Digital light Projection based Additive Manufacturing (AM) enables fabrication of complex three-dimensional (3D) geometries for applications ranging from rapid prototyping jet parts to scaffolds for cell cultures. Despite the ability in producing complex, three-dimensional architectures, the state of art DLP AM systems is limited to a single homogenous photo-polymer and it requires a large volume of resin bath to begin with. Extensible Multi-material Stereolithography (EMSL) is a novel high-resolution projection stereolithography system capable of manufacturing hybrid 3D objects. This system provides new capabilities, allowing more flexible design criteria through the incorporation of multiple feedstock materials throughout the structure. With EMSL manufacturing ability, multi-material programmable negative Poissons ratio honeycomb reentrant structures are realized. Researchers have been studying auxetic structures over decades, the mechanical property control of auxetic structure mainly relies on geometry design in previous studies. Now with the help of EMSL system, other design variables associated with auxetic structures, such as material properties of local structural members, are added into design process. The additional variables are then proved to have significant effects on the material properties of the auxetic structures. The ability to accurately manufacture multi-material digital design will not only allow for novel mechanical and material researches in laboratory, but also extend the additive manufacturing technology to numerous future applications with characteristics such as multiple electrical, electromechanical and biological properties. The design and optimization of EMSL system realizes novel structures have not been producible, therefore it will stimulate new possibilities for future additive manufacturing development. / Master of Science

