NiTi shows a very promising combination of properties among different shape memory alloys. However, machining NiTi is a challenging task, making the manufacturing of complex geometries hard to nearly impossible using conventional manufacturing routes. As a result, the material’s full potential of the material has not been harnessed. The pseudoelastic properties of bulk NiTi are restricted to an 8 % strain. Additive manufacturing of NiTi using laser powder bed fusion (LPBF) has been demonstrated as a successful alternative production route, capable of exhibiting pseudoelastic behavior even in the as-built state. Existing literature has shown that modifications of the processing parameters can change the properties of Ni-rich NiTi significantly, which can be utilized intentionally to control the pseudoelastic properties in LPBF-manufactured NiTi. The fabrication of porous and lattice structures using LPBF allows to attain specific properties. This is achieved not only through the adjustment of the laser parameters and scanning pattern but also by enabling the creation of specifically tailored feature sizes and geometrical designs, such as unit cell design, the number and distribution of unit cells, and gradation. These geometrical structures go beyond the conventional unit cell designs (like the bcc unit cell), and when combined with the unique material behavior, they can result in extraordinary properties. It is possible to create a programmable material whose behavior can follow a logical description. The influence of lattice structure geometry and manufacturing parameters on the mechanical and functional performance will be discussed in the following. In addition, we present a structure whose stiffness behavior follows an if-then-else statement regarding to the effective strain and permits an effective strain exceeding 20 % without failure. The structure can be implemented in a planar clamping element which allows an adjustment to different shapes because of the high and low stiffness in different strain ranges.

While SMA wire-based actuators hold great potential across a range of industries, including medical, automotive, and consumer goods, the system integration of these wires poses a significant challenge, particularly in the context of fully automated mass production. Currently in all known industrial applications, only crimp or splice connectors are employed to connect the wire to its system environment. However, there is no standardized method for systematically designing crimp connectors while considering application-specific requirements. Furthermore, the property rights situation becomes more restrictive, as the protection claim of an expanding number of patents extends beyond the technical design of SMA actuators to their production processes in detail. Nevertheless, crucial process characteristics, particular those related to a crimping process, are undisclosed. In addition, since these documents usually describe specific products, transferring them to other applications remains difficult. To address these challenges, the fundamental connection mechanisms of crimp connectors will be analyzed, and an easily scalable crimping concept will be developed, considering existing intellectual property rights. This crimping concept is then characterized by a parameter study using the Design of Experiments method and static pull-out tests to identify crucial influencing factors and their interactions and to be able to build a mathematical model that maps the parameter- dependent pull-out strength of the connection. Based on the theoretical analysis of the fundamental connection mechanisms and the practical insights into influences and interactions affecting the static pull-out strength of the crimp connection, a systematic method will be devised to facilitate the design of model-based, cycle-resistant crimp connections in accordance with application-specific requirements.

While SMA wire-based actuators hold great potential across a range of industries, including medical, automotive, and consumer goods, the system integration of these wires poses a significant challenge, particularly in the context of fully automated mass production. Currently in all known industrial applications, only crimp or splice connectors are employed to connect the wire to its system environment. However, there is no standardized method for systematically designing crimp connectors while considering application-specific requirements. Furthermore, the property rights situation becomes more restrictive, as the protection claim of an expanding number of patents extends beyond the technical design of SMA actuators to their production processes in detail. Nevertheless, crucial process characteristics, particular those related to a crimping process, are undisclosed. In addition, since these documents usually describe specific products, transferring them to other applications remains difficult. To address these challenges, the fundamental connection mechanisms of crimp connectors will be analyzed, and an easily scalable crimping concept will be developed, considering existing intellectual property rights. This crimping concept is then characterized by a parameter study using the Design of Experiments method and static pull-out tests to identify crucial influencing factors and their interactions and to be able to build a mathematical model that maps the parameter- dependent pull-out strength of the connection. Based on the theoretical analysis of the fundamental connection mechanisms and the practical insights into influences and interactions affecting the static pull-out strength of the crimp connection, a systematic method will be devised to facilitate the design of model-based, cycle-resistant crimp connections in accordance with application-specific requirements.