A new concept of structural smart fabric activated by shape memory alloys

This work presents the development, prototyping and validation of a new concept of structure called structural smart fabric (SSF). An SSF is a chainmail fabric composed by interconnected elements, called cells, which can be stiffened by reactive elements, such as those made by shape memory alloy (SMA). Exploiting the shape memory functionality, SSFs are capable of sensing and reacting to external stimuli. Based on this concept, in this study we propose an SSF that integrates SMA wires into a 3D-printed chainmail structure. The shape memory effect of these wires is used as an actuating mechanism that, at high temperature, tightens the adjacent cells together and provides increased structural stiffness. In this study, finite element simulations were initially conducted to enhance the comprehension of the SSF’s mechanical behaviour. The influence of the initial cell spacing on the SSF stiffness and the wire stress profiles was evaluated during bending loading, as well as the evolution of contact pressure profiles between adjacent cells. This numerical approach enabled to tune the design of the SSF prototypes which were successively manufactured using selective laser sintering additive manufacturing technology with PA12. After the integration with the SMA wires, the SSF prototypes were tested under a 3-point bending configuration at different temperatures. The results revealed a remarkable increase in structural stiffness at elevated temperatures compared to ambient conditions. This study set the basis for a deeper understanding of SSF’s unique capabilities and potential applications in fields where adaptive and responsive structures are required.