Methods to mitigate the risk posed by seismic and blast loads to structures are of high interest to researchers. Auxetic structures are a new class of metamaterials that exhibit counterintuitive negative Poisson's ratio (NPR) behavior based on their geometric configuration. Cellular auxetics are light-weight and cost-effective materials that have the potential to demonstrate high strength and resilience under axial forces. Existing research on metallic auxetics is scarce and based mostly on analytical studies. Apparent NPR behavior of auxetics has also been linked to enhanced energy absorbing potential. A pilot study was undertaken to investigate and understand auxetic behavior in tubes constructed using ductile metals commonly found in structural applications i.e. steel and aluminum. The main objective was to establish whether performance enhancements could be obtained through auxetic behavior in ductile metal tubes. In addition, any potential benefits to auxetic performance due to base material plasticity were studied. These objectives were fulfilled by conducting an experimental and analytical investigation, the results of which are presented in this thesis. The experimental program consisted of establishing a design methodology, manufacturing, and laboratory testing for tubular metallic specimens. A total of eight specimens were designed and manufactured comprising five steel and three aluminum. For each base metal, three different geometric configurations of cells were designed: one with a rectangular array of circular voids and two with void geometries based on the collapsed shape of circular cells in a design tube under uniaxial compressive stress. A parameter called the Deformation Ratio (DR) was introduced to quantify cell geometry. Designed tubes were manufactured via a six-axis laser cutting process. A custom-made test assembly was constructed and specimens were tested under reverse-cyclic uniaxial loading, with one exception. Digital Image Correlation (DIC) was used to acquire experimental strain data. The performance of the auxetic and non-auxetic tubular structures was evaluated based on the axial load-deformation characteristics, global deformations, and the specific energy absorption of the test specimens. The experimental test results confirmed that ductile metal tubes with special collapsed cell geometries were capable of demonstrating auxetic behavior under the applied elastic and inelastic uniaxial strains; both tensile and compressive. Base material plasticity was observed to have an insignificant effect on the auxetic response. Experimental results suggested that the unique deformation mechanism precipitated by the auxetic cell geometries resulted in more stable deformed shapes. Stability in global deformed shapes was observed to increase with an increase in DR value. In addition, the unique auxetic mechanism demonstrated an ability to distribute radial plastic strains uniformly over the height of the auxetic pattern. As a result, plastic strains were experienced by a greater fraction of auxetic tubes; this enhanced the energy-dissipating properties of auxetic specimens in comparison to the tested non-auxetic tubes. Tubes with cell geometries associated with higher DR values exhibited greater energy absorption relative to the non-auxetic specimen. For the same base metal, auxetic specimens exhibited greater axial strength and effective strain range, when compared to their non-auxetic counterparts. The increased strength was partially attributed to the increased cell wall thickness of the auxetic specimens. However, the increased strain range was attributed to the rotation in unit cells induced by the unique auxetic geometry. Experimental test data was used to validate the finite element (FE) and simplified macromechanical modeling approaches. These methods were adopted to develop design tools capable of replicating material performance and behavior as well as accurately predicting failure loads. Load-deformation response and effective Poisson's ratio behavior was established using FE models of as-built specimens, while simplified macromechanical equations were derived based on the equilibrium of forces to compute failure loads in tension. These equations relied on pattern geometry and measured experimental unit cell deformations. It was established that the manufacturing process had a detrimental effect on the properties of the aluminum specimens. Accordingly, empirical modifications were applied to the aluminum material model to capture this effect. FE models accurately replicated load-deformation behavior for both non-auxetic and auxetic specimens. Hence, the FE modeling approach was shown to be an effective tool for predicting material properties and response in ductile metal tubes without the need for experimental testing. The simplified strength equations also described material failure with reasonable accuracy, supporting their implementation as effective design tools to gauge tube strength. It is recommended that FE models be refined further through the addition of failure criteria and damage accumulation in material models. The result of this study established that auxetic behavior could be induced in ductile metal tubes through the introduction of unique cell geometry, thereby making them highly tunable and capable of exhibiting variable mechanical properties. Owing to their deformation mechanism and NPR behavior, auxetic tubes demonstrated geometric stability at greater deformations, which highlighted their potential for use as structural elements in systems designed to deform while bearing extreme loads e.g earthquakes and blast events. Additionally, the capability of auxetic geometries to distribute strains uniformly along their length was linked to the potential development of energy-dissipating structural components. It was suggested that new knowledge acquired in this study about auxetic behavior in ductile metals could support the development of new structural systems or methods of structural control based on NPR behavior. Finally, recommendations for future research were presented, based on the expansion of research to study the effects of multiple loading regimes and parametric changes on auxeticity as well as additional mechanical characteristics e.g shear resistance. / Master of Science / Special structures known as Auxetics have been studied that exhibit counterintuitive behavior based on their geometric configuration. The novel shapes and architecture of these structures allow them to deform such that they expand laterally in tension and contract laterally in compression; a property known as negative Poisson's ratio (NPR) which is rarely observed in naturally-occurring materials. Auxetic materials demonstrate mechanical properties such as high resilience, indentation resistance, and energy-absorption. An experimental and analytical study was undertaken to explore the beneficial properties of auxetic behavior, along with the effect of inelastic deformations in ductile metal auxetics. To this end, tubular test specimens, made with steel and aluminum, were designed and manufactured. To achieve auxetic behavior, a unique array of collapsed cells was cut out from metal tubes using a laser cutting process. Subsequently, specimens were tested in the laboratory under cyclic and monotonic loads. Experimental results indicate that tubes with auxetic geometries exhibited NPR behavior and a unique deformation mechanism based on the rotation of the unit cells. Owing to this mechanism, auxetic specimens possessed greater geometric stability under applied axial deformations, when compared to the tested non-auxetic specimens. The deformation mechanism was also responsible for a uniform distribution of strains along the length of the auxetic geometry which was linked to relatively better energy absorbing capacity than the non-auxetic tubes. Developed finite element (FE) models captured the response and behavior of all specimens with good accuracy. Derived simplified strength equations were also able to calculate the ultimate tensile failure loads for all specimens accurately. Both numerical methods demonstrated the potential to be utilized as design and evaluation tools for predicting material properties. Finally, recommendations to expand research, based on metal auxetic structures, were presented to further our understanding of auxetic behavior in ductile metals and to explore its benefits under varying loading regimes. Results from this research can be used to support the design of new structural systems or methods to control existing structures by exploiting NPR properties of ductile metal auxetics. Furthermore, energy-dissipating properties of metal auxetic materials may prove to be beneficial for structural applications under extreme loading conditions such as earthquakes and blasts.

Negative Poisson’s ratio, or auxetic, materials present the possibility of designing structures and components with tailored or enhanced mechanical properties. This thesis explores the phenomenon of auxetic behaviour in cubic crystals using classical and quantum modelling techniques and assesses the validity of these techniques when predicting auxetic behaviour in cubic elemental metals. These techniques are then used to explore the mechanism of this behaviour. The findings of the atomistic modelling are then used as a template to create networks of bending beams with tailored Poisson’s ratio behaviour.

