Introduction: What is 4D Printing?
When
Skylar Tibbits got up on stage to address his audience at the TED 2013
conference, he presented the project that he has been working on and painted a
picture of his vision for the future. 4D printing: what he believes is the next
step in additive manufacturing (TEDTalks, 2013). At first, it sounds like a
catchy name for a 3D printing technology with an extra feature or two. However,
after watching his whole presentation and upon further reading, it became clear
that this was much more. Although seemingly in the very early stages of
development, 4D printing garners the potential to have countless applications
across industries, and is an innovation that will monumentally disrupt traditional
materials used in industries such as manufacturing, healthcare, and retail.
So,
what is it? Simply put, it is 3D printed material that can change shape upon
interaction with a specific medium. The material’s ability to change shape
comes from a pre-set code that is placed into the printer containing details of
the object’s geometric nature and measurements that detail the object’s behaviour
with an external stimulus. The 4th dimension being time, as the
object’s shape changes over time. Tibbits used water as the medium to spark the
interaction in his presentation, however different material reacts to different
stimuli (@randyrieland,
2014). He placed a printed material in water and, over a period, it changed
from a straight-line shape to the shape of the letters “MIT”. A correct
combination of materials will cause parts of the object to contract and other
parts to relax, folding into a different shape over time. Other stimuli include
temperature, light, and pressure have all proven successful (Stratasys.com,
2013).
Potential and Nature of Innovation
A glance at Gartner’s hype cycle for emerging technologies will show that
4D printing is very much in its early stages of development. Second to last
only beaten by Smart Dust, (sounds more like a sci-fi term than a real technology),
4D printing is estimated to take over 10 years to reach the mainstream (Forni & Meulen, 2016).
Tibbits’ own collaborator Stratasys states that it is still not commercially
available. However, the material’s innovative ability to adapt to its
environment by self-assembly indicates that its agility will prove highly
useful in the future (Stratasys.com, 2013). When placed in the right
circumstances, 4D printed technology has the potential to be the solution for reducing
costs and saving time that is used to assemble and construct traditional
material utilised across industries today. By replacing “legacy” materials with
4D printed ones, companies can be more cost and time-efficient, reducing the
energy and man-hours spent on constructing rigid structures.
As
innovative as 4D printing is, it is not a completely new and radical
innovation. This technology is considered a product performance innovation
since it is printed objects that are SMART because they can adapt to a change
in external stimuli. Product performance innovation is described as updates or
extensions to products that add value through sustainability, customisation,
and simplification. Tibbits describes it as “nothing new” and that the
innovative part is what happens after printing (TEDTalks, 2013).
Who will Develop the Technology?
Currently the institution to introduce the technology is Skylar TIbbits’s
Self-Assembly Lab in partnership with Stratasys, a leading innovative 3D
printing company. It is important to note that there is currently no
standardized hardware design for 4D printing (Khan et. al., 2015).
Stratasys’s Education and R&D departments are collaborating with MIT’s
Self-Assembly Lab (Tibbits) in developing 4D printing. The technology they are
using is the Connex multi-material 3D printing. The SMART materials they use
known as multi-material allow transformation into different shapes and
experiment with the properties to produce insights into geometry and new ways
of transformation. Stratasys and Tibbits are the main developers now, however
there is potential for other companies and institutions to enter the race (Stratasys.com,
2013).
Another technology
being developed is the Rova4D. A successful Kickstarter project, Rova4D is a
different kind of 4D printer. The 4Th dimension they are promoting
is the ability to print using several different colours simultaneously, unlike an
average 3D printer which prints each colour separately. If this technology is
developed further, it could be capable of printing smart materials and become a
4D printer (ROVA,
2016).
United States Institutions have received grants from the U.S. army
research office to develop 4D printed materials. The University of Pittsburgh
is one example where adaptive 4D printed materials are currently being
developed after a research grant of $855,00 (News.Pitt, 2013).
The University of Colorado Boulder has their researchers deep in the
development of composite materials that are adaptive and go a step above 3D
printing (Qi,
2013). These materials can be used in manufacturing, packaging
and biomedical applications. These among other institutions across the United
States have been granted funding primarily for the fields of aerospace, military,
manufacturing, and healthcare.
Competences Needed
The competences and skills needed to develop this technology are built on
existing skills required for 3D printing. Understanding how to use 3D printers
is an important skill as 4D printing differs in the blueprint of design and the
materials used. There will be difficulty when assessing the different kinds of
materials and delving into research of how the materials behave. The team at
Wollongong University in Australia is experimenting with materials to try and
find a solution for the irreversibility and strain of the 4D print. A
limitation of this material is after they have changed shape, the effect is permanent.
The team experimented with ICE gel (ionic covalent entanglement) which
increases the strength of the material and prevents it from cracking if there
is strain (Wassmer,
2015).
The example above highlights one aspect of risk of using this technology
that may require gaining competences in and understanding different solutions
in the event of failure.
