Emerging 4D printing techniques have enabled the realization of smart materials whose shape or properties can change with time. Two important phenomena play important roles in the 4D printing of shape memory polymeric materials. First, the anisotropic deformation of the printed filaments due to residual stresses can be harnessed to create out-of-plane shape transformations. Second, the unavoidable formation of micro-defects during the printing processes often affects the programmability of the printed object. Here, we propose a design approach that harnesses these two effects occurring during fused deposition modeling to create tailor-made curved geometries from initially 2D flat disks. We first determined the size and distribution of the imperfections formed within printed structures by varying two printing parameters namely the printing speed and the number of printed materials. Spatially varying the printing speed and combining polylactic acid filaments with a softer material without shape memory properties allowed us to cover a variety of shapes from negative to positive values of the mean and Gaussian curvature. We propose an analytical model to calculate the magnitude of the maximum out-of-plane deformation from the anisotropic expansion factor of the constituting microstructures. Furthermore, we develop computational models to predict the complex shape-changing of thermally actuated 4D printed structures given the distribution of rationally introduced imperfections and we demonstrate the potential applications of such defect-based metamaterials in drug delivery systems.

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Individual cells and multicellular systems respond to cell-scale curvatures in their environments, guiding migration, orientation, and tissue formation. However, it remains largely unclear how cells collectively explore and pattern complex landscapes with curvature gradients across the Euclidean and non-Euclidean spectra. Here, we show that mathematically designed substrates with controlled curvature variations induce multicellular spatiotemporal organization of preosteoblasts. We quantify curvature-induced patterning and find that cells generally prefer regions with at least one negative principal curvature. However, we also show that the developing tissue can eventually cover unfavorably curved territories, can bridge large portions of the substrates, and is often characterized by collectively aligned stress fibers. We demonstrate that this is partly regulated by cellular contractility and extracellular matrix development, underscoring the mechanical nature of curvature guidance. Our findings offer a geometric perspective on cell-environment interactions that could be harnessed in tissue engineering and regenerative medicine applications.

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The rational design of bone-substituting biomaterials is relatively complex because they should meet a long list of requirements for optimal performance. Meta-biomaterials are micro-architected materials that hold great promise for meeting those requirements as they offer a unique combination of mechanical, mass-transport, and biological properties. There are, however, inherent couplings between the different types of properties of many such materials that make it impossible to simultaneously achieve all the design criteria. An example of such a coupling exists between the mechanical properties and the surface area. Strut-based, metallic meta-biomaterials are known to offer bone-mimicking mechanical properties, but they have limited surface area for cell adherence. Increasing the surface generally results in an undesirable increase in the mechanical properties that could lead to stress shielding. Here, we combine strut-based lattices with minimal surfaces to decouple these two properties. We added minimal surface patches to the designs of both auxetic and non-auxetic meta-biomaterials while minimizing their contribution to the mechanical properties of the resulting meta-biomaterials through the rational application of cuts or “slits”. All designs were additively manufactured using selective laser melting and mechanically tested to obtain their quasi-static mechanical properties, including their Poisson's ratio, in two configurations. A finite element-based computational homogenization code was used to compute the elastic moduli and anisotropy of the structures. The results show that the minimal surface patches substantially increase the available surface area without significantly affecting the mechanical properties. Without the slits, the surfaces significantly affected the elastic modulus and deformation behavior of the meta-biomaterials. A similar strategy could be used to tune the biodegradation rate of biodegradable metals and the permeability of meta-biomaterials in general.

