Smart dynamic structures with integrated actuation and sensing enable vibration control, and single-process multi-material 3D printing enables manufacturing from thermoplastics without post-processing. Realizing such structures requires a single-process 3D-printed electrothermal actuator governed by an analytical model that accounts for temperature-dependent and orthotropic material properties. Additionally, a non-contact characterization method and temperature compensation of embedded sensors subjected to actuator-induced heating are necessary. This dissertation presents a non-contact method for the simultaneous identification of the elastic modulus, damping ratio, and coefficient of thermal expansion of 3D-printed structures. Based on these characterizations, the first single-process 3D-printed bimorph electrothermal actuator is developed, accompanied by a three-step analytical model predicting tip deflection, blocking force, and actuation time. For reliable sensor operation, a temperature self-compensation model for dynamic sensitivity is proposed, exploiting the proportionality between resistance and sensitivity changes in piezoresistive sensors. The results demonstrate that composite polymers exhibit orthotropic properties, while all investigated 3D-printed thermoplastics display strong temperature dependence. The proposed model accurately predicts actuator response, whereas conventional models overestimate blocking force by 97 to 108 %. Sensitivity self-compensation achieves errors below 5 % without requiring an additional temperature sensor. Collectively, these contributions establish the foundations for single-process 3D-printed smart dynamic structures with integrated actuation and sensing functionality.
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