The demand for lightweight and high-strength composite structures is rapidly growing in aerospace and robotics, particularly for optimized drone frames. However, conventional composite manufacturing methods struggle to achieve complex 3D architectures for weight savings and rely on assembling separate components, which introduce weak points at the joints. Additionally, maintaining continuous fiber reinforcement remains challenging, limiting structural efficiency. In this study, we demonstrate the lightweight Face Centered Cubic (FFC) lattice structured conceptualization of drone frames for weight reduction and complex topology fabrication through 3D Fiber Tethering (3DFiT) using continuous single tow fiber ensuring precise fiber alignment, eliminating weak points associated with traditional composite assembly. Mechanical testing demonstrates that the fabricated drone frame exhibits a high specific strength of around four to eight times the metal and thermoplastic, outperforming other conventional 3D printing methods. The drone frame weighs only 260 g, making it 10% lighter than the commercial DJI F450 frame, enhancing structural integrity and contributing to an extended flight time of three minutes, while flight testing confirms its stability and durability under operational conditions. The findings demonstrate the potential of single tow lattice truss-based drone frames, with 3DFiT serving as a scalable and efficient manufacturing method.

Shape memory structures are playing an important role in many cutting-edge intelligent fields. However, the existing technologies can only realize 4D printing of a single polymer or metal, which limits practical applications. Here, we report a construction strategy for TSMP/M heterointerface, which uses Pd2+-containing shape memory polymer (AP-SMR) to induce electroless plating reaction and relies on molecular dynamics, which has both shape memory properties and metal activity and information processing power. Through multi-material DLP 3D printing technology, the interface can be 3D selectively programmed on functional substrate parts of arbitrary shapes to become 4D electronic smart devices (Robotics). Microscopically, this type of interface appears as a composite structure with a nanometer-micrometer interface height, which is composed of a pure substrate layer (smart materials), an intermediate layer (a composite structure in which metal particles are embedded in a polymer cross-linked network) and a pure metal layer. The structure programmed by TSMP/M heterointerface exhibits both SMA characteristics and metal properties, thus having more intelligent functions (electroactive, electrothermal deformation, electronically controlled denaturation) and higher performance (selectivity of shape memory structures can be realized control, remote control, inline control and low voltage control). This is expected to provide a more flexible manufacturing process as platform technology for designing, manufacturing and applying smart devices with new concepts, and promote the development of cutting-edge industries such as smart robots and smart electronics.

Soft deployable structures - unlike conventional piecewise rigid deployables based on hinges and springs - can assume intricate 3-D shapes, thereby enabling transformative technologies in soft robotics, shape-morphing architecture, and pop-up manufacturing. Their virtually infinite degrees of freedom allow precise control over the final shape. The same enabling high dimensionality, however, poses a challenge for solving the inverse design problem involving this class of structures: to achieve desired 3D structures it typically requires manufacturing technologies with extensive local actuation and control during fabrication, and a trial and error search over a large design space. We address both of these shortcomings by first developing a simplified planar fabrication approach that combines two ingredients: strain mismatch between two layers of a composite shell and kirigami cuts that relieves localized stress. In principle, it is possible to generate targeted 3-D shapes by designing the appropriate kirigami cuts and selecting the right amount of prestretch, thereby eliminating the need for local control. Second, we formulate a data-driven physics-guided framework that reduces the dimensionality of the inverse design problem using autoencoders and efficiently searches through the ``latent" parameter space in an active learning approach. We demonstrate the effectiveness of the rapid design procedure via a range of target shapes, such as peanuts, pringles, flowers, and pyramids. Tabletop experiments are conducted to fabricate the target shapes. Experimental results and numerical predictions from our framework are found to be in good agreement.

