4D printing for crack trapping and adaptive damage-tolerant structures

Morteza Sayah Irani, Mohammad Lakhi, Sadegh Ranjbar, Ali Zolfagharian · Emerald · 2025

A review synthesizes how 4D printing can enable crack trapping and damage-tolerant behavior through smart, metamaterial-based self-sensing and time-dependent shape change.

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Plain English summary

This paper reviews how damage tolerance can be achieved in 4D-printed mechanical structures. It focuses on how choosing materials, designing structures, and using 4D printing processes affect how structures respond to stress. The review emphasizes smart materials and metamaterials, especially mechanisms that can sense damage (self-sensing) and change shape over time (shape-morphing). It also considers fatigue and cyclic loading, where repeated stress can drive crack growth. Across experimental and computational studies, the paper highlights design and fabrication factors such as layer-by-layer control and stimulus-responsive behaviors. These are linked to improved crack deflection, energy dissipation, and structural recovery in 4D-printed systems.

Why this matters

It claims originality by uniquely synthesizing damage-tolerant design in 4D-printed structures and framing it as a multi-functional outcome enabled by 4D printing’s intrinsic capabilities (self-adaptivity, shape transformation, time-dependent behavior). The abstract describes a review of experimental and computational studies but provides no evidence of prototypes, field testing, or commercial deployment.

Key findings

  • 4D-printed structures can better handle damage when smart materials (notably metamaterials) and time-changing designs are used.
  • Self-sensing and shape-morphing capabilities are highlighted as effective for detecting and mitigating damage under cyclic loading and fatigue.
  • Layer-by-layer control and stimulus-responsive behaviors are associated with improved crack deflection, energy dissipation, and structural recovery.

Limitations

As a review, it does not present new experimental results in the abstract; it summarizes and compares existing experimental and computational studies. The abstract does not specify quantitative performance metrics, specific material systems, or which designs are most effective.

Publication

Publisher
Emerald
Publication date
October 14, 2025
Research type
Paper
License
https://creativecommons.org/licences/by/4.0/

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Method note: Summaries and ratings on this page are generated by AI from the abstract only. Read the original paper for full context. · Model: gpt-5.4-nano-2026-03-17