An accurate finite element approach for programming 4D-printed self-morphing structures produced by fused deposition modeling

Abstract

Fused deposition modeling (FDM) is a commonly used three-dimensional (3D) printing technology that can program shape memory polymers (SMPs) with performance-driven self-deforming functions. Deformation programming of four-dimensional (4D) printed models is particularly important for many applications. The purpose of this study was to develop an accurate simulation method for FDM-printed monolayer SMP models based on the secondary development of ABAQUS software, which could accurately and simply simulate the deformation processes of various pre-programmed structures. The constitutive function of SMPs used in engineering applications was developed to describe their thermo-mechanical parameters. Based on the constitutive model, the degree and mode of model deformation due to external temperature were simulated by configuring the anisotropic pre-strain stored in the printed model. As a result, the deformation of the SMP models controlled by structural parameters was consistent with the simulation results. The self-folding origami structures controlled by structural factors were designed by the proposed simulation method. The origami structures folded according to the predicted deformation angle and direction under thermal stimulation. Verifiably, this method was able to accurately simulate the deformations of complex 3D models with different structural parameters. This work can advance the development of FDM printed pre-programmed self-deformed SMP structure.