Design and Development of Thermoformable Shape

Memory Polymer Based Components

A state-of-the-art report submitted.
In partial fulfilment of the requirement for the award of the degree
Of
Master of Technology
In
Computer Aided Design and Manufacturing
By
Ashutosh S. Chaudhari
Reg No. 2022CC09
Dr. V.R. Komma, Associate Professor

DEPARMENT OF MECHANICAL ENGINEERING

MOTILAL NEHRU NATIONAL INSTITUTE OF TECHNOLOGY
ALLAHABAD, PRAYAGRAJ- 211004
NOVEMBER- 2023

1
 ABSTRACT

The objective of the state of art is to review the literature related to recent development in

Additive Manufacturing field and its application in 4D Printing of Smart Polymers based

thermoformable orthopaedic devices. Aim of this project is to overcome the limitations of the

conventional POP and fiberglass cast as well as introduce a methodology to improve the

additional user-centric metrics such as comfort, aesthetics, etc and reduce currently required

time and complexity for printing. 3D printing is the process of layer-by-layer addition of

material and producing product, utilizing inherent properties of the material in this case heat

responsiveness printed structure can be modified with time using a stimulus or trigger this

process called 4D printing opens new avenues in the field of biomedical, soft robotics and

many more. In this literature design and printing of initially flat shaped fracture cast model

was done and then transformed into a cast by wrapping into user’s hand using heating by

Magnetic inductive heating. It can be observed that whole process can be optimised using this

methodology.

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 CONTENTS

Contents Page No.

CHAPTER 1. INTRODUCTION`
1.1 Additive Manufacturing.....................................................................................................5
1.2 Classification of 3D Printing Technology……………………………………………..6
1.3 Bioprinting…………………………...............................................................................8
1.4 4D Printing……………….………………………………………………………….......8
1.5 Smart Materials……………………………………………………………………………9
1.6 Thermo-Responsive SMM………………………………………………………………….10

CHAPTER 2. APPLICATION OF 4D PRINTING

…2.1 Biomedical Field.............................................................................................................12
…2.2 Fracture Cast...........................................................................................................................12

CHAPTER. 3 LITERATURE REVIEW

3.1 Literature review on Design Methodology.....................................................................14
3.2 Literature review on Material Selection Process …………………………………...….
….14
3.3 Literature review on FEA analysis of fracture cast …………………...…………………..15
3.4 Research Gaps ...............................................................................................................17
3.5 Motivation......................................................................................................................18
3.6 Objective of Thesis Work………………………………………………………………18
3.4 Thesis Work Plan............................................................................................................19

REFERENCES……………………………………………………………………………….20

3
 LIST OF FIGURES

Figure 1.1. Additive manufacturing process chain [24] ……………………………………. 5

Figure 1.2. Fused Deposition Modeling based printing [23] ………………………………..6
Figure 1.3. The differences between 3D printing and 4D printing processes [22] …………9
Figure 1.4. Classification of SMP’s based on Stimuli [2] ………………………………….11

Figure 2.1. Applications of 4D printing. ………………..………………………………….12

Figure 2.2. (a) Conventional plaster and (b) Custom designed 3D printed plaster…………13

Figure 3.1 Flowchart of Thesis work………………………………………………………..19

LIST OF TABLES

Table 1. Summary of Literature……………………………………………………………..16

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CHAPTER 1

INTRODUCTION

1.1. Additive Manufacturing

The term "additive manufacturing" (AM) refers to a technique that uses digital 3D data to

build up a component layer by depositing material. AM and 3D printing are frequently used

interchangeably. 3D printing is a cutting-edge procedure that constructs products layer by

layer, as opposed to typical subtractive manufacturing processes, which involve cutting raw

material and machining to a desired precision level to achieve a desired shape. This method

has gained popularity in recent years because to the accessibility of CAD/CAM software,

advancements in automation and technology, an expanding selection of printable materials,

and user-driven design. This ground-breaking method has been used in a variety of fields,

including biomedicine, soft robotics, aerospace, the automobile industry, civil engineering,

etc. The process follows as model generation in CAD software in which 3D geometry is

defined for the part, and CAD file gets converted to STL file, this conversion from part file to

STL file is done for the Slicing software. Slicing software cuts/divide the entire model in thin

slices according to the requirements and specifications of machine and then sliced STL file is

converted to machine code file (G-code, M-code) file which then transferred to the 3D printer

for printing.