Soft materials have attracted much scientific and technical interest in recent years. In this thesis, attention has been placed on the underpinning relations between molecular structure and properties of one type of soft matter - main chain liquid crystalline elastomers (MCLCEs), which may have application as shape memory or as auxetic materials. In this work, a number of siloxane-based MCLCEs and their linear polymer analogues (MCLCPs) with chemical variations were synthesized and examined. Among these chemical variations, rigid p-phenylene transverse rod and flat-shaped anthraquinone (AQ) mesogenic monomers were specifically incorporated. Thermal and X-ray analysis found a smectic C phase in most of our MCLCEs, which was induced by the strong self-segregation of siloxane spacers, hydrocarbon spacers and mesogenic rods. The smectic C mesophase of the parent LCE was not grossly affected by terphenyl transverse rods. Mechanical studies of MCLCEs indicated the typical three-region stress-strain curve and a polydomain-to-monodomain transition. Strain recovery experiments of MCLCEs showed a significant dependence of strain retentions on the initial strains but not on the chemical variations, such as the crosslinker content and the lateral substituents on mesogenic rods. The MCLCE with p-phenylene transverse rod showed a highly ordered smectic A mesophase at room temperature with high stiffness. Mechanical properties of MCLCEs with AQ monomers exhibit a strong dependence on the specific combination of hydrocarbon spacer and siloxane spacer, which also strongly affect the formation of ð-ð stacking between AQ units. Poisson s ratio measurement over a wide strain range found distinct trends of Poisson s ratio as a function of the crosslinker content as well as terphenyl transverse rod loadings in its parent MCLCEs.

Concrete is the most widely used construction material in the world and is responsible for 7% of global carbon emissions. It is inherently brittle, and it requires frequent repair or replacement which is economically expensive and further generates large volumes of carbon dioxide. Current methods of repair by agents such as mortar, epoxies, and bacteria result in structures with reduced strength and resiliency. Recent advances in the design of structural composites often mimic natural microstructures. Specifically, the structure of abalone nacre with its high stiffness, tensile strength, and toughness is a source of inspiration from the process of evolution. The inspiration from nacre can lead to design of a new class of architected structural materials with superb mechanical properties. This body of work first presents a method to reinforce concrete with an architected polymer phase. Second is presented how a ubiquitous enzyme, Carbonic anhydrase (CA), can be used to repair and strengthen cracked concrete, and how it can be used as an additive in fresh concrete. The first study presents an experimental and computational study on a set of bioinspired architected composites created using a cement mortar cast with brick-and-mortar and auxetic polymer phases. The impact of this unit-cell architected polymer phase on the flexural and compressive strengths, resilience, and toughness is studied as a function of microstructural geometry. All mechanical properties of the architected composite samples are found to be greater than those of control samples due to prevention of localized deformation and failure, resulting in higher strength. The microstructurally designed composites showed more layer shear sliding during fracture, whereas the control samples showed more diagonal shear failure. After initial cracking, the microstructurally designed composites gradually deformed plastically due to interlocking elements and achieved high stresses and strains before failure. Results also show that microstructurally designed composites with the architected polymer phase outperform control samples with equal volume fraction of a randomly oriented polymer fiber phase. Computational studies of the proposed unit cells are also performed, and the results suggest that the orientation of cells during loading is critical to achieve maximum performance of a cementitious composite. The implications of these results are immense for future development of high performing construction materials. The second study outlines methods for repair of concrete and lays the groundwork to develop a self-healing concrete that uses trace amounts of the CA enzyme. The CA catalyzes the reaction between calcium ions and carbon dioxide to create calcium carbonate that naturally incorporates into concrete structures with similar thermomechanical properties as concrete. The reaction is safe, actively consumes carbon dioxide, generates low amounts of heat, and avoids using unhealthy reagents, resulting in a strong structure. This repair method results in concrete samples with similar strength and water permeability as the intact materials. These results offer an inexpensive, safe, and efficient method to create self-healing concrete structures. The science underlying the creation of self-healing concrete is described, producing a material intrinsically identical to the original using the CA enzyme. Using this strategy, a preliminary self-healing concrete mix is able to self-repair fractures via hydration. This body of work addresses a major issue: Is there an efficient and ecological repair for decaying concrete infrastructure? These methods propose alternative reinforcement, alleviates high monetary and energy costs associated with concrete replacement, and consume the greenhouse gas, carbon dioxide.

No description available.

