Design Concept for Direct 4D-Printed Thermally Actuated PLA Components for Potential Biomedical Applications

The development of 4D-printing technology enables the fabrication of smart structures capable of transforming in response to external stimuli, offering potential for future minimally invasive biomedical applications. This study explores a direct 4D-printing approach for producing thermally actuated polylactic acid (PLA) components, focusing on self-expanding vascular stent prototypes. Unlike conventional 4D printing, which typically requires a separate post-printing programming step (e.g., heating, mechanical loading, cooling, and unloading), direct 4D printing embeds the programming phase directly into the layer-wise printing process by controlling the adjustment of process parameters, so that components are ready for shape transformation immediately after fabrication. A systematic experimental workflow was applied by combining a problem-solving methodology with action research and structured experimentation to identify and optimize the key parameters governing shape-shifting behavior. Bilayer plate structures were fabricated via fused filament fabrication (FFF) using multiple PLA material combinations and were thermally actuated under controlled conditions to characterize the influence of printing speed, printing temperature, and infill pattern on the magnitude and directionality of deformation. Building on these results, three functional demonstrators were developed, culminating in a grid-based cylindrical prototype that achieved approximately 5.8% radial expansion upon actuation at temperatures above 80 °C. Overall, the results suggest the fundamental technological feasibility of direct 4D printing as a manufacturing route for thermally actuated components, serving as a foundational proof-of-concept for future patient-specific, self-deploying medical devices.