Shape-morphing structured materials have the ability to transform a range of applications. However, their design and fabrication remain challenging due to the difficulty of controlling the underlying metric tensor in space and time. Here, we exploit a combination of multiple materials, geometry, and 4-dimensional (4D) printing to create structured heterogeneous lattices that overcome this problem. Our printable inks are composed of elastomeric matrices with tunable cross-link density and anisotropic filler that enable precise control of their elastic modulus (E) and coefficient of thermal expansion (α). The inks are printed in the form of lattices with curved bilayer ribs whose geometry is individually programmed to achieve local control over the metric tensor. For independent control of extrinsic curvature, we created multiplexed bilayer ribs composed of 4 materials, which enables us to encode a wide range of 3-dimensional (3D) shape changes in response to temperature. As exemplars, we designed and printed planar lattices that morph into frequency-shifting antennae and a human face, demonstrating functionality and geometric complexity, respectively. Our inverse geometric design and multimaterial 4D printing method can be readily extended to other stimuli-responsive materials and different 2-dimensional (2D) and 3D cell designs to create scalable, reversible, shape-shifting structures with unprecedented complexity.

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A new class of silicon-based deformable mirrors is described. These devices are capable of correcting time-varying aberrations in imaging or beam forming applications. Each mirror is composed of a flexible silicon membrane supported by an underlying array of electrostatic parallel plate actuators. All structural and electronic elements were fabricated through conventional surface micromachining using polycrystalline silicon thin films. A layout and fabrication design strategy for reducing nonplanar topography in multilayer micromachining was developed and used to achieve nearly flat membrane surfaces. Several deformable mirrors were characterized for their electromechanical performance. Real-time correction of optical aberrations was demonstrated using a single mirror segment connected to a closed-loop feedback control system. Undesirable mirror contours caused by residual stress gradients in the membrane were observed.

The authors describe the development of a new type of micromachined device designed for use in correcting optical aberrations. A nine-element continuous deformable mirror was fabricated using surface micromachining. The electromechanical behavior of the deformable mirror was measured. A finite-difference model for predicting the mirror deflections was developed. In addition, novel fabrication techniques were developed to permit the production of nearly planar mirror surfaces.

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