Controlled shape changing components using 4D printing technology by fused filament fabrication

The talk presents in detail 4D printing technology, its classification, and shape controlling techniques. The main focus is on using fused filament fabrication/ fused deposition modeling 3D printing for creating shape-changing structures. The mechanism of the shape memory effect and different programming strategies involved has been presented with various experimental case studies.

The case study provides an essential aspect for controlling the shape-changing capabilities applied to few 4D printed prototypes. This combination of shape memory property and widely used low-cost 3D printing offers a simple and economically feasible means to print very complex structures that can be self-morphing, self-healing, and reconfigurable.

A presentation by Bijaya Bikram Samal, Indian Institute of Technology, Kharagpur.


Question 1: What drives you?
Nature. Nature is the only thing that drives me to develop materials that can be smart enough to behave/ mimic like living things around us. I have been working on 4D printing and smart materials for the last 5 years and I want to explore how we can control the shape-changing capability by tuning the processing conditions to create unimaginable applications.

Question 2: Why should the delegate attend your presentation?
4D printing is in its initial stage of research and development. My presentation will discuss the broad classification of 4D printing technology that will be useful for researchers/ delegates to choose their area of interest. In my presentation, I will present experimental studies on shape memory alloy embedded 4D printing, 4D printing of shape memory polymer using fused filament fabrication, and the shape control mechanisms for 4D printed parts which are actually beneficial for real-time applications.

Question 3: What emerging technologies/trends do you see as having the greatest potential in the short and long run?
One of the emerging technology that has great potential in near future is application-driven 4D printing of shape memory composites

Question 4: What kind of impact do you expect them to have?
Application-driven material development for 4D printing applications can have a great impact in the field of medicine, aerospace, military, MEMS devices, electronics, etc.

Question 5: What are the barriers that might stand in the way?
Printability of the developed composites
High material and manufacturing cost

About Bijaya Bikram Samal
He is a senior doctoral researcher working in the Direct Digital Manufacturing Lab, Indian Institute of Technology, Kharagpur, India. His research focuses on developing controlled self morphing structures using 4D printing technology. He is using the process of shape memory-material extrusion additive manufacturing to explore the ability to control shape morphing. Apart from that, he is also developing a novel hybrid nanocomposite of thermoplastic shape memory polymers for 4D printing applications.

He is an M.Tech university gold medalist and his research work was focused on “Controlled shape changing components using 4D printing technology”. To achieve it, embedding the pre-programmed shape memory alloy during the process of FFF 3D printing was explored. Finally, he was able to demonstrate the actuation of an origami structure. He was awarded by Hon’ble Chief Minister of Odisha, India for his innovation which involved making a smart engine that can produce electricity from waste hot water like from hot springs. He co-founded “FreeGEn” which was selected among the top startup ideas by Startup India. He has also worked extensively on micromachining of Ni-Ti shape memory alloy using advanced manufacturing processes.

He is a strong proponent of open and collaborative research in the field of 4D printing technology and the processing of smart materials.

For more details go to this page.

About Indian Institute of Technology, Kharagpur
Indian Institute of Technology Kharagpur (IIT Kharagpur) is a public technical university established by the government of India in Kharagpur, West Bengal, India. Established in 1951, the institute is the first of the IITs to be established and is recognised as an Institute of National Importance. In 2019 it was awarded the status of Institute of Eminence by the government of India. Indian Institute of Technology Kharagpur (IIT-KGP) is one of the top Public universities in Kharagpur, India. It is ranked #280 in QS Global World Rankings 2022.
The institute was initially established to train engineers after India attained independence in 1947. However, over the years, the institute’s academic capabilities diversified with offerings in management, law, architecture, humanities, etc. IIT Kharagpur has an 8.7-square-kilometre (2,100-acre) campus and has about 22,000 residents. IIT Kharagpur has 19 academic departments, eight multi-disciplinary centres/schools, and 13 schools of excellence in addition to more than 25 central research and development units.

The Institute aligns all its activities to serve national interest and seeks
To provide broad-based education, helping students hone their professional skills and acquire the best-in-class capabilities in their respective disciplines
To draw the best expertise in science, technology, management and law so as to equip students with the skills to visualize, synthesize and execute projects in these fields
To imbibe a spirit of entrepreneurship and innovation in its students
To undertake sponsored research and provide consultancy services in industrial, educational and socially relevant areas

To be a centre of excellence in education and research, producing global leaders in science, technology and management
To be a hub of knowledge creation that prioritises the frontier areas of national and global importance
To improve the life of every citizen of the country

Bijaya Bikram Samal is speaker at the 2022 edition of the 4D Printing & Meta Materials Conference.

Leave a Reply

Your email address will not be published.