A Numerical Framework for Improving the Design of Shape-Memory Polymers using Fused Deposition Modeling 4D Printing

• Applicant: Dr.-Ing. Felipe González
• Subject Area: Plastics Engineering
• Term: since 2025
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 566317635

This project aims to improve the manufacturing process of shape-memory polymers (SMP) using fused deposition modeling 4D printing. By employing numerical modeling, we will be able to achieve a detailed analysis of the thermoviscoelastic behavior of the polymer melt during printing. This will enhance our understanding of elastic stress formation, which is crucial for the shape-morphing mechanism in SMPs. Key project objectives are modeling the polymer melt as thermoviscoelastic flow, and developing a multi-strand framework to improve two critical components of the manufacturing process: the nozzle design and printing strategies. Current nozzle designs are based on standard 3D printing and do not account for the complexities of manufacturing SMPs. We will produce a shape-optimization tool specifically designed for producing efficient nozzles for the fabrication of SMPs. Additionally, the developed multi-strand framework will be used to investigate the effects of various printing conditions on elastic stress formation. We will investigate different stacking configurations with respect to the stresses generated within the printed structure and quality factors, such as porosity and interfilament adhesion. This project will be carried out over 24 months, with the expected outcome being a validated, efficient, and open-source numerical tool for predicting the elastic stress generated during printing. This tool will support researchers and engineers in designing 4D-printed objects with customized shape-shifting capabilities.

• DFG Programme: Research Grants