Another skill required is the ability to code useful blueprints and
design for the shapes and structures of these materials. This will be essential
for the growth and expansion of this technology so that new innovative methods
for the materials to change shape will arise.
Another
competency is the understanding of the behaviours of different SMART material
and the ability of workers to combine them adequately. 4D printed materials
change shape and conform because of the structure and interaction of materials.
There are several examples of SMART materials including polymeric gal,
self-healing materials, smart metal alloys, and Piezoelectric material. When
pyro-electric material experiences a change in temperature, it emits an electric
signal. This can be applied to opening doors via personnel sensors (Khan
et. al., 2015). Another example is the material used to make the
LG G-flex phone cover, which is a self-healing material that reacts after it
gets scratched. These materials and more all differ in their phases of
development, as some materials will enter their commerciality prior to others. Knowing
how to use these materials is essential to the matter behaving as intended, and
will need investment into R&D and training.
In terms of commercialising the technology, it is advantageous that the
3D printing market exists and is in full swing. Although 4D printers are
inherently different, they have a basis to work from that other innovative
technologies might have not.
Competition
The competition will come both from the 3D printing industry and external
industries that can benefit from the technology. Stratasys and Tibbits are at
the forefront now, but sooner or later other 3D printing companies will begin
to develop their own capabilities of using SMART materials. The issue can come
from patents and IP; however, it is still very open in that regard, with
patents increasing every year. The product’s ability to transform into
different structures may make things complicated, as some patents are issued
for whole product lines (Khan et. al., 2015).
In terms of regional competition,
the chart below highlights the key advances in the different regions of North
America, Europe, and Asia-Pacific.
Source:
Frost, Sullivan 2014
As is the case
with most innovations, North America sees the highest intensity of adoption,
and the most funding injected into the R&D for 4D printing (Khan
et. al., 2015).
In terms of external competition, the
competition will come from innovative companies that have funding and
capabilities to invest in 4D printing research. In the healthcare industry, for
example, hospitals and medical institutions will begin to research and develop
this technology, much like they did with 3D printing before. The United States department
of Defence is an enabler of this competition, providing funding as explained
previously.
Applications of Disruption Across Industries
Before
looking at applications on a macro scale, there have been advances on a
micro-biological scale, specifically in nanotechnology. Although not directly
called 4D printing, scientists have developed physical and micro-biological
materials that can change shapes and directions. One such example that Tibbits
mentions is the use of nano-sized materials comprised of DNA that act as small
computers. When placed in small animals such as bugs, it can allow the organism
to perform small logic operations (Spickernell, 2014). This technology can pave
the groundwork achieving successful implementation in large industries in the
future.
Healthcare
In healthcare, doctors have been working with 4D printed structures that
can be used as implantations in the body. By changing shape over time and
conforming to their surroundings, 4D printed materials are more sustainable
than any other material used. For example, the University of Michigan developed
4D printed structures known as splints in a patient born with bronchomalacia,
weak cartilage in the bronchial tubes. The splints hold open airways and act in
the place of the cartilage, as it reforms into the body. They are said to last
around 2-3 years. This indication means that 4D printing can be successfully
implemented as a solution for medical diseases.
Source: http://www.computerworld.com/article/3071666/3d-printing/how-4d-printing-is-now-saving-lives.html
Above is a picture of the 4D printed
stints implanted in the patients. The main difference between 4D technology and
3D is that of rigidity. The adaptive nature of the 4D printed material gives it
an advantage because it can be sustained in the event of changes in the
environment around it. Of course, there are risks such as lack of compatibility
with the patient’s immune system, or no room for expansion of the material (Mearian,
2016).
Other developments are in very early
phases. Scientists are trying to use 4D printing to create self-folding proteins,
that can later be used for structural purposes. Other applications include
using materials for facial reconstruction, rebuilding cartilage, and holding
tissues in place. These examples show the potential of 4D printing to enact
change in the treatments and processes used in healthcare today. If 4D printed
materials are proven to be objectively superior to the rigid 3D prints, then
they will be entirely disruptive to healthcare treatments in the future.
Construction & Infrastructure
Infrastructure is a core industry that will be disrupted by 4D printed
materials. These materials have the potential to replace many, if not all,
existing materials and technologies used to create infrastructure. For example,
4D printed water pipes can prove to be significantly beneficial, with their
ability to change shape and adapt to changes in the ground such as earthquakes.
Another application is creating piping that acts as a pump, moving water
through the system to the designated location by the expanding and contracting
properties of the material. 4D printed piping material could also mean the ability
to control flow-rates of water, increasing protection and resilience and
decreasing risks of disasters from unattended piping systems. Not only will
this mean reducing investment costs on these devices, but also saving time and
labour costs previously needed to monitor the devices (Innovation, 2015).