Sandwich Panels with cellular cores are widely used in the aerospace industry for their higher stiffness to mass, strength to mass ratio, and excellent energy absorption capability. Even though, sandwich panels are considered state of the art for lightweight aerospace structures, the requirement to further reduce the mass exists due to the direct impact of mass on mission costs. Traditional manufacturing techniques have limited the shape of the cores to be either hexagonal or rectangular, but, with rapid advancements in additive manufacturing, other core shapes can now be explored. This research aims to identify and evaluate the mechanical performance of two-dimensional cores having standard wall geometry, which provide higher specific stiffness than honeycomb cores. Triangular cores were identified to have higher specific in-plane moduli and equivalent specific out-of-plane and transverse shear moduli. To consider practical use of the triangular cores, elastic and elastic-plastic structural analysis was performed to evaluate the stiffness, strength, failure, and energy absorption characteristics of both the core and sandwich panels. The comparison made between triangular cores and hexagonal cores having the same cell size and relative density showed that triangular cores outperform hexagonal cores in elastic range and for applications where in-plane loading is dominant. Triangular cores also have excellent in-plane energy absorption capabilities at higher densities. / Master of Science

<p>  </p> <p>With the advent of femtosecond lasers in the early 1990s, ultrafast laser processing has proven to be an imperative tool for micro/nanomachining. Two-photon lithography (TPL) is one such unique microfabrication technique exploiting the nonlinear dependency of the polymerization rate on the irradiating light intensity to produce true three-dimensional structures with feature sizes beyond the diffraction limit. This characteristic has revolutionized laser material processing for the fabrication of micro and nanostructures. This research first gives a general overview of TPL, including its operating principle, experimental setup, compatible materials, and techniques for improving the final resolution of the fabricated structure. Insights to improve throughput and speed of fabrication to pave a way for the industrialization of this technique are provided.</p> <p>Following that, the report delves into the process of fabricating two true three-dimensional mechanical metamaterials via the stereolithography technique. This chapter encompasses the design, fabrication, and experimental analysis of a three-dimensional axisymmetric structure with elliptical perforations distributed periodically on the walls of the structure with varying thicknesses. Furthermore, this study discusses the significance of the elliptical perforations in terms of auxetic behavior and load-bearing capacity against a so-called plain structure under quasistatic compression loading.</p> <p>Finally, the report explores the technique of fabricating a true three-dimensional cylindrical auxetic structure via two-photon polymerization. This section of the report examines the optical setup utilized, the sample preparation procedure, and calibration experiments performed in order to fabricate a three-dimensional thin-walled right cylinder with bowtie like perforations arranged on the walls to promote the exhibition of symmetric negative Poisson’s ratio under uniaxial quasistatic compression loading.</p>

No description available.

Les matériaux architecturés font émerger de nouvelles possibilités en termes de propriétés structurales et fonctionnelles, repoussant ainsi les limites des cartes d'Ashby. Le terme "matériaux architecturés" inclus toute microstructure conçue de façon astucieuse, de sorte que certaines de ses propriétés soient optimisées. Les exemples sont nombreux : composites fibreux et particulaires, matériaux cellulaires, structures sandwiches, matériaux tissés, structures treillis, etc. Un enjeu de taille pour l'emploi de tels matériaux est la prédiction de leurs propriétés effectives. Dans ce travail, deux types de microstructures sont considérées : des structures auxétiques périodiques et des milieux fibreux aléatoires. Les auxétiques sont des matériaux apparus au milieu des années 1980, présentant un coefficient de Poisson négatif. On attend des auxétiques qu'ils présentent des propriétés mécaniques améliorées, comme le module de cisaillement ou la résistance à l'indentation. Les milieux fibreux aléatoires considérés dans ce travail sont constitués de fibres 3D infinies interpénétrantes aléatoirement distribuées et orientées. Ce type de structure aléatoire est très défavorable à la détermination d'une taille de volume élémentaire statistiquement représentatif. Pour les deux types de matériaux, l'homogénéisation numérique à l'aide de la méthode des éléments finis est implémentée dans le but d'estimer les propriétés thermiques et mécaniques effectives. / Architectured materials bring new possibilities in terms of structural and functional properties, filling gaps and pushing the boundaries of Ashby's materials maps. The term "architectured materials" encompasses any microstructure designed in a thoughtful fashion, so that some of its materials properties have been improved. There are many examples: particulate and fibrous composites, foams, sandwich structures, woven materials, lattice structures, etc. One engineering challenge is to predict the effective properties of such materials. In this work, two types of microstructures are considered: periodic auxetic lattices and stochastic fibrous networks. Auxetics are materials with negative Poisson's ratio that have been engineered since the mid-1980s. Such materials have been expected to present enhanced mechanical properties such as shear modulus or indentation resistance. The stochastic fibrous networks considered in this work is made of 3D infinite interpenetrating fibres that are randomly distributed and oriented. This case of random structure is challenging regarding the determination of a volume element size that is statistically representative. For both materials, computational homogenization using finite element analysis is implemented in order to estimate the effective thermal and mechanical properties.