials via Vat Photopolymerization

Additive manufacturing or 3D printing of materials is a prominent process technology which involves the fabrication of materials layer-by-layer or point-by-point in a subsequent manner. With recent advancements in additive manufacturing, the technology has excited a great potential for extension of simple designs to complex multi-material geometries. Vat photopolymerization is a subdivision of additive manufacturing which possesses many attractive features, including excellent printing resolution, high dimensional accuracy, low-cost manufacturing, and the ability to spatially control the material properties. However, the technology is currently limited by design strategies, material chemistries, and equipment limitations. This review aims to provide readers with a comprehensive comparison of different additive manufacturing technologies along with detailed knowledge on advances in multi-material vat photopolymerization technologies. Furthermore, we describe popular material chemistries both from the past and more recently, along with future prospects to address the material-related limitations of vat photopolymerization. Examples of the impressive multi-material capabilities inspired by nature which are applicable today in multiple areas of life are briefly presented in the applications section. Finally, we describe our point of view on the future prospects of 3D printed multi-material structures as well as on the way forward towards promising further advancements in vat photopolymerization.

Application and Prospects of Hydrogel Additive Manufacturing

Hydrogel has become a commonly used material for 3D and 4D printing due to its favorable biocompatibility and low cost. Additive manufacturing, also known as 3D printing, was originally referred to as rapid prototyping manufacturing. Variable-feature rapid prototyping technology, also known as 4D printing, is a combination of materials, mathematics, and additives. This study constitutes a literature review to address hydrogel-based additive manufacturing technologies, introducing the characteristics of commonly used 3D printing hydrogel methods, such as direct ink writing, fused deposition modeling, and stereolithography. With this review, we also investigated the stimulus types, as well as the advantages and disadvantages of various stimulus-responsive hydrogels in smart hydrogels; non-responsive hydrogels; and various applications of additive manufacturing hydrogels, such as neural catheter preparation and drug delivery. The opportunities, challenges, and future prospects of hydrogel additive manufacturing technologies are discussed.

Plant-inspired TransfOrigami microfluidics

The healthy functioning of the plants' vasculature depends on their ability to respond to environmental changes. In contrast, synthetic microfluidic systems have rarely demonstrated this environmental responsiveness. Plants respond to environmental stimuli through nastic movement, which inspires us to introduce transformable microfluidics: By embedding stimuli-responsive materials, the microfluidic device can respond to temperature, humidity, and light irradiance. Furthermore, by designing a foldable geometry, these responsive movements can follow the preset origami transformation. We term this device TransfOrigami microfluidics (TOM) to highlight the close connection between its transformation and the origami structure. TOM can be used as an environmentally adaptive photomicroreactor. It senses the environmental stimuli and feeds them back positively into photosynthetic conversion through morphological transformation. The principle behind this morphable microsystem can potentially be extended to applications that require responsiveness between the environment and the devices, such as dynamic artificial vascular networks and shape-adaptive flexible electronics.

Bio-Inspired Bianisotropic Magneto-Sensitive Elastomers with Excellent Multimodal Transformation

Magneto-sensitive soft materials that can accomplish fast, remote, and reversible shape morphing are highly desirable for practical applications including biomedical devices, soft robotics, and flexible electronics. In conventional magneto-sensitive elastomers (MSEs), there is a tradeoff between employing hard magnetic particles with costly magnetic programming and utilizing soft magnetic particle chains causing tedious and small deformation. Here, inspired by the shape and movement of mimosa, a novel soft magnetic particle doped shape material bianisotropic magneto-sensitive elastomer (SM bianisotropic MSE) with multimodal transformation and superior deformability is developed. The high-aspect-ratio shape anisotropy and the material anisotropy in which the magnetic particles are arranged in a chainlike structure together impart magnetic anisotropy to the SM bianisotropic MSE. A magneto-elastic analysis model is proposed, and it is elucidated that magnetic anisotropy leads to peculiar field-direction-dependent multimodal transformation. More importantly, a quadrilateral assembly and a regular hexagon assembly based on this SM bianisotropic MSE are designed, and they exhibit 2.4 and 1.7 times the deformation capacity of shape anisotropic samples, respectively. By exploiting the multidegree of freedom and excellent deformability of the SM bianisotropic MSE, flexible logic switches and ultrasoft magnetic manipulators are further demonstrated, which prove its potential applications in future intelligent flexible electronics and autonomous soft robotics.