Figure 1.1. Additive manufacturing process chain [24]

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Through 3D printing technology complexity with which we can build the product has

increased immensely. Objects like jet engines, aerospace parts, jewellery, surgical devices,

prosthetic/orthotics, electronics and so on. Available options for the material that can be used

to manufacture a part has increased for example metal, plastics, ceramics, biomaterials,

composites. Using different 3D printers based on different technique of material addition fast

prototypes can be made with much less time hence reducing the product development phase.

Objects with functionally graded or mixed multiple materials are possible. In conventional

manufacturing processes cost/unit reduces as number of units or volume increases but the

trend is opposite for complex and customised parts this limitation is overcome by AM since

cost of production remains constant with changing complexity.

1.2. Classification of 3D Printing Technology

1.2.1. Fused Deposition Modeling (FDM): In this technique filament in form of wire is

fed into the temperature and pressure-controlled nozzle, in the extrusion nozzle

filament gets melted into a semisolid state. By keeping constant pressure inside the

nozzle constant flow of material is achieved. Support structures are needed for this

method.

Figure 1.2. Fused Deposition Modeling based printing [23].

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1.2.2. Vat Photopolymerization: Vat polymerization employs a reservoir containing a liquid

photopolymer resin, from which the model is gradually built layer by layer. To

solidify the resin as needed, an ultraviolet (UV) light is utilized, while a platform

moves the object downwards after each layer is hardened. Unlike powder-based

techniques, which lack material support during the construction stage, this method

relies on the use of liquid to shape objects.

1.2.3. Material Jetting: Material is deposited onto a build platform by means of either a

continuous or Drop on Demand (DOD) method. The material is then jetted onto the

build surface or platform, resulting in its solidification and the subsequent

construction of the model layer by layer. The material layers are exposed to

ultraviolet (UV) light for curing.

1.2.4. Binder Jetting: The binder jetting process utilizes powder-based material and liquid

binder as adhesive between powder layers. The print head deposits alternating layers

of build and binding material along the x and y axes.

1.2.5. Direct Energy Deposition: Directed Energy Deposition (DED) is a integration of

various terminologies such as 'Laser engineered net shaping, directed light

fabrication, direct metal deposition, 3D laser cladding'. It is an intricate additive

manufacturing technique that is frequently employed for the purpose of mending or

augmenting material onto pre-existing components.

1.2.6. Sheet Lamination: Sheet lamination processes include ultrasonic additive

manufacturing and laminated object manufacturing. The Ultrasonic Additive

Manufacturing process uses sheets or ribbons of metal, bound together using

ultrasonic welding. Laminated object manufacturing (LOM) uses a similar layer by

layer approach but uses paper as material and adhesive instead of welding.

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 1.2.7. Powder Bed Fusion: PBF methods fuse powder with laser or electron beam. All PBF

processes involve spreading powder over previous layers. Mechanisms include roller

or blade.

1.3. Bioprinting

Additive manufacturing technology, specifically Material Extrusion (Jetting) Fusion

deposition modeling, is utilized in the production of functional 3D tissues using

biomaterials known as bioinks, which replicate natural tissue compositions. These bioinks

can be derived from various sources, including natural or animal-based materials,

ensuring biocompatibility. Key considerations in this process include maintaining precise

viscosity, controlling the rate of solidification, and managing syringe pressure. This

technology finds applications in printing organ structures, regenerative medicine,

addressing organ transplantation issues, and creating soft tissues. Various software tools

like AutoCAD, Matter Control, Mesh Mixer, Miniaturizer, SolidWorks, and 3D Builder

are employed for design and modeling. However, challenges in this field revolve around

achieving anatomical similarity, modeling complex vascular structures, optimizing

printing parameters, and ensuring functional tissue similarity.

1.4. 4D Printing

4D printing is a process where a 3D printed object transforms into another structure due to

external energy inputs like temperature or light. This technology uses commercial 3D printers

and inputs a smart material, such as hydrogel or shape memory polymer. Smart materials

have thermomechanical properties that allow shape change, distinguishing them from

common 3D printing materials.

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 Figure 1.3. The differences between 3D printing and 4D printing processes [22].

3D printing, on the other hand, creates static structures, while 4D printing introduces time,

allowing controlled shape transformations in response to external stimuli. Shape memory

polymers (SMPs) are a promising choice for 4D printing due to their ability to revert back to

their original shape upon exposure to specific triggers. By merging 4D printing technology

with SMPs, researchers can create structures that undergo programmable, time-dependent

shape changes, enabling the creation of dynamic and functional systems. SMPs are crucial in

biomedical and soft robotics due to their ability to undergo shape transformation in response

to external stimuli, making them ideal for generating dynamic structures.

