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Four-dimensional (4D) printing, a new technology emerged from additivemanufacturing (3D printing), is widely known for its capability of programmingpost-fabrication shape-changing into artifacts. Fused deposition modeling(FDM)-based 4D printing, in particular, uses thermoplastics to produceartifacts and requires computational analysis to assist the design processes ofcomplex geometries. However, these artifacts are weak against structural loads,and the design quality can be limited by less accurate material models andnumerical simulations. To address these issues, this paper propounds acomposite structure design made of two materials - polylactic acid (PLA) andcarbon fiber reinforced PLA (CFPLA) - to increase the structural strength of 4Dprinted artifacts and a workflow composed of several physical experiments andseries of dynamic mechanical analysis (DMA) to characterize materials. We applythis workflow to 3D printed samples fabricated with different printedparameters to accurately characterize the materials and implement a sequentialfinite element analysis (FEA) to achieve accurate simulations. The accuracy ofdeformation induced by the triggering process is both computationally andexperimentally verified with several creative design examples, and the 95%confidence interval of the accuracy is (0.972, 0.985). We believe the presentedworkflow is essential to the combination of geometry, material mechanism anddesign, and has various potential applications.

Material characterization and precise finite element analysis of fiber reinforced thermoplastic composites for 4D printing