Lightweight mechanical metamaterials with exception specific stiffness and strength are useful in many applications, such as transportation, aerospace, architectures and etc. These materials show great potential in mechanical tasks where weight of the material is restrained due to economy or energy reasons. To achieve both the lightweight and the high specific mechanical properties, the metamaterials are often in form of periodic cellular structures with well-designed unit cells. The strategies in designing and improving such cellular structures become the key in the studies of such mechanical metamaterials. In this work, we use both experimental and numerical approaches while probing three types of mechanical metamaterials: i) composite bending dominated hollow lattices (HLs); ii) triply periodic minimal surfaces (TPMSs) and extended TPMSs (eTPMSs); iii) corrugated TPMSs. We have demonstrated a few strategies in designing and improving the specific stiffness or strength via these examples of mechanical metamaterials. Using carbon/ceramic composite in the bending dominated HLs, we prove that using the composite layered material against the single layer ceramic is effective in improving the specific mechanical performances of the mechanical metamaterials. Next, while studying the nature of TPMS, we discover that under isotropic deformation TPMSs are stretch dominated with no stress concentrations within the shell structure. They also have an optimal specific bulk modulus approaching the H-S upper bound. Furthermore, we establish a strategy to smoothly connect the zero-mean-curvature surfaces in TPMSs with the extension of zero-Gaussion-curvature surfaces, forming new ‘eTPMSs”. These new shellular structures trade off its isotropy and have improved specific Young’s modulus along their stiffest orientation compared to their TPMS base structures. Lastly, we introduce corrugated sub-structures to existing TPMSs to improve their mechanical properties, such as Young’s modulus, yield strength and failure strength in compression. It is found that the corrugated sub-structure can effectively suppress the local bending behavior and redirect crack propagation while such structures were under uniaxial compression.

No description available.

Mechanical metamaterials are becoming an emerging frontier in scientific research and engineering innovation due to its unique properties, arising from innovative geometrical designs rather than constituent materials. Reconfigurable metamaterials can change their shapes and structures dramatically under external forces or environmental stimuli. It offers an enhanced flexibility in performance by coupling dynamically changing structural configuration and tunable properties, which has found broad potential applications in 3D meso-structures assembly and programmable machines. Despite extensive studies on harnessing origami, the ancient paper folding art, for design of mechanical metamaterials, the study on utilizing its close cousin, kirigami (“kiri” means cut), for programmable reconfigurable mechanical metamaterials and machines remains largely unexplored. In this dissertation, I explore harnessing the uniqueness of cuts in kirigami for achieving extraordinary mechanical properties and multifunctionalities in krigami-based metamaterials, as well as its potential applications in programmable machines and soft robotics. I first exploit the design of hierarchical cuts for achieving high strength, high stretchability, and tunable mechanical properties in hierarchical rotation-based kirigami mechanical metamaterials. Hierarchical line cuts are introduced to a thin sheet composed of non-stretchable materials (copy paper), less stretchable materials (acrylics), and highly stretchable materials (silicone rubber, PDMS), to explore the role of constituent material properties. The cut unit in the shape of solid rectangles with the square shape as a special case was demonstrated for achieving the extreme stretchability via rigid rotation of cut units. It shows that a higher hierarchical level contributes to a higher expandability and lower stiffness to constituent material. However, when such kirigami structure is applied onto less-stretchable materials (e.g. acrylics), its stretchability is almost eliminated regardless of the hierarchical level, because severe stress concentration at rotation hinges leads to the structure failure at the very beginning stage of pattern transformation. To address this challenge, I propose a hinge design which can significantly reduce the stress concentration at cut tips and enable high stretchability for rotation-based kirigmai structure, even on acrylic thin sheet. I also study the tunable photonic behavior of proposed hierarchical kirigami metamaterial by simple strain-induced structural reconfiguration. I then explore the programmability of kiri-kirgami structures by introducing notches to the simplest kirigami structure patterned with parallel line cuts for breaking its deformation symmetry. Engraving the flat-cut kirigami structure enables programmable control of its out-of-plane tilting orientation, thus generating a variety of inhomogeneous structural configurations on demand. I find that compared to the its counterpart without engraving notches, the introduced notches have a negligible effect on both the stress-strain curve over the large strain range and the extreme stretchability, however, they reduce the critical buckling force largely. Furthermore, I demonstrate the adaptive kiri-kirigami structure through local actuation with its tilting directions to be programmed and switched in response to the change of environmental temperature. Lastly, I demonstrate the potential promising outcome of kiri-kirigami structures as adaptive building envelope in energy efficient buildings, especially in electric saving for lighting and cooling load saving through numerical simulation. In addition to kirigami based soft metamaterials, I also investigate the utilization of soft materials and soft structures for robotics functions. First, I explore the design of soft doming actuator upon pneumatic actuation and its implications in design of multifunctional soft machines. I propose a novel bilayer actuator, which is composed of patterned embedded pneumatic channel on top for radial expansion and a solid elastomeric layer on bottom for strain-limiting. I show that both the cavity volume and bending angle at the rim of the actuated dome can be controlled by tuning the height gradient of the pneumatic channel along the radial direction. I demonstrate its potential multifunctional applications in swimming, adhesion, and gripping. I further explore harnessing doming-based bilayer doming actuator for developing soft climbing robot. I characterize and optimize the maximum shear adhesion force of the proposed soft adhesion actuator for strong and rapid reversible adhesion on multiple types of smooth and semi-smooth surfaces. Based on the switchable adhesion actuator, I design and fabricate a novel load-carrying amphibious climbing soft robot (ACSR) by combining with a soft bending actuator. I demonstrate that it can operate on a wide range of foreign horizontal and vertical surfaces, including dry, wet, slippery, smooth, and semi-smooth ones on ground, as well as under water with certain load-carrying capability. I show that the vertical climbing speed can reach about 286 mm/min (1.6 body length/min) while carrying over 200g object (over 5 times the weight of ACSR itself) during climbing on ground and under water. / Mechanical Engineering