1.5. Smart Materials

Shape-memory materials (SMMs) are smart featured materials that can remember and

recover their original shape from a significant and seemingly plastic deformation upon a

particular external stimulus such as temperature, magnetic field, electric field, chemical

(moisture, solvent, and pH change), and light (UV and infrared light). SMMs are classified

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into groups of shape-memory alloys (SMAs), shape-memory polymers (SMPs), shape-

memory composites (SMCs), and shape-memory hybrids (SMHs).

1.6. Thermo-responsive SMM

In SMMs, shape memory alloy (SMA) and shape memory polymer (SMP) have been used in

practical applications. These are the smart materials that are responsive to the heat or

temperature stimuli. SMMs are further divided as one-way, two-way, and three-way materials

depending upon the number of shape transformation. In one-way SMMs, the initial shape

cannot be regained after deformation whereas in two and three-way SMMs the original shape

can be regained after deforming into a temporary shape via an intermediate shape.

1. Shape Memory Alloy (SMA): Shape memory effect mechanism in shape memory alloys

is based on the reversible transformation of the alloy's crystal structure under thermal or

mechanical stimulus. The alloy's atoms move and rearrange themselves in a specific

pattern, allowing the alloy to change shape.

2. Shape Memory Polymer (SMP): The SMPs have a characteristic glass transition

temperature (Tg) which is usually higher than the temperature at which they are mostly

operated. Above Tg, and at specific thermal and mechanical conditions they are

programmed and when cooled they possess a temporary shape which is free from any

external loading. And when the temperature is again raised above T g, they retain their

original shape. This is due to the reason that below Tg, the internal energy of polymer

chains is low, and they cannot move freely resulting in the material being glassy and

rigid. But above Tg, the energy is provided to the polymer chains causing their movement

as a result the material becomes rubbery and prone to deformation and manipulation.

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 The key characteristics of shape memory materials include:

 Shape Memory Effect: The ability to remember and recover a specific shape upon

exposure to a particular stimulus, such as temperature change or mechanical stress.

 Reversibility: The transformation between the temporary and original shapes is

typically reversible, allowing the material to undergo multiple cycles of shape change.

 Responsive to Multiple Stimuli: Some shape memory materials can respond to various

stimuli, including temperature, stress, or magnetic fields.

Figure 1.4. Classification of SMP’s based on Stimuli [2].

Applications of shape memory materials are diverse and include:

 Biomedical Devices: Smart Orthopedic Devices, Postoperative Rehabilitation Aids:

Customized assistive devices, such as splints and braces, adjustable in shape to aid

patient recovery and rehabilitation. Drug delivery system etc.

 Aerospace: SMAs are used in various aerospace applications, including actuators,

landing gear components, and morphing aircraft wings.

 Automotive: SMAs can be employed in automotive systems for applications like active

grille shutters and engine components.

 Robotics: Shape memory materials are used in robotics for soft actuators and

components that change shape based on the task at hand.

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CHAPTER 2

APPLICATION OF 4D PRINTING

2.1. Biomedical Field

4D printing has emerged as a transformative technology in the field of biomedical

engineering, offering the potential for dynamic, stimuli-responsive structures with

applications in following area:

Drug Delivery
Systems
Customized
Wound Medical
healing Devices

Biodegradable Dental
stents Application

Patient specific Smart

rehabilitation Orthopaedic
tools Devices

Tissue
engineering

Figure 2.1. Applications of 4D printing

2.2. Fracture Cast

Bone fractures present a major challenge to the healthcare system and a significant financial

burden for society and the patient. For nonsurgically treatment of fractures, the concept of

using 3D printing technology to make a personalized cast with an appropriate fit and a

ventilated structure for patients has also emerged. Since the introduction of the plaster casting

(gypsum plaster or plaster of Paris) in the 10th century, the technique has not significantly

changed. The advantages of the conventional casts are its easy handling, subsequent

plasticity, and low cost, although its heavy weight, low breathability, and lack of water

resistance, in addition to the inability to directly observe soft tissue and the possible skin

12
reactions, limit its use. The introduction of fiberglass casts in the 1970s provided a more

durable and water-repellent alternative, although they could not eliminate the other

disadvantages. To gain a 3D-printed cast, technicians can use the image data with 3D spatial

information of limbs captured by the 3D scanner or medical imaging devices and then

conduct the computer-aided design to obtain the Stereolithography (STL) format file for 3D

printing. For the pressure more appropriately distributing, a 3D-printed cast is expected to be

more comfortable during the treatment. In addition to the benefit from personalized design

and use of lightweight materials for 3D printing, the novel cast is more fashionable and

portable as well. Although 3D printing had made advances in the development of casting

techniques, most published works for application of 3D-printed casts were still in the concept

stage or initial phase, speaking to the need for experimental data and clinical experiences.