Emerging 4D Printing Strategies for Next-Generation Tissue Regeneration and Medical Devices

The rapid development of 3D printing has led to considerable progress in the field of biomedical engineering. Notably, 4D printing provides a potential strategy to achieve a time-dependent physical change within tissue scaffolds or replicate the dynamic biological behaviors of native tissues for smart tissue regeneration and the fabrication of medical devices. The fabricated stimulus-responsive structures can offer dynamic, reprogrammable deformation or actuation to mimic complex physical, biochemical, and mechanical processes of native tissues. Although there is notable progress made in the development of the 4D printing approach for various biomedical applications, its more broad-scale adoption for clinical use and tissue engineering purposes is complicated by a notable limitation of printable smart materials and the simplistic nature of achievable responses possible with current sources of stimulation. In this review, the recent progress made in the field of 4D printing by discussing the various printing mechanisms that are achieved with great emphasis on smart ink mechanisms of 4D actuation, construct structural design, and printing technologies, is highlighted. Recent 4D printing studies which focus on the applications of tissue/organ regeneration and medical devices are then summarized. Finally, the current challenges and future perspectives of 4D printing are also discussed.

Light-Induced Topological Patterning toward 3D Shape-Reconfigurable Origami

Shape-reconfigurable materials are crucial in many engineering applications. However, because of their isotropic deformability, they often require complex molding equipment for shaping. A polymeric origami structure that follows predetermined deformed and non-deformed patterns at specific temperatures without molding is demonstrated. It is constructed with a heterogeneous (dynamic and static) network topology via light-induced programming. The corresponding spatio-selective thermal plasticity creates varied deformability within a single polymer. The kinematics of site-specific deformation allows guided origami deployment in response to external forces. Moreover, the self-locking origami can fix its geometry in specific states without pressurization. These features enable the development of shape-reconfigurable structures that undergo on-demand geometry changes without requiring bulky or heavy equipment. The concept enriches polymer origamis, and could be applied with other polymers having similar chemistries. Overall, it is a versatile material for artificial muscles, origami robotics, and non-volatile mechanical memory devices.

Programming Soft Shape-Morphing Systems by Harnessing Strain Mismatch and Snap-Through Bistability: A Review

Multi-modal and controllable shape-morphing constitutes the cornerstone of the functionalization of soft actuators/robots. Involving heterogeneity through material layout is a widely used strategy to generate internal mismatches in active morphing structures. Once triggered by external stimuli, the entire structure undergoes cooperative deformation by minimizing the potential energy. However, the intrinsic limitation of soft materials emerges when it comes to applications such as soft actuators or load-bearing structures that require fast response and large output force. Many researchers have explored the use of the structural principle of snap-through bistability as the morphing mechanisms. Bistable or multi-stable mechanical systems possess more than one local energy minimum and are capable of resting in any of these equilibrium states without external forces. The snap-through motion could overcome energy barriers to switch among these stable or metastable states with dramatically distinct geometries. Attributed to the energy storage and release mechanism, such snap-through transition is quite highly efficient, accompanied by fast response speed, large displacement magnitude, high manipulation strength, and moderate driving force. For example, the shape-morphing timescale of conventional hydrogel systems is usually tens of minutes, while the activation time of hydrogel actuators using the elastic snapping instability strategy can be reduced to below 1 s. By rationally embedding stimuli-responsive inclusions to offer the required trigger energy, various controllable snap-through actuations could be achieved. This review summarizes the current shape-morphing programming strategies based on mismatch strain induced by material heterogeneity, with emphasis on how to leverage snap-through bistability to broaden the applications of the shape-morphing structures in soft robotics and mechanical metamaterials.

Flexible Sensory Systems: Structural Approaches

Biology is characterized by smooth, elastic, and nonplanar surfaces; as a consequence, soft electronics that enable interfacing with nonplanar surfaces allow applications that could not be achieved with the rigid and integrated circuits that exist today. Here, we review the latest examples of technologies and methods that can replace elasticity through a structural approach; these approaches can modify mechanical properties, thereby improving performance, while maintaining the existing material integrity. Furthermore, an overview of the recent progress in wave/wrinkle, stretchable interconnect, origami/kirigami, crack, nano/micro, and textile structures is provided. Finally, potential applications and expected developments in soft electronics are discussed.