Composite materials with 3D architectures are desirable in a variety of applications for the capability of tailoring their properties to meet multiple functional requirements. By the arrangement of materials' internal components, structure design is of great significance in tuning the properties of the composites. However, most of the composite structures are proposed by empirical designs following existing patterns. Hindered by the complexity of 3D structures, it is hard to extract customized structures with multiple desired properties from large design space. Here we report a multi-objective driven Wasserstein generative adversarial network (MDWGAN) to implement inverse designs of 3D composite structures according to given geometrical, structural and mechanical requirements. Our framework consists a GAN based network which generates 3D composite structures possessing with similar geometrical and structural features to the target dataset. Besides, multiple objectives are introduced to our framework for the control of mechanical property and isotropy of the composites. Real time calculation of the properties in training iterations is achieved by an accurate surrogate model. We constructed a small and concise dataset to illustrate our framework. With multiple objectives combined by their weight, and the 3D-GAN act as a soft constraint, our framework is proved to be capable of tuning the properties of the generated composites in multiple aspects, while keeping the selected features of different kinds of structures. The feasibility on small dataset and potential scalability on objectives of other properties make our work a novel, effective approach to provide fast, experience free composite structure designs for various functional materials.

Fully soft bistable mechanisms have shown extensive applications ranging from soft robotics, wearable devices, and medical tools, to energy harvesting. However, the lack of design and fabrication methods that are easy and potentially scalable limits their further adoption into mainstream applications. Here a top-down planar approach is presented by introducing Kirigami-inspired engineering combined with a pre-stretching process. Using this method, Kirigami-Pre-stretched Substrate-Kirigami trilayered precursors are created in a planar manner; upon release, the strain mismatch -- due to the pre-stretching of substrate -- between layers would induce an out-of-plane buckling to achieve targeted three dimensional (3D) bistable structures. By combining experimental characterization, analytical modeling, and finite element simulation, the effect of the pattern size of Kirigami layers and pre-stretching on the geometry and stability of resulting 3D composites is explored. In addition, methods to realize soft bistable structures with arbitrary shapes and soft composites with multistable configurations are investigated, which could encourage further applications. Our method is demonstrated by using bistable soft Kirigami composites to construct two soft machines: (i) a bistable soft gripper that can gently grasp delicate objects with different shapes and sizes and (ii) a flytrap-inspired robot that can autonomously detect and capture objects.

The goal of this paper is to analyze and predict the central deflection, natural frequency, and critical buckling load of the multi-directional functionally graded (FG) plate with variable thickness resting on an elastic Winkler foundation. First, the mathematical models of the static and eigenproblems are formulated in great detail. The FG material properties are assumed to vary smoothly and continuously throughout three directions of the plate according to a Mori-Tanaka micromechanics model distribution of volume fraction of constituents. Then, finite element analysis (FEA) with mixed interpolation of tensorial components of 4-nodes (MITC4) is implemented in order to eliminate theoretically a shear locking phenomenon existing. Next, influences of the variable thickness functions (uniform, non-uniform linear, and non-uniform non-linear), material properties, length-to-thickness ratio, boundary conditions, and elastic parameters on the plate response are investigated and discussed in detail through several numerical examples. Finally, a deep neural network (DNN) technique using batch normalization (BN) is learned to predict the non-dimensional values of multi-directional FG plates. The DNN model also shows that it is a powerful technique capable of handling an extensive database and different vital parameters in engineering applications.

Developing machine learning enabled smart manufacturing is promising for composite structures assembly process. To improve production quality and efficiency of the assembly process, accurate predictive analysis on dimensional deviations and residual stress of the composite structures is required. The novel composite structures assembly involves two challenges: (i) the highly nonlinear and anisotropic properties of composite materials; and (ii) inevitable uncertainty in the assembly process. To overcome those problems, we propose a neural network Gaussian process model considering input uncertainty for composite structures assembly. Deep architecture of our model allows us to approximate a complex process better, and consideration of input uncertainty enables robust modeling with complete incorporation of the process uncertainty. Based on simulation and case study, the NNGPIU can outperform other benchmark methods when the response function is nonsmooth and nonlinear. Although we use composite structure assembly as an example, the proposed methodology can be applicable to other engineering systems with intrinsic uncertainties.