Influence of Carbonyl Iron Particle Loading on the Dimensional and Rheological Properties of 4D-Printed TPU-Based Magnetorheological Elastomers

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nThis is an unedited manuscript accepted for publication and provided as an Article in Press for early access at the author’s request. The article will undergo copyediting, typesetting, and galley proof review before final publication. Please be aware that errors may be identified during production that could affect the content. All legal disclaimers of the journal apply.n

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Year : 2025 [if 2224 equals=””]14/10/2025 at 12:08 PM[/if 2224] | [if 1553 equals=””] Volume : 13 [else] Volume : 13[/if 1553] | [if 424 equals=”Regular Issue”]Issue : [/if 424][if 424 equals=”Special Issue”]Special Issue[/if 424] [if 424 equals=”Conference”][/if 424] 06 | Page : 127 138

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    Ahmad Fitri Sukarman, Norasyidah Mohd Noh, Nurulhuda Khalid, Saiful Amri Mazlan, Mohd Aidy Faizal Johari, Muhammad Farhan Mohamad Fitri, Shahir Mohd Yusuf, Nur Azmah Nordin, Abdul Yasser Abd Fatah,

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  1. Student, Lecturer, Lecturer, Professor, Post Doctoral, Student, Senior Lecturer, Senior Lecturer, Senior Lecturer, Department of Engineering Materials and Structures (eMast) iKohza, Malaysia-Japan International Institute of Technology (MJIIT), Universiti Teknologi Malaysia (UTM), Department of Mechanical Engineering, Politeknik Banting Selangor, Department of Mechanical Engineering, Politeknik Banting Selangor, Department of Engineering Materials and Structures (eMast) iKohza, Malaysia-Japan International Institute of Technology (MJIIT), Universiti Teknologi Malaysia (UTM), Department of Engineering Materials and Structures (eMast) iKohza, Malaysia-Japan International Institute of Technology (MJIIT), Universiti Teknologi Malaysia (UTM), Department of Engineering Materials and Structures (eMast) iKohza, Malaysia-Japan International Institute of Technology (MJIIT), Universiti Teknologi Malaysia (UTM), Department of Engineering Materials and Structures (eMast) iKohza, Malaysia-Japan International Institute of Technology (MJIIT), Universiti Teknologi Malaysia (UTM), Department of Engineering Materials and Structures (eMast) iKohza, Malaysia-Japan International Institute of Technology (MJIIT), Universiti Teknologi Malaysia (UTM), Department of Smart Engineering and Advanced Technology, Faculty of Artificial Intelligence, Universiti Teknologi Malaysia (UTM), Kuala Lumpur, Banting, Banting, Kuala Lumpur, Kuala Lumpur, Kuala Lumpur, Kuala Lumpur, Kuala Lumpur, Kuala Lumpur, Malaysia, Malaysia, Malaysia, Malaysia, Malaysia, Malaysia, Malaysia, Malaysia, Malaysia

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nThe advancement of 4D printing technologies has created new opportunities for fabricating smart materials with tunable properties, including magnetorheological elastomers (MREs). This study investigates the fabrication and characterization of thermoplastic polyurethane (TPU)-based MREs with varying carbonyl iron particle (CIP) loadings (10–50 wt.%) using the fused filament fabrication (FFF) method. MRE filaments were produced through a solvent-assisted mixing and extrusion process, ensuring consistent diameters within 1.75 ± 0.10 mm. Test specimens were printed under fixed processing parameters to assess printability, dimensional fidelity, mechanical hardness, and rheological behaviour. Results showed that all FFF-printed MREs achieved high dimensional accuracy, with deviations below 5.5%, and exhibited a progressive increase in Shore A hardness and off-state storage modulus (G′) with higher CIP content. Under an applied magnetic field, all samples displayed the magnetorheological effect, with stiffness enhancement proportional to CIP loading. Comparative analysis with previously reported fused granulate fabrication (FGF)-printed MREs revealed that FFF yields higher baseline stiffness but a comparatively lower MR effect, attributed to anisotropic particle alignment during filament extrusion. These findings highlight the trade-offs between dimensional precision, inherent stiffness, and field responsiveness in additively manufactured MREs, providing valuable insights for their application in adaptive structures, tunable damping systems, and soft robotic actuators.nn

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Keywords: 4D printing, 3D printing, fused filament fabrication, fused granulate fabrication, magnetorheological elastomer.

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nAhmad Fitri Sukarman, Norasyidah Mohd Noh, Nurulhuda Khalid, Saiful Amri Mazlan, Mohd Aidy Faizal Johari, Muhammad Farhan Mohamad Fitri, Shahir Mohd Yusuf, Nur Azmah Nordin, Abdul Yasser Abd Fatah. [if 2584 equals=”][226 wpautop=0 striphtml=1][else]Influence of Carbonyl Iron Particle Loading on the Dimensional and Rheological Properties of 4D-Printed TPU-Based Magnetorheological Elastomers[/if 2584]. Journal of Polymer and Composites. 08/10/2025; 13(06):127-138.

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nAhmad Fitri Sukarman, Norasyidah Mohd Noh, Nurulhuda Khalid, Saiful Amri Mazlan, Mohd Aidy Faizal Johari, Muhammad Farhan Mohamad Fitri, Shahir Mohd Yusuf, Nur Azmah Nordin, Abdul Yasser Abd Fatah. [if 2584 equals=”][226 striphtml=1][else]Influence of Carbonyl Iron Particle Loading on the Dimensional and Rheological Properties of 4D-Printed TPU-Based Magnetorheological Elastomers[/if 2584]. Journal of Polymer and Composites. 08/10/2025; 13(06):127-138. Available from: https://journals.stmjournals.com/jopc/article=08/10/2025/view=0

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Volume 13
[if 424 equals=”Regular Issue”]Issue[/if 424][if 424 equals=”Special Issue”]Special Issue[/if 424] [if 424 equals=”Conference”][/if 424] 06
Received 26/08/2025
Accepted 05/09/2025
Published 08/10/2025
Retracted
Publication Time 43 Days

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