Morphing Metal and Elastomer Bicontinuous Foams for Reversible Stiffness, Shape Memory, and Self-Healing Soft Machines

Multi-stimulus perception and visualization by an intelligent liquid metal-elastomer architecture

Multi-stimulus responsive soft materials with integrated functionalities are elementary blocks for building soft intelligent systems, but their rational design remains challenging. Here, we demonstrate an intelligent soft architecture sensitized by magnetized liquid metal droplets that are dispersed in a highly stretchable elastomer network. The supercooled liquid metal droplets serve as microscopic latent heat reservoirs, and their controllable solidification releases localized thermal energy/information flows for enabling programmable visualization and display. This allows the perception of a variety of information-encoded contact (mechanical pressing, stretching, and torsion) and noncontact (magnetic field) stimuli as well as the visualization of dynamic phase transition and stress evolution processes, via thermal and/or thermochromic imaging. The liquid metal-elastomer architecture offers a generic platform for designing soft intelligent sensing, display, and information encryption systems.

Synthesis of Superelastic, Highly Conductive Graphene Aerogel/Liquid Metal Foam and its Piezoresistive Application

Graphene aerogel (GA) has important application potential as piezoresistive sensors due to its low density, high conductivity, high porosity, and good mechanical properties. However, the fabrication of GA-based sensors with good mechanical properties and excellent sensing performance is still challenging. Herein, liquid- metal-modified GAs (GA/LM) are proposed for the development of an excellent GA-based sensor. GA/LM with three-dimensional interconnected layered structure exhibits excellent compressive stress of 41 KPa and fast response time (<20 ms). While generally flexible GA composites cannot be compressed beyond 80 % strain without plastic deformation, GA/LM demonstrates a high compressive strength of 60 kPa under a strain of 90 %. A real-time pressure sensor was fabricated based on GA/LM-2 to monitor swallowing, pulse beating, finger, wrist and knee bending, and even plantar pressure during walking. These excellent features enable potential applications in health detection.

Hydraulic-driven adaptable morphing active-cooling elastomer with bioinspired bicontinuous phases

The active-cooling elastomer concept, originating from vascular thermoregulation for soft biological tissue, is expected to develop an effective heat dissipation method for human skin, flexible electronics, and soft robots due to the desired interface mechanical compliance. However, its low thermal conduction and poor adaptation limit its cooling effects. Inspired by the bone structure, this work reports a simple yet versatile method of fabricating arbitrary-geometry liquid metal skeleton-based elastomer with bicontinuous Gyroid-shaped phases, exhibiting high thermal conductivity (up to 27.1 W/mK) and stretchability (strain limit >600%). Enlightened by the vasodilation principle for blood flow regulation, we also establish a hydraulic-driven conformal morphing strategy for better thermoregulation by modulating the hydraulic pressure of channels to adapt the complicated shape with large surface roughness (even a concave body). The liquid metal active-cooling elastomer, integrated with the flexible thermoelectric device, is demonstrated with various applications in the soft gripper, thermal-energy harvesting, and head thermoregulation.

Liquid metal biomaterials: translational medicines, challenges and perspectives

Until now, significant healthcare challenges and growing urgent clinical requirements remain incompletely addressed by presently available biomedical materials. This is due to their inadequate mechanical compatibility, suboptimal physical and chemical properties, susceptibility to immune rejection, and concerns about long-term biological safety. As an alternative, liquid metal (LM) opens up a promising class of biomaterials with unique advantages like biocompatibility, flexibility, excellent electrical conductivity, and ease of functionalization. However, despite the unique advantages and successful explorations of LM in biomedical fields, widespread clinical translations and applications of LM-based medical products remain limited. This article summarizes the current status and future prospects of LM biomaterials, interprets their applications in healthcare, medical imaging, bone repair, nerve interface, and tumor therapy, etc. Opportunities to translate LM materials into medicine and obstacles encountered in practices are discussed. Following that, we outline a blueprint for LM clinics, emphasizing their potential in making new-generation artificial organs. Last, the core challenges of LM biomaterials in clinical translation, including bio-safety, material stability, and ethical concerns are also discussed. Overall, the current progress, translational medicine bottlenecks, and perspectives of LM biomaterials signify their immense potential to drive future medical breakthroughs and thus open up novel avenues for upcoming clinical practices.

