FluxLab: Creating 3D Printable Shape-Changing Devices with Integrated Deformation Sensing

TL;DR

FluxLab addresses the challenge of creating 3D-printed shape-changing devices with integrated deformation sensing by introducing FluxIO, a three-layer architectural design that nests an SMA-based actuator/sensor channel inside a gyroid padding lattice and a parallel helix surface framework. The system includes FluxEditor for converting models and tuning elasticity and deformation behavior, along with FluxShaper for generating ML-based classifiers that recognize deformation from inductive sensing. Through a workflow that culminates in post-print SMA installation and ML deployment, FluxLab enables rapid prototyping of interactive devices, demonstrated by examples such as a self-deformable steamer clip, remotely controllable gripper, and kids’ desk lamp. The work offers a reproducible framework for integrating actuation and sensing via structural design, with implications for accessible, printable shape-changing interfaces, while outlining limitations and directions for broader material choices, multi-part designs, and non-expert usability.

Abstract

We present FluxLab, a system comprising interactive tools for creating custom 3D-printable shape-changing devices with integrated deformation sensing. To achieve this, we propose a 3D printable nesting structure, consisting of a central SMA channel for sensing and actuation, lattice-based padding in the middle for structural support and controllable elasticity, and parallel helix-based surface wires that preserve the overall form and provide anchoring struts for guided deformation. We developed a design editor to embed these structures into custom 3D models for printing with elastic silicone resin on a consumer-grade SLA 3D printer and minimal post-printing assembly. A deformation authoring tool was also developed for users to build a machine learning-based classifier that distinguishes desired deformation behaviors using inductive sensing. Finally, we demonstrate the potential of our system through example applications, including a self-deformable steamer bowl clip, a remotely controllable gripper, and an interactive desk lamp.

Figures (9)

• Figure 1: The integrated FluxIO mechanism comprises three components (a): a two-way Nitinol SMA spring (inner), gyroid-based lattice padding (middle), and parallel helix-based surface wireframe (outer). (b) A solid surface anchor can be added to produce lateral bending.
• Figure 2: The spring SMA becomes a (a) coil-based inductor for inductive sensing under different body deformation, such as (b) compression and bending.
• Figure 3: The anchor width is a contributing factor to impact the bending behavior: (a) a narrow anchor leads to a larger lateral bending angle compared with (b) the one with a wide anchor.
• Figure 4: The user interfaces of (a) FluxEditor and (b) FluxShaper.
• Figure 5: The post-printing process includes: (a) crimp the SMA spring and the conductive wire on one end, (b) crimp another end while the wire goes through the spring's central body, (c) insert one end of the SMA-and-wire group into the model, (d) install the other end of the group with the other part of the model, and (e) bond two model parts with silicone adhesive.