Mechanical metamaterials are novel materials that display unique properties from their underlying microstructure topology rather than the constituent material they are made from. Their effective properties displayed at macroscale depend on the design of their microstructural topology. In this work, two classes of mechanical metamaterials are studied within the 2D-space. The first class is made of trusses, referred to as truss-based mechanical metamaterials. These materials are studied through their application to a beam component, where finite element analysis is performed to determine how truss-based microstructures affect the displacement behavior of the beam. This analysis is further subsidized with the development of a graphical user interface, where users can design a beam made of truss-based microstructures to see how their design affects the beam's behavior. The second class of mechanical metamaterial investigated is made of self-assembled structures, called spinodoids. Their smooth topology makes them less prone to high stress concentrations present in truss-based mechanical metamaterials. A large database of spinodoids is generated in this study. Through data-driven modeling the geometry of the spinodoids is coupled with their Young's modulus value to approach inverse design under uncertainty. To see mechanical metamaterials applied to industry they need to be better understood and thoroughly characterized. Furthermore, more tools that specifically help push the ease in the design of these metamaterials are needed. This work aims to improve the understanding of mechanical metamaterials and develop efficient computational design strategies catered solely for them. / Master of Science / Mechanical metamaterials are hierarchical materials involving periodically or aperiodically repeating unit cell arrangements in the microscale. The design of the unit cells allows these materials to display unique properties that are not usually found in traditionally manufactured materials. This will enable their use in a multitude of potential engineering applications. The presented study seeks to explore two classes of mechanical metamaterials within the 2D-space, including truss-based architectures and spinodoids. Truss-based mechanical metamaterials are made of trusses arranged in a lattice-like framework, where spinodoids are unit cells that contain smooth structures resulting from mimicking the two phases that coexist in a phase separation process called spinodal decomposition. In this research, computational design strategies are applied to efficiently model and further understand these sub-classes of mechanical metamaterials.