Vat Photopolymerization Additive Manufacturing of Functionally Graded Materials: A Review

Functionally Graded Materials (FGMs) offer discrete or continuously changing properties/compositions over the volume of the parts. The widespread application of FGMs was not rapid enough in the past due to limitations of the manufacturing methods. Significant developments in manufacturing technologies especially in Additive Manufacturing (AM) enable us nowadays to manufacture materials with specified changes over the volume/surface of components. The use of AM methods for the manufacturing of FGMs may allow us to compensate for some drawbacks of conventional methods and to produce complex and near-net-shaped structures with better control of gradients in a cost-efficient way. Vat Photopolymerization (VP), a type of AM method that works according to the principle of curing liquid photopolymer resin layer-by-layer, has gained in recent years high importance due to its advantages such as low cost, high surface quality control, no need to support structures, no limitation in the material. This article reviews the state-of-art and future potential of using VP methods for FGM manufacturing. It was concluded that improvements in printer hardware setup and software, design aspects and printing methodologies will accelerate the use of VP methods for FGMs manufacturing.

Engineering Stress in Thin Films: An Innovative Pathway Toward 3D Micro and Nanosystems

Transformation of conventional 2D platforms into unusual 3D configurations provides exciting opportunities for sensors, electronics, optical devices, and biological systems. Engineering material properties or controlling and modulating stresses in thin films to pop-up 3D structures out of standard planar surfaces has been a highly active research topic over the last decade. Implementation of 3D micro and nanoarchitectures enables unprecedented functionalities including multiplexed, monolithic mechanical sensors, vertical integration of electronics components, and recording of neuron activities in 3D organoids. This paper provides an overview on stress engineering approaches to developing 3D functional microsystems. The paper systematically presents the origin of stresses generated in thin films and methods to transform a 2D design into an out-of-plane configuration. Different types of 3D micro and nanostructures, along with their applications in several areas are discussed. The paper concludes with current technical challenges and potential approaches and applications of this fast-growing research direction.

Suppressing the Step Effect of 3D Printing for Constructing Contact Lenses

3D printing has been considered as a sustainable method to construct complicated 3D structures. However, the step effect induced by the traditional point-by-point or layer-by-layer additive manufacturing mode inevitably occurs and remains an obstacle to realizing the smoothness and uniformity of 3D samples. Here, a continuous liquid film confined 3D printing strategy is proposed to fabricate high-precision 3D structures based on the Digital Light Processing (DLP) technology. With the control of the confinement of the liquid-solid interface and the continuous printing mode, liquid film adhering to the cured structure is sucked into the cured layer structures with excess resin adhering to the cured structure scraping off, where the step effect is eliminated and post-washing is avoided. The morphology and dimension of the confined liquid film can be well regulated by ink properties and printing parameters to optimize the surface smoothness and printing fidelity. In addition, heat accumulation and thermal diffusion are also suppressed, ensuring the long-term printing stability. A centimeter-scale contact lens structure with central thickness of ≈135 µm comparable to commercial ones can be printed, which possesses extreme smoothness (sub 1.3 nm), homogeneous mechanical characteristic, biocompatibility, and high optical properties with imaging resolution of up to 228.1 lp mm^-1 .

Light activation of 3D-printed structures: from millimeter to sub-micrometer scale

Three-dimensional (3D) printing enables the fabrication of complex, highly customizable structures, which are difficult to fabricate using conventional fabrication methods. Recently, the concept of four-dimensional (4D) printing has emerged, which adds active and responsive functions to 3D-printed structures. Deployable or adaptive structures with desired structural and functional changes can be fabricated using 4D printing; thus, 4D printing can be applied to actuators, soft robots, sensors, medical devices, and active and reconfigurable photonic devices. The shape of 3D-printed structures can be transformed in response to external stimuli, such as heat, light, electric and magnetic fields, and humidity. Light has unique advantages as a stimulus for active devices because it can remotely and selectively induce structural changes. There have been studies on the light activation of nanomaterial composites, but they were limited to rather simple planar structures. Recently, the light activation of 3D-printed complex structures has attracted increasing attention. However, there has been no comprehensive review of this emerging topic yet. In this paper, we present a comprehensive review of the light activation of 3D-printed structures. First, we introduce representative smart materials and general shape-changing mechanisms in 4D printing. Then, we focus on the design and recent demonstration of remote light activation, particularly detailing photothermal activations based on nanomaterial composites. We explain the light activation of 3D-printed structures from the millimeter to sub-micrometer scale.