(a) (b)

Figure 2.2. (a) Conventional plaster, (b) Custom designed 3D printed plaster [6].

Forearm fractures are common skeletal injuries and occur at all ages especially in children

and in the elderly, and distal radius fractures are the most common type. Cast immobilization

is preferred in most patients with nonsurgically treated forearm fractures. Poor ventilation

and improper fit present in traditional casts are associated with treatment complications. Our

previously published studies developed a novel cast fabricated by 3D printing and gained

preliminary clinical experiences, which was the first clinical experience reported.

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CHAPTER 3

LITERATURE REVIEW

The literature review has been organized into three different sections namely, design

methodology, material selection and FEA analysis of fracture cast model. At the end of the

chapter identified research gaps and objectives of the thesis work have been presented.

3.1. Literature Review on Design Methodology

N P Sorimpuk et al. (2022) [4] Initially 3D printed the cast as a flat object, heated at 60 ºC,

and then transformed into a functional orthopedic cast by wrapping it around the user’s hand

while it is still soft. Thermoformable cast design was set to 5 mm thickness. Thermoformable

PLA using FDM shows better results than SLS printed and POP cast. Safety factor simulation

shows low readings in cast structure corners, particularly around ventilation holes.

Elimination of these edges using fillet features improves structure strength. Yanjun Chen et

al. (2020) [5] Given that the Velcro straps were adopted as fixation straps, it was convenient

to adjust, disassemble, and assemble the 3D-printed cast. It took about 3-5 days for a cast to

be designed and manufactured relatively high fabrication cost of a 3D printing cast restricted

its application. Drawback of long designing and manufacturing time can be overcome by use

of PLA based cast using FDM rather than SLS which is used in this study and heat responsive

property can be utilized.

3.2. Literature Review on Material Selection Process

Mehrshad et al. (2021) [3] focused on improving the programming behavior of PLA by

addition of nanofillers during the polymerization of PLA. Much previously published

literature in this regard uses a blend of PLA with other polymers, like polyurethane (PU), to

enhance shape recovery and to reduce the glass transition temperature ( T g) of PLA, thereby

increasing its sensitivity to thermal programming. PLA is a compelling material for FDM-3D

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printing due to its desirable properties including low T g and shape memory. PLA presents

other advantages, including biocompatibility, biological inertness, and biodegradability, that

suggest its applications to the biomedical field. Capability of PLA for commercial FDM 3D

printing process as a high quality and inexpensive method for producing parts. Schlégl et al.

(2021) [6] study shows that 3D-printed materials cast is better in both static and dynamic

mechanical tests. The 3D-printed materials were shown to have a higher tensile strength and

flexural strength than plaster cast and fiberglass cast. Total time required for production of 3D

printed cast was higher due to printing complete cast in one piece. The polymer and

composite-based casts have a significantly greater resistance to dynamic forces. Prices and

time needed for application are still more favorable for traditional methods. Liu et al., (2022)

[26] magneto-responsive shape memory composite filaments for 3D printing based PLA,

TPU and Fe3O4 particles were fabricated via direct melt blending. high tensile strength and

modulus were achieved, suggesting an excellent load-carrying capacity of proposed

composites.

3.3. Literature Review on FEA analysis of fracture cast

Yanjun Chen et al. (2020) [5] This is the first comparative study on the application of 3D-

printed cast and traditional cast. A three-dimensional FEA model was developed to simulate

the external cast fixation in the fore- arm fracture model and to simulate the different loading

tests. Computed tomography (CT) volume data was used to create 3D model in SolidWorks.

Wei Yan et al. (2019) [9] provides a systematic topology optimization-based design approach

to design lightweight and porous splint for distal radius fractures. Lin et al., (2016) [25]

performed FEA analysis by setting the opening edges are set as fixed boundaries and applied

3MPa load to simulate accidental mechanical impact.

15
Other than above discussed literature few more researchers has worked in this area, a brief

summary of those papers has been tabulated below.

