Stronger than bolts: New 3D-printed joints could change engineering

An individual cell of the two proposed versions of ILMs in their different engagement states. Credit: Dr. Ibrahim Karaman.

Researchers from Texas A&M University and Sandia National Laboratories have developed a groundbreaking joining technology called interlocking metasurfaces (ILMs).

This new method could make mechanical joints in industries like aerospace, robotics, and biomedical devices stronger and more stable compared to traditional techniques like bolts or adhesives.

ILMs work by locking two surfaces together in a way similar to how Velcro or Legos connect pieces.

However, unlike bolts or glue, ILMs offer the possibility of easily taking apart and reassembling parts without losing strength or stability.

The research team, led by Dr. Ibrahim Karaman from Texas A&M’s Department of Materials Science and Engineering, has advanced this technology by integrating shape memory alloys (SMAs) into ILMs.

SMAs, specifically nickel-titanium, have the unique ability to return to their original shape after being deformed when exposed to changes in temperature.

This innovation allows ILMs to be actively controlled, meaning the joints can be engaged or disengaged on demand simply by changing the temperature.

Dr. Karaman explains that this technology could revolutionize mechanical joint designs, making them smarter and more adaptable to different needs.

For example, ILMs could be used in aerospace engineering where parts need to be assembled and disassembled multiple times.

In robotics, ILMs could offer more flexible joints, allowing robots to perform tasks with greater precision.

In the medical field, ILMs could improve the design of implants or prosthetics, allowing them to adjust to the body’s movements or temperature changes.

The researchers have already demonstrated that ILMs made with SMAs can maintain their shape and strength with the application of heat.

They are now working on improving this design by exploring the superelastic properties of SMAs, which could allow ILMs to withstand large amounts of stress and quickly recover their original shape.

While challenges remain in perfecting this technology, the research team is excited about the future potential of ILMs.

Dr. Karaman believes that ILMs could eventually provide stronger, more flexible, and more reliable connections in extreme environments, such as outer space or deep-sea exploration. The team’s findings were published in Materials & Design.

This exciting new technology could soon replace traditional methods of joining materials, offering stronger and more versatile connections across multiple industries.

Source: Texas A&M University.