Recent Progress in Active Mechanical Metamaterials and Construction Principles

Active mechanical metamaterials (AMMs) (or smart mechanical metamaterials) that combine the configurations of mechanical metamaterials and the active control of stimuli-responsive materials have been widely investigated in recent decades. The elaborate artificial microstructures of mechanical metamaterials and the stimulus response characteristics of smart materials both contribute to AMMs, making them achieve excellent properties beyond the conventional metamaterials. The micro and macro structures of the AMMs are designed based on structural construction principles such as, phase transition, strain mismatch, and mechanical instability. Considering the controllability and efficiency of the stimuli-responsive materials, physical fields such as, the temperature, chemicals, light, electric current, magnetic field, and pressure have been adopted as the external stimuli in practice. In this paper, the frontier works and the latest progress in AMMs from the aspects of the mechanics and materials are reviewed. The functions and engineering applications of the AMMs are also discussed. Finally, existing issues and future perspectives in this field are briefly described. This review is expected to provide the basis and inspiration for the follow-up research on AMMs.

3D-to-3D Microscale Shape-Morphing from Configurable Helices with Controlled Chirality

Tunable and reconfigurable materials with autonomic shape transformation in response to the environment have emerged as one of the most promising approaches for a variety of biomedical applications, such as tissue engineering, biosensing, and in vivo biomedical devices. Currently, it is still quite challenging to fabricate soft, microscaled 3D shape-reconfigurable structures due to either complicated microfabrication or limited microscale photopolymerization-based printing approaches to enable adaptive shape transformation. Here, a one-step photo-cross-linking approach has been demonstrated to obtain a 3D-to-3D morphological transformable microhelix from a self-rolled hydrogel microsheet, resulting in chirality conversion. It was enabled by a custom-designed "hard" stripe/"soft" groove topography on the microsheets for introducing, which introduced both in-planar and out-of-planar anisotropies. Both experiment and simulation confirmed that a stripe/groove geometry can effectively control the 3D transformation by activating in-planar or/and out-of-planar mismatch stress within the microsheets, resulting in switching of the rolling direction between perpendicular/parallel to the length of the stripe. Furthermore, versatile 3D microconstructs with the ability to transform between two distinct 3D configurations have been achieved based on controlled rolling of microhelices, demonstrated as "windmill"-to-"T-cross" and "cylinder"-to-"scroll" transformations and dynamic blossoming of biomimetic orchids. In contrast to conventional 2D-to-3D micro-origami, we have successfully demonstrated an approach for fabricating microscale, all-soft-material-based constructs with autonomic 3D-to-3D structural transformation, which presents an opportunity for designing more complex hydrogel-based microrobotics.

Ultrafast Digital Fabrication of Designable Architectured Liquid Crystalline Elastomer

The muscle-like activities of liquid crystalline elastomers (LCEs) offer great potential for designing future soft machines. Their motion complexity, however, relies on inflexible and cumbersome mesogen alignment techniques. Here, a digital photocuring method for ultrafast template-free fabrication of LCE artificial muscles capable of designable complex motions is reported. This method utilizes the intrinsic light attenuation in the through-plane direction to create mesogen alignment for reversible bending action. To turn this simple actuation into complex motions, the principles of muscles are borrowed which realize diverse motions through the cooperative actions of otherwise simple contraction/expansion of individual muscle bundles. Specifically, the spatiotemporal digital light is utilized to design LCE architectures composed of strategically arranged bending modules. As such, LCE capable of highly designable motions can be fabricated within 25 s light curing without employing any physical alignment templates, which offers an attractive option toward designing functionally diverse soft machines.

Unconstrained 3D Shape Programming with Light-Induced Stress Gradient

Programming 2D sheets to form 3D shapes is significant for flexible electronics, soft robots, and biomedical devices. Stress regulation is one of the most used methods, during which external force is usually needed to keep the stress, leading to complex processing setups. Here, by introducing dynamic diselenide bonds into shape-memory materials, unconstrained shape programming with light is achieved. The material could hold and release internal stress by themselves through the shape-memory effect, simplifying programming setups. The fixed stress could be relaxed by light to form stress gradients, leading to out-of-plane deformations through asymmetric contractions. Benefiting from the variability of light irradiation, complex 3D configurations can be obtained conveniently from 2D polymer sheets. Besides, remotely controlled "4D assembly" and actuation, including object transportation and self-lifting, can be achieved by sequential deformation. Taking advantage of the high spatial resolution of light, this material can also produce 3D microscopic patterns. The light-induced stress gradients significantly simplify 3D shape programming procedures with improved resolution and complexity and have great potential in soft robots, smart actuators, and anti-counterfeiting techniques.

