Development of Multi-material FDM 3D Printing Processes for Exploring Reinforced Soft Mechanisms

This internship investigates the manufacturing and performance of reinforced soft mechanisms. A re-entrant honeycomb auxetic structure is produced using multi-material FDM 3D printing, combining flexible materials (TPU, TPE) for compliance with carbon-filled materials (PLA-CF, PC-CF) for structural reinforcement. Safety considerations regarding emissions of Volatile Organic Compounds (VOCs) are addressed via the development of an air-filtered printer enclosure for an existing multi-material FDM 3D printer. Material bonding in the produced prototype specimens is achieved through mechanical interlocking, a technique that relies on geometric modifications at the connection points. Elongation and cyclic tests were conducted to identify failure locations and assess the presence of nonlinear material behavior.