Liquid Metal Combinatorics toward Materials Discovery

Liquid metals and their derivatives provide several opportunities for fundamental and practical exploration worldwide. However, the increasing number of studies and shortage of desirable materials to fulfill different needs also pose serious challenges. Herein, to address this issue, a generalized theoretical frame that is termed as "Liquid Metal Combinatorics" (LMC) is systematically presented, and summarizes promising candidate technical routes toward new generation material discovery. The major categories of LMC are defined, and eight representative methods for manufacturing advanced materials are outlined. It is illustrated that abundant targeted materials can be efficiently designed and fabricated via LMC through deep physical combinations, chemical reactions, or both among the main bodies of liquid metals, surface chemicals, precipitated ions, and other materials. This represents a large class of powerful, reliable, and modular methods for innovating general materials. The achieved combinatorial materials not only maintained the typical characteristics of liquid metals but also displayed distinct tenability. Furthermore, the fabrication strategies, wide extensibility, and pivotal applications of LMC are classified. Finally, by interpreting the developmental trends in the area, a perspective on the LMC is provided, which warrants its promising future for society.

Multi-modal deformation and temperature sensing for context-sensitive machines

Owing to the remarkable properties of the somatosensory system, human skin compactly perceives myriad forms of physical stimuli with high precision. Machines, conversely, are often equipped with sensory suites constituted of dozens of unique sensors, each made for detecting limited stimuli. Emerging high degree-of-freedom human-robot interfaces and soft robot applications are delimited by the lack of simple, cohesive, and information-dense sensing technologies. Stepping toward biological levels of proprioception, we present a sensing technology capable of decoding omnidirectional bending, compression, stretch, binary changes in temperature, and combinations thereof. This multi-modal deformation and temperature sensor harnesses chromaticity and intensity of light as it travels through patterned elastomer doped with functional dyes. Deformations and temperature shifts augment the light chromaticity and intensity, resulting in a one-to-one mapping between stimulus modes that are sequentially combined and the sensor output. We study the working principle of the sensor via a comprehensive opto-thermo-mechanical assay, and find that the information density provided by a single sensing element permits deciphering rich and diverse human-robot and robot-environmental interactions.

Electrochemical Healing of Fractured Metals

Repairing fractured metals to extend their useful lifetimes advances sustainability and mitigates carbon emissions from metal mining and processing. While high-temperature techniques are being used to repair metals, the increasing ubiquity of digital manufacturing and "unweldable" alloys, as well as the integration of metals with polymers and electronics, call for radically different repair approaches. Herein, a framework for effective room-temperature repair of fractured metals using an area-selective nickel electrodeposition process refered to as electrochemical healing is presented. Based on a model that links geometric, mechanical, and electrochemical parameters to the recovery of tensile strength, this framework enables 100% recovery of tensile strength in nickel, low-carbon steel, two "unweldable" aluminum alloys, and a 3D-printed difficult-to-weld shellular structure using a single common electrolyte. Through a distinct energy-dissipation mechanism, this framework also enables up to 136% recovery of toughness in an aluminum alloy. To facilitate practical adoption, this work reveals scaling laws for the energetic, financial, and time costs of healing, and demonstrates the restoration of a functional level of strength in a fractured standard steel wrench. Empowered with this framework, room-temperature electrochemical healing can open exciting possibilities for the effective, scalable repair of metals in diverse applications.

