Shape control of an adaptive 3D-printed beam with integrated FBG sensors and SMA wires: modeling and experimental testing

The advancement of 3D-printing technology has opened a new horizon in the product development and production of machine components. However, there are numerus parameters (infill pattern, density, temperature, etc.) affecting the mechanical properties of the final product. This fact leads to huge uncertainty between the design and the final product. In this work, an adaptive 3D-printed beam integrated with FBG sensors and Shape Memory alloy wires has been developed. The FBG sensors provide accurate and real-time measurement of strains at desired locations upon application of external loads. Upon detecting excessive strain, the embedded SMA wires activate to recover the deflection to the safe zone. An in-house experimental setup has been developed to illustrate the performance and functionality of the proposed adaptive beam. An electric current is utilized to activate the SMA wires when desired using an on–off control system. Depending on the applied loads, activation of SMA wires can fully or partially recover the original shape of the beam.