Researchers develop new joining technology with 3D printing

As part of a collaboration between Texas A&M University and Sandia National Laboratories, researchers have significantly improved a new joining technology, interlocking metasurfaces (ILMs), to increase the strength and stability of a structure compared to traditional techniques such as screws and adhesives through the use of shape memory alloys (SMAs).

“ILMs are poised to redefine joining technologies across a range of applications, much like Velcro did decades ago,” said Dr. Ibrahim Karaman, professor and head of the Department of Materials Science and Engineering Department at Texas A&M. “In collaboration with Sandia National Laboratories, the original developers of ILMs, we have engineered and fabricated ILMs from shape memory alloys. Our research demonstrates that these ILMs can be selectively disengaged and re-engaged on demand while maintaining consistent joint strength and structural integrity.”

The research results were published in the journal Materials & Design. By using 3D printing, the teams were able to develop active ILMs that are controlled by temperature changes. This opens up new possibilities for intelligent, adaptive structures that retain their flexibility and functionality.

“Active ILMs have the potential to revolutionize mechanical joint design in industries requiring precise, repeatable assembly and disassembly,” said Abdelrahman Elsayed, graduate research assistant in the materials science and engineering department at Texas A&M.

Practical applications of this technology include reconfigurable components in aerospace, flexible joints for robots, and customizable implants and prosthetics in medical devices.

“We anticipate that incorporating SMAs into ILMs will unlock numerous future applications, though several challenges remain,” said Karaman. “Achieving superelasticity in complex 3D-printed ILMs will enable localized control of structural stiffness and facilitate reattachment with high locking forces. Additionally, we expect this technology to address longstanding challenges associated with joining techniques in extreme environments. We are highly enthusiastic about the transformative potential of ILM technology.”

The research is funded by the Texas A&M Engineering Experiment Station (TEES) and contributes to the further development of additive manufacturing technologies.