Stretchable origami robotic arm with omnidirectional bending and twisting

Inspired by the embodied intelligence observed in octopus arms, we introduce magnetically controlled origami robotic arms based on Kresling patterns for multimodal deformations, including stretching, folding, omnidirectional bending, and twisting. The highly integrated motion of the robotic arms is attributed to inherent features of the reconfigurable Kresling unit, whose controllable bistable deploying/folding and omnidirectional bending are achieved through precise magnetic actuation. We investigate single- and multiple-unit robotic systems, the latter exhibiting higher biomimetic resemblance to octopus' arms. We start from the single Kresling unit to delineate the working mechanism of the magnetic actuation for deploying/folding and bending. The two-unit Kresling assembly demonstrates the basic integrated motion that combines omnidirectional bending with deploying. The four-unit Kresling assembly constitutes a robotic arm with a larger omnidirectional bending angle and stretchability. With the foundation of the basic integrated motion, scalability of Kresling assemblies is demonstrated through distributed magnetic actuation of double-digit number of units, which enables robotic arms with sophisticated motions, such as continuous stretching and contracting, reconfigurable bending, and multiaxis twisting. Such complex motions allow for functions mimicking octopus arms that grasp and manipulate objects. The Kresling robotic arm with noncontact actuation provides a distinctive mechanism for applications that require synergistic robotic motions for navigation, sensing, and interaction with objects in environments with limited or constrained access. Based on small-scale Kresling robotic arms, miniaturized medical devices, such as tubes and catheters, can be developed in conjunction with endoscopy, intubation, and catheterization procedures using functionalities of object manipulation and motion under remote control.

Shape-Deformed Mushroom-like Reentrant Structures for Robust Liquid-Repellent Surfaces

Artificial liquid-repellent surfaces inspired by biomimetic structures provide a wide range of functional surfaces for various practical applications, such as self-cleaning, antisticking, oil/water separation, and droplet manipulation. However, functional biomimetic structures cannot be fabricated using conventional techniques. For example, mushroom-like topologies on the skin of springtails, which are referred to as "doubly reentrant structures," have attracted significant attention owing to their extraordinary liquid-repellent properties. Current methods of fabricating these reentrant structures have several limitations, such as complex material systems, processing steps, and additional chemical treatments. This study proposed a simple micro-shape-deformed approach to fabricate mushroom-like reentrant structures by digital light processing, a three-dimensional (3D) printing technique, with volumetric shrinkage. The nonuniform cross-linking process and light propagation during photopolymerization caused the deformation of the topological patterns atop the micropillar arrays, resulting in bent structures for mushroom-like shape-deformed microarchitectures. This 3D-printed shape-deformed microstructure exhibits a highly stable liquid repellency without perfluorinated coatings.

Direct 2D-to-3D transformation of pen drawings

Pen drawing is a method that allows simple, inexpensive, and intuitive two-dimensional (2D) fabrication. To integrate such advantages of pen drawing in fabricating 3D objects, we developed a 3D fabrication technology that can directly transform pen-drawn 2D precursors into 3D geometries. 2D-to-3D transformation of pen drawings is facilitated by surface tension-driven capillary peeling and floating of dried ink film when the drawing is dipped into an aqueous monomer solution. Selective control of the floating and anchoring parts of a 2D precursor allowed the 2D drawing to transform into the designed 3D structure. The transformed 3D geometry can then be fixed by structural reinforcement using surface-initiated polymerization. By transforming simple pen-drawn 2D structures into complex 3D structures, our approach enables freestyle rapid prototyping via pen drawing, as well as mass production of 3D objects via roll-to-roll processing.

Voxel based method for predictive modelling of solidification and stress in digital light processing based additive manufacture

A method for predicting the solidification and stress of a digital light processing 3D print process is presented, using a voxel-based, multi-layer model to predict the degree of polymerization of the material at every stage during the print. Additive manufacturing offers extremely short development cycles, making predictive modelling of the complex chemical and mechanical interactions of photo-polymerization during part construction unappealing compared to iterative work-flows. Accurate predictions of stress, and the impact of the print parameters and post-print process upon stress, become increasingly important for 3D printing micro-scale electrical and mechanical systems as we design resonators and conductive layers. The process uses a simple method of printed cantilevers to calibrate the stress from various print processes such as propagation of the polymerization front and polymerization gradient. The model is found to have good predictive value and is capable of stress and solidification prediction from a computer aided design file.