Table 3.1. Summary of Literature

Author/Year Brief Summary
Yan-Jun 3D–printed cast offers a proper fit to immobilise an injured arm and
Chen et al. holds the fracture reduction appropriately. Compartment syndrome and
(2017) [8] pressure sores are not present. ventilated structure increase patient
comfort and satisfaction.
Wei Yan et More than 40% lighter than traditional cast. simulation results show that
al. (2019) [9] the maximum displacement of the structure is 1.00 mm under the
boundary condition.
P. Varga et Thermoforming processes are considerably easier with the composites
al. (2019) containing CaC O3. do not absorb significant amount of water.
[12] Lightweight and rigid. materials can be also used for medical modelling,
suitable for disinfection procedures.
Time required for whole procedure reduced from 19h to 2h using
thermoforming.
Fenghua Uniform heating is achieved due to uniform distribution of Fe3 O4
Zhang et al. magnetic particles. Addition of Fe3 O4 causes slight increase in transition
(2019) [16] temperature. Fe3 O4 particles improved thermal stability of PLA.
temporary shape returned to its initial shape after 60 s. Storage modulus
of the composite filaments increases.
Francesco Literature shows a systematic approach to the CAD modelling process
Buonamici et for the reconstruction of patient-specific orthosis envisaging a future
al.(2018) automatization of the whole process within a CAD environment. The
[10] questionnaire confirms the patients positive review of the cast.
Performed FEA proves the effectiveness, in terms of strength, of the
proposed random configuration of pre-determined diameter holes.
Sivanagaraju Adding GNP has significantly improved the mechanical properties.
Namathoti et Rapid heating of PLA has been achieved because of the strong
al. (2022) microwave absorption. to prevent aggregation of magnetic NPs with
[15] surfactants. (Oleic Acid-Coated Fe3 O4 nanoparticles).
Anil Bastola Programming is much reasonable for the hard-magnetic fillers, and thus
et al. (2021) hard-magnetic particle-filled MSMs are more attractive in the case of
[17] producing shape-morphing structures.
Magnetizing only after the matrix material is fully cured (solidified)
programming is not applicable to soft- magnetic filler.

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 Fernando Printing times and high initial investment represent the main
Blaya et al. complications to be overcome in previous 3D printing technique for cast.
(2017) [11] Considerable reduction in waste generated because of recyclability of
material.

Pasquale Compared with the plaster cast, the ABS CAD/CAM device entails
Guida et al. greater convenience, compliance, and satisfaction for both patients and
(2019) [18] their families. Easy removal. Study shows effective treatment whose
costs are like or even lower also since removal involves merely cutting
the strips that join the two shells, thereby eliminating use of the
oscillating saw that is necessary to remove the traditional plaster cast.

3.4. Research Gaps

i. Shape memory property of PLA is not utilized.

ii. Due to the current printing method high precision 3d printer is required with long

printing times.

iii. Slower actuation due thermoforming by hot water.

iv. Due to high water absorption rate for PLA at elevated temperature water-based

thermoforming degrades mechanical properties.

v. Until now Magneto Thermal actuation is not utilized for thermoforming of the Patient

specific cast.

vi. There were no papers which used nanoparticles and Smart polymer blend to improve

properties of the filament material and integration of fast magneto thermal actuation.

17
3.5. Motivation

1. Bone fractures are a major public health concern across the world, but there hasn't been a

thorough investigation of their incidence and burden.

2. Fractures are a significant burden on people, families, societies, and healthcare systems

because they can cause job absenteeism, lower productivity, disability, diminished quality

of life, health loss, and high healthcare expenditures.

3. A 2019 survey found that 455 million people were suffering from pain or other issues

related to recent or ancient fractures. number of fractures per 100,000 people, there were

around 2,296 fractures in 2019.

4. Traditional cast materials commonly used for treatment have certain disadvantages,

including a lack of mechanical and water resistance, poor hygiene, and odors. Three-

dimensional printing is a dynamically developing technology which can potentially

replace the traditional casts.

3.6. Objective of Thesis work

i. To evaluate and select suitable smart materials for 4D printing applications.

ii. To experimentally analyze the performance of a shape memory polymer.

iii. To identify potential applications and limitations of shape memory polymers in 4D

printing.

iv. To evaluate the efficacy of the design and proposed methodology of thermoforming

actuation for fracture cast.

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 3.7. THESIS WORK PLAN

Literature Review.

Selection of Material Composition based on

literature and Procurement of selected
Material Selection
composite material filament.

Modeling of fracture cast model based on

CAD model of anatomical hand in
Modeling SolidWorks. Shape morphing of flat cast
model on the hand CAD model in CATIA
software.

FEA analysis of
fracture cast in
ANSYS
UTM testing for determination of tensile
strength and Young’s modulus.
Material Testing
Charpy impact test to test the impact
resistance.

To test the magnetic inductive heating

Experimental
stimulus for the application of fracture
Setup
cast.

Evaluation of
results

Thesis Write-up

Figure 3.1 Flowchart of Thesis work

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