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The rapidly expanding field of tissue engineering presents enticing, yet demanding challenges for scientists and engineers across many different disciplines. The ultimate goal of tissue engineering is ambitious: to regenerate damaged or missing tissue in its full complexity, either in vitro or in situ, and restore organ function. In addition to cells and biochemical factors, biomaterial scaffolds form the other essential ingredient within the tissue engineering paradigm. These scaffolds support, guide, and stimulate neotissue formation and are rationally designed to meet the desired balance between mechanical, mass transport and biological properties necessary for regeneration and implantation.@en

Rapid advances in additive manufacturing have kindled widespread interest in the rational design of metamaterials with unique properties over the past decade. However, many applications require multi-physics metamaterials, where multiple properties are simultaneously optimized. This is challenging since different properties, such as mechanical and mass transport properties, typically impose competing requirements on the nano-/micro-/meso-architecture of metamaterials. Here, a parametric metamaterial design strategy that enables independent tuning of the effective permeability and elastic properties is proposed. Hyperbolic tiling theory is applied to devise simple templates, based on which triply periodic minimal surfaces (TPMS) are partitioned into hard and soft regions. Through computational analyses, it is demonstrated how the decoration of hard, soft, and void phases within the TPMS substantially enhances their permeability–elasticity property space and offers high tunability in the elastic properties and anisotropy at constant permeability. Also shown is that this permeability–elasticity balance is well captured using simple scaling laws. To demonstrate the proposed concept through multi-material additive manufacturing of representative specimens is then proceed. The approach, which is generalizable to other designs, offers a route towards multi-physics metamaterials that need to simultaneously carry a load and enable mass transport, such as load-bearing heat exchangers or architected tissue-substituting meta-biomaterials.

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The design of advanced functional devices often requires the use of intrinsically curved geometries that belong to the realm of non-Euclidean geometry and remain a challenge for traditional engineering approaches. Here, it is shown how the simple deflection of thick meta-plates based on hexagonal cellular mesostructures can be used to achieve a wide range of intrinsic (i.e., Gaussian) curvatures, including dome-like and saddle-like shapes. Depending on the unit cell structure, non-auxetic (i.e., positive Poisson ratio) or auxetic (i.e., negative Poisson ratio) plates can be obtained, leading to a negative or positive value of the Gaussian curvature upon bending, respectively. It is found that bending such meta-plates along their longitudinal direction induces a curvature along their transverse direction. Experimentally and numerically, it is shown how the amplitude of this induced curvature is related to the longitudinal bending and the geometry of the meta-plate. The approach proposed here constitutes a general route for the rational design of advanced functional devices with intrinsically curved geometries. To demonstrate the merits of this approach, a scaling relationship is presented, and its validity is demonstrated by applying it to 3D-printed microscale meta-plates. Several applications for adaptive optical devices with adjustable focal length and soft wearable robotics are presented.

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The organization and shape of the microstructural elements of trabecular bone govern its physical properties, are implicated in bone disease, and serve as blueprints for biomaterial design. To devise fundamental structure-property relationships and design truly bone-mimicking biomaterials, it is essential to characterize trabecular bone structure from the perspective of geometry, the mathematical study of shape. Using micro-CT images from 70 donors at five different sites, we analyze the local and global geometry of human trabecular bone in detail, respectively by quantifying surface curvatures and Minkowski functionals. We find that curvature density maps provide distinct and sensitive shape fingerprints for bone from different sites. Contrary to a common assumption, these curvature maps also show that bone morphology does not approximate a minimal surface but exhibits a much more intricate curvature landscape. At the global (or integral) perspective, our Minkowski analysis illustrates that trabecular bone exhibits other types of anisotropy/ellipticity beyond interfacial orientation, and that anisotropy varies substantially within the trabecular structure. Moreover, we show that the Minkowski functionals unify several traditional morphometric indices. Our geometric approach to trabecular morphometry provides a fundamental language of shape that could be useful for bone failure prediction, understanding geometry-driven tissue growth, and the design of bone-mimicking tissue scaffolds. Statement of significance: The architecture of trabecular bone is key in determining bone properties, and is often a starting point for the design of bone-substitutes. Despite the substantial history of bone morphometry, a fundamental characterization of trabecular bone geometry is still lacking. Therefore, we introduce a robust framework to quantify local and global trabecular bone geometry, which we apply to hundreds of micro-CT scans. Our approach relies on quantifying surface curvatures and Minkowski functionals, which are the most fundamental local and global shape quantifiers. Our results show that these shape metrics are sensitive to differences between bone types and unify traditional metrics within a single mathematical framework. This geometrical framework could also be useful to design bone-mimicking scaffolds and understand geometry-driven tissue growth.