<p>Metamaterials are artificially structured materials which attain their unconventional macroscopic properties from their cellular configuration rather than their constituent chemical composition. The judicious design of this cellular structure opens the possibility to program and control the optical, mechanical, acoustic, or thermal responses of metamaterials. This Ph.D. dissertation focuses on scalable design and manufacturing strategies for optical and mechanical metamaterials.<br> <br> </p> <p>The fabrication of optical metamaterials still relies heavily on low-throughput process such as electron beam lithography, which is a serial technique. Thus, there is a growing need for the development of high-throughput, parallel processes to make the fabrication of optical metamaterials more accessible and cost-effective. The first part of this dissertation presents a scalable manufacturing method, termed “roll-to-roll laser induced superplasticity” (R2RLIS), for the production of flexible optical metamaterials, specifically metallic near-perfect absorbers. R2RLIS enables the rapid and inexpensive fabrication of ultra-smooth metallic nanostructures over large areas using conventional CO₂ engravers or inexpensive diode lasers. Using low-cost metal/epoxy nanomolds, the minimum feature size obtained by R2RLIS was <40 nm, facilitating the rapid fabrication of flexible near-perfect absorbers at visible frequencies with the capability to wrap around non-planar surfaces.</p> <p> </p> <p>The existing approaches for designing mechanical metamaterials are mostly <i>ad hoc</i>, and rely heavily on intuition and trial-and-error. A rational and systematic approach to create functional and programmable mechanical metamaterials is therefore desirable to unlock the vast design space of mechanical properties. The second part of this dissertation introduces a systematic, algorithmic design strategy based on Voronoi tessellation to create architected soft machines (ASMs) and twisting mechanical metamaterials (TMMs) with programmable motion and properties. ASMs are a new class of soft machines that benefit from their 3D-architected structure to expand the range of mechanical properties and behaviors achievable by 3D printed soft robots. On tendon-based actuation, ASMs deform according to the topologically encoded buckling of their structure to produce a wide range of motions such as contraction, twisting, bending, and cyclic motion. TMMs are a new class of chiral mechanical metamaterials which exhibit compression-twist coupling, a property absent in isotropic materials. This property manifests macroscopically and is independent of the flexible material chosen to fabricate the TMM. The nature of this compression-twist coupling can be programmed by simply tuning two design parameters, giving access to distinct twisting regimes and tunable onset of auxetic (negative Poisson’s ratio) behavior. Taking a metamaterial approach toward the design of soft machines substantially increases their number of degrees of freedom in deformation, thus blurring the boundary between materials and machines.</p>

<p dir="ltr">Structural instability, traditionally deemed undesirable in engineering, can be leveraged for beneficial outcomes through intelligent design. One notable instance is elastic buckling, often leading to structures with two stable equilibria (bistable). Connecting bistable elements to form multistable mechanical metamaterials can enable the discretization and offer tunability of mechanical properties without the need for continuous energy input.<i> </i>In this work, we study the physics of these multistable metamaterials and utilize their state and property alterations along with snap-through instabilities resulting from state change for engineering applications. These materials hold potential for diverse applications, including mechanical and thermo-mechanical defrosting, energy absorption, energy harvesting, and mechanical storage and computation.</p><p dir="ltr">Focusing on defrosting, we find that the energy-efficient mechanical method using embedded bistable structures in heat exchanger fins significantly outperforms the thermal methods. The combination of manufacturing methods, material choice, boundary conditions, and actuation methodologies is systematically investigated to enhance defrosting performance. A purely mechanical strategy is effective against solid, glaze-like ice accumulations; however, performance is substantially diminished for low-density frost. To address this limitation, we study frost formation on the angular shape morphing fins and subsequently introduce a thermo-mechanical defrosting strategy. This hybrid approach focuses on the partial phase transition of low-density frost to solid ice through thermal methods, followed by mechanical defrosting. We experimentally validate this approach on a multistable heat exchanger fin pack.</p><p dir="ltr">Recent advancements have led to a new paradigm of reusable energy-absorbing materials, known as Phase Transforming Cellular Materials (PXCM) that utilize multiple negative stiffness elements connected in series. We explore the feasibility of this multistable metamaterial as frequency up-conversion material and utilize these phase transformations for energy harvesting. We experimentally demonstrate the energy-harvesting capabilities of a phase-transforming unit-cell-spring configuration and investigate the potential of multicell PXCM as an energy harvesting material.</p><p dir="ltr">The evolution towards intelligent matter, or physical intelligence, in the context of mechanical metamaterials can be characterized into four distinct stages: static, responsive, adaptive, and intelligent mechanical metamaterials. In the pursuit of designing intelligent mechanical metamaterials, there has been a resurgence in the field of mechanical computing. We utilize multistable metamaterials to develop mechanical storage systems that encode memory via bistable state changes and decode it through a global stiffness readout. We establish upper bounds for maximum memory capacity in elastic bit blocks and propose an optimal stiffness distribution for unique and identifiable global states. Through both parallel and series configurations, we realize various logic gates, thereby enabling in-memory computation. We further extend this framework by incorporating viscoelastic mechano-bits, which mimic the decay of neuronal action potentials. This allows for temporal stiffness modulation and results in increased memory storage via non-abelian behavior, for which we define a fundamental time limit of detectability. Additionally, we investigate information entropy in both elastic and viscoelastic systems, showing that temporal neural coding schemes can extend the system’s entropy beyond conventional limits. This is experimentally validated and shown to not only enhance memory storage but also augment computational capabilities.</p><p dir="ltr">The work in this thesis establishes multistability as a key design principle for developing responsive, adaptive, and intelligent materials, opening new avenues for future research in the field of multistable metamaterials.</p>