Source: https://sites.psu.edu/anirudhnambiar/2013/12/14/extra-blog-4-d-printing-the-future-may-build-itself/
On a larger scale, this technology can affect the process of construction
projects. The idea of self-assembling a large structure such as a desk or a
cabinet could be possible under the right conditions. Imagine the self-assembly
of an entire home out of 4D printed material. This may sound far-fetched, but
if these 4D printed materials are combined correctly and placed in the right
environment, they can transform into any shape required. Houses can be lined
with SMART materials that expand to keep in heat during the winter, and
contract on in the heat (Atlantic Council, 2014).
Retail
In the retail
industry, 4D printed material can be used as a replacement to the material that
clothing is made of. An example is upgrading traditional footwear to “smarter”
shoes. This is done by adding 4D printed material that can change shape and
transform shoes to suit different needs. If the shoe is needed for basketball,
the material will change shape to support the ankles, transforming into
basketball shoes. The same goes for waterproof needs and any other adaptation
to the environment such as hot conditions or high pressure areas (Al-Rodhan,
2014).
Building on the
same idea, these materials can be implemented on clothing for stylistic
purposes. A company called Nervous System designed a 4D printed dress that can
transform into different shapes and expand or shrink to the wearer’s size. This
is advantageous for displaying different fashion styles from the same piece of
clothing, but also for comfort reasons. The key to the design is small hinges
that are printed along with the dress. They allow the piece of clothing to move
and conform to a size accordingly (Innovation, 2015).
Source: https://www.dezeen.com/2014/12/09/moma-acquires-first-4d-printed-dress-nervous-system-kinematics/
These are major disruptions to all three industries highlighted, however
there are many other applications for 4D printing that are being developed
every day. The image below shows the extent of these applications.
One thing is for certain: 4D
printed materials have the potential to change the way we approach everyday
problems and reshape the processes we use to solve them.
Barriers to Adoption
With any potentially disruptive technology comes challenges along the way.
4D printing will face barriers to adoption including regulation barriers, lack
of technical expertise, and resistance to new technology. Given that Tibbits is
the main supplier of this technology now, any new entrant supplying 4D printing
technology will have high barriers to entry and difficulty in competition. These
barriers will slow down the rate of progression of the technology as well as the
time to market.
The first barrier is the lack of experience dealing with the technology
itself. 4D printing is very new and it will take time for the technology to be
accepted in the mainstream. There are a few elements to consider here: the
software involved, the programmable matter itself, and the know-how needed to
combine the materials into the perfect fit. Failure to develop any one of those
three aspects will lead to investors potentially veering away from it due to
high risk. With pre-existing 3D printers and experts in the field, it will be
easier for 4D printing to be accepted in the industry. My recommendation is for
the companies that adopt 4D printing to invest in training. This will not be as
expensive since it is an innovation that builds on existing ideas, easing the
learning process.
For software in specific, existing additive manufacturing devices will
need to have their coding and internal software updated to be compatible with
the programmable matter that is complex, multi-material, and multifunctional. Tibbits
himself has expressed that bringing 4D printing to human scale industries such
as construction will be challenging (Atlantic Council, 2014).
But as stated previously, investment in training software developers to
understand how to create the blueprint for the 4D printed material is the most efficient
way to overcome this barrier.
The second barrier is regulation. There will need to be standardization
of design. This means there is a standard operations protocol agreed upon to
ensure that the systems and materials undergo faultless interaction (Atlantic
Council, 2014). Since standards previously exist for 3D printing,
the issue here is whether these standards are updated and moved over to the 4D
systems, or will new standards be created? Regardless, it will lead to a
slowdown in the time to market of the technology. The second legal aspect is
certifications, which might prove to be tedious like standardization. This
innovation will either need new certifications as per FAA certifications or through
the usual means. The more complicated aspect of legality will arise in the
event of failure or harm done by the technology. Since there are many players
involved, (manufacturer, software developer, materials provider) it will be
difficult to determine who is to blame for this failure. Thus, guidelines will
need to be drawn out ensuring proper conduct.
The last of the barriers is the willingness of companies to take the leap
and implement 4D printing. This is less of a concrete barrier but nevertheless important
to the lifespan and application of 4D printing. How willing are companies in
industries such as infrastructure, retail, and Healthcare, to take the risk and
invest in 4D printing technology? The high risk of a new technology and the
switching costs involved (potentially from 3D material) will mean a lack of
willingness to adopt early on. My recommendation here is to target a niche and
focus on serving a small portion of the market. Over time, the technology will expand
and target other sectors of the industry.
Conclusion
There are very few technologies that have as much potential staring us in
the eyes as 4D printing does. The technology’s key characteristics of adaptive,
complex, shape-changing, conforming multi-material coupled with its variety of
SMART materials capable of reacting to several different stimuli, proves that
it has the potential to disrupt several major industries worldwide. Although
the technology is currently in early phases, the amount of IP is increasing
every year, and the next decade will prove crucial to the development of
innovative processes capable of handling this material (Khan et. al., 2015).
Manufacturing alone will be completely changed, as an increase in efficiency
will see the production of new materials to build infrastructure with, transforming
our capitals into truly “Smart” cities.
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