This study describes a multi-faceted materials selection problem that ultimately produces a new class of polymerfiber composites with failure strains of near 400% and ultimate tensile strengths (UTSs) up to 20 MPa. Independent control of the rubbery modulus (proportional to the compressive force the composite can apply) is demonstrated by altering the crosslinker density of the polymer matrix and the fiber weave. The stress the composite can withstand can be modified with changing fiber material and weave geometry. The resulting SMPfiber composites can be designed with glass transition temperatures (Tgs) ranging from 0C to 75C, and specific multi-layer combinations of these systems provide a promising candidate for orthopedic casts: specifically, a woven anteres nylon lycra mesh rigidized with a polymer synthesized from methyl acrylate, butyl acrylate, isobornyl acrylate, and trimethylol propane triacrylate. The results of this study are intended to enable future orthopedic applications where the ability to accurately and independently position Tg and the ability to tune recoverable force in toughened, fiber-reinforced SMPs are required.
