A-line: 4D Printing Morphing Linear Composite Structures

This paper presents A-line, a 4D printing system for designing and fabricating morphing three-dimensional shapes out of simple linear elements. In addition to the commonly known benefit of 4D printing to save printing time, printing materials, and packaging space, A-line also takes advantage of the unique properties of thin lines, including their suitability for compliant mechanisms and ability to travel through narrow spaces and self-deploy or self-lock on site. A-line integrates a method of bending angle control in up to eight directions for one printed line segment, using a single type of thermoplastic material. A software platform to support the design, simulation and tool path generation is developed to support the design and manufacturing of various A-line structures. Finally, the design space of A-line is explored through four application areas, including line sculpting, compliant mechanisms, self-deploying, and self-locking structures.