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Almost every tissue in the human body is curved in a certain way. Examples are the extracellular matrix of different tissues such as trabecular bone, different acini and blood vessels. As such, the ability to create complex curved structures is crucial in the development of biomimetic biomaterials that could be used, for example, for tissue regeneration purposes. Currently, most of these different curved substrates and porous materials are fabricated with 3D-printing techniques. These techniques, however, have limitations. The 3D-printed structures, for example, have limited resolution and the production process is not compatible with planar functionality-inducing processes. A solution for these problems could be the concept of shape-shifting. Shape-shifting is the process through which an object transforms itself into a different shape under the influence of an external stimulus, such as temperature or light. A special interest goes to shape-shifting of initially flat materials (2D) into different complex 3D structures. This method has as main advantage that planar printing, patterning or other 2D processing techniques can be used on the planar (non-shape-shifted) state. In this research, the most important principles of shape-shifting of curved hyperbolic surfaces are explored. With this technique, the benefits of both hyperbolic surfaces and shape-shifting can be combined and exploited. A new way of hyperbolic shape-shifting is introduced. This is done by using a passive rigid frame and an active shape memory polymer (SMP). The passive material determines how and where the structure will fold, while the active SMP generates the force in order to fold and forms a curved (hyperbolic) surface spanned between the frame. A simple square patch design consisting of four rigid beams and an SMP was used as the basis of this research. When activated, this patch forms a saddle shaped (hyperbolic) surface. The design, activation and materials of the patch were changed and manipulated in different ways in order to perform a parametric study and to analyse different important aspects of the process. In order to quantify and assess the quality of the different patches and the effects of the manipulations, different test set-ups were made and the most valuable output parameters were chosen. Lastly, a finite element model of the principle was developed in order to further analyse the concept.

Recent evidence clearly shows that cells respond to various physical cues in their environments, guiding many cellular processes and tissue morphogenesis, pathology, and repair. One aspect that is gaining significant traction is the role of local geometry as an extracellular cue. Elucidating how geometry affects cell and tissue behavior is, indeed, crucial to design artificial scaffolds and understand tissue growth and remodeling. Perhaps the most fundamental descriptor of local geometry is surface curvature, and a growing body of evidence confirms that surface curvature affects the spatiotemporal organization of cells and tissues. While well-defined in differential geometry, curvature remains somewhat ambiguously treated in biological studies. Here, we provide a more formal curvature framework, based on the notions of mean and Gaussian curvature, and summarize the available evidence on curvature guidance at the cell and tissue levels. We discuss the involved mechanisms, highlighting the interplay between tensile forces and substrate curvature that forms the foundation of curvature guidance. Moreover, we show that relatively simple computational models, based on some application of curvature flow, are able to capture experimental tissue growth remarkably well. Since curvature guidance principles could be leveraged for tissue regeneration, the implications for geometrical scaffold design are also discussed. Finally, perspectives on future research opportunities are provided.

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Triply Periodic Minimal Surfaces (TPMS) have earned great popularity in porous meta- biomaterials by cause of unique mass transfer properties, tunable mechanical properties, large pore space and high surface to volume ratio. Numerical and experimental studies suggest a great potential for TPMS-based architectures in the treatment of segmental bone defects, where supporting scaffolds are crucial in bridging the gap unable to heal naturally. However, current studies are limited to investigating the properties of classic TPMS archi- tectures. In this thesis, I present the design, fabrication and characterisation of a novel type of meta-biomaterials inspired by TPMS morphology. I show a practical application of Weierstrass equations to define Schwarz P, Schwarz D and Gyroid surfaces, which pro- vides an opportunity to remove fundamental patches from the original surface and design unique structures. Moreover, one of the developed designs applied basics of graph theory to construct the material which mimics the randomness of the trabecular bone structure, while preserving the benefits of regular TPMS morphology. The results demonstrate the improved performance of the modified TPMS scaffolds compared to classic structures in terms of permeability and compliance properties, crucial for the materials applied in or- thopaedic implants. The porosity and permeability values of the developed metamaterial were found to be in the range of trabecular bone. Additionally, the possibilities to simulate the mass transfer properties of the novel material were examined in COMSOL and valu- able qualitative results, like fluid velocity distribution and flow-induced wall shear stress, retrieved. Overall my thesis introduces an innovative idea for biomaterial design and adds a strong argument in favour of TPMS morphology application in the orthopaedic material research field.

Origami-inspired folding methods present novel pathways to fabricate three-dimensional (3D) structures from 2D sheets. A key advantage of this approach is that planar printing and patterning processes could be used prior to folding, affording enhanced surface functionality to the folded structures. This is particularly useful for 3D lattices, possessing very large internal surface areas. While folding polyhedral strut-based lattices has already been demonstrated, more complex, curved sheet-based lattices have not yet been folded due to inherent developability constraints of conventional origami. Here, a novel folding strategy is presented to fold flat sheets into topologically complex cellular materials based on triply periodic minimal surfaces (TPMS), which are attractive geometries for many applications. The approach differs from traditional origami by employing material stretching to accommodate non-developability. Our method leverages the inherent hyperbolic symmetries of TPMS to assemble complex 3D structures from a net of self-foldable patches. We also demonstrate that attaching 3D-printed foldable frames to pre-strained elastomer sheets enables self-folding and self-guided minimal surface shape adaption upon release of the pre-strain. This approach effectively bridges the Euclidean nature of origami with the hyperbolic nature of TPMS, offering novel avenues in the 2D-to-3D fabrication paradigm and the design of architected materials with enhanced functionality.

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Two-matrix composites combine fibers with two distinct matrices. This is achieved by impregnating fiber bundles with a high-stiffness matrix and embedding the cured bundles in a flexible matrix. Two-matrix composites have been shown to offer unprecedented combinations of transverse flexibility and longitudinal tensile strength, and could offer improved fiber alignment and manufacturability. Here, we explore this concept further by embedding carbon fiber micropultrusions in flexibilized epoxy matrices and examining the longitudinal compression behavior. Our results on thin-walled rings reveal that the failure mode depends on micropultrusion diameter, with small diameters resulting in micropultrusion kinking and larger diameters in splitting and crushing. Additionally, we find that two-matrix composites can offer higher compression strength than conventional composites with the same flexible matrix, despite a lower fiber volume fraction. The inherent manufacturing advantages and high anisotropy could make two-matrix composites interesting candidates for specific applications, such as morphing wings or additively manufactured composites.@en

Transforming flat sheets into three-dimensional structures has emerged as an exciting manufacturing paradigm on a broad range of length scales. Among other advantages, this technique permits the use of functionality-inducing planar processes on flat starting materials, which after shape-shifting, result in a unique combination of macro-scale geometry and surface topography. Fabricating arbitrarily complex three-dimensional geometries requires the ability to change the intrinsic curvature of initially flat structures, while simultaneously limiting material distortion to not disturb the surface features. The centuries-old art forms of origami and kirigami could offer elegant solutions, involving only folding and cutting to transform flat papers into complex geometries. Although such techniques are limited by an inherent developability constraint, the rational design of the crease and cut patterns enables the shape-shifting of (nearly) inextensible sheets into geometries with apparent intrinsic curvature. Here, we review recent origami and kirigami techniques that can be used for this purpose, discuss their underlying mechanisms, and create physical models to demonstrate and compare their feasibility. Moreover, we highlight practical aspects that are relevant in the development of advanced materials with these techniques. Finally, we provide an outlook on future applications that could benefit from origami and kirigami to create intrinsically curved surfaces.

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