Stiffness Variable Polymer for Soft Actuators with Sharp Stiffness Switch and Fast Response

Stiffness variable polymers are an essential family of materials that have aroused considerable attention in soft actuators. Although lots of strategies have been proposed to achieve variable stiffness, it remains a formidable challenge to achieve a polymer with a wide stiffness range and fast stiffness change. Herein, a series of variable stiffness polymers with a fast stiffness change and wide stiffness range were successfully synthesized, and the formulas were optimized via Pearson correlation tests. The rigid/soft stiffness ratio of the designed polymer samples can reach up to 1376-folds. Impressively, owing to the phase-changing side chains, the narrow endothermic peak can be observed with full width at half-maximum within 5 °C. Moreover, the shape memory properties of the shape fixity (R_f) and shape recovery ratio (R_r) values of the shape memory properties could reach up to 99.3 and 99.2%, respectively. Then, the obtained polymer was introduced into a kind of designed 3D printing soft actuator. The soft actuator can achieve sharp heating-cooling cycle of 19 s under a 1.2 A current with 4 °C water as coolant and can lift a 200 g weight at the actuating state. Moreover, the stiffness of the soft actuator can reach up to 718 mN/mm. The soft actuator exhibits an outstanding actuate behavior and stiffness switchable capability. We expect our design strategy and obtained variable stiffness polymers to be potentially applied in soft actuators and other devices.

Magnetically induced stiffening for soft robotics

Soft robots are well-suited for human-centric applications, but the compliance that gives soft robots this advantage must also be paired with adequate stiffness modulation such that soft robots can achieve more rigidity when needed. For this reason, variable stiffening mechanisms are often a necessary component of soft robot design. Many techniques have been explored to introduce variable stiffness structures into soft robots, such as pneumatically-controlled jamming and thermally-controlled phase change materials. Despite fast response time, jamming methods often require a bulkier pneumatic pressure line which limits portability; and while portable via electronic control, thermally-induced methods require compatibility with high temperatures and often suffer from slow response time. In this paper, we present a magnetically-controlled stiffening approach that combines jamming-based stiffening principles with magnetorheological fluid to create a hybrid mechanical and materials approach. In doing so, we combine the advantages of fast response time from pneumatically-based jamming with the portability of thermally-induced phase change methods. We explore the influence of magnetic field strength on the stiffening of our magnetorheological jamming beam samples in two ways: by exploiting the increase in yield stress of magnetorheological fluid, and by additionally using the clamping force between permanent magnets to further stiffen the samples via a clutch effect. We introduce an analytical model to predict the stiffness of our samples as a function of the magnetic field. Finally, we demonstrate electronic control of the stiffness using electropermanent magnets. In this way, we present an important step towards a new electronically-driven stiffening mechanism for soft robots that interact safely in close contact with humans, such as in wearable devices.

An atomically smooth container: Can the native oxide promote supercooling of liquid gallium?

Metals tend to supercool-that is, they freeze at temperatures below their melting points. In general, supercooling is less favorable when liquids are in contact with nucleation sites such as rough surfaces. Interestingly, bulk gallium (Ga) can significantly supercool, even when it is in contact with heterogeneous surfaces that could provide nucleation sites. We hypothesized that the native oxide on Ga provides an atomically smooth interface that prevents Ga from directly contacting surfaces, and thereby promotes supercooling. Although many metals form surface oxides, Ga is a convenient metal for studying supercooling because its melting point of 29.8°C is near room temperature. Using differential scanning calorimetry (DSC), we show that freezing of Ga with the oxide occurs at a lower temperature (-15.6 ± 3.5°C) than without the oxide (6.9 ± 2.0°C when the oxide is removed by HCl). We also demonstrate that the oxide enhances supercooling via macroscopic observations of freezing. These findings explain why Ga supercools and have implications for emerging applications of Ga that rely on it staying in the liquid state.

A variable-stiffness and healable pneumatic actuator

Pneumatic-powered actuators are receiving increasing attention due to their widespread applications. However, their inherent low stiffness makes them incompetent in tasks requiring high load capacity or high force output. On the other hand, soft pneumatic actuators are susceptible to damage caused by over-pressuring or punctures by sharp objects. In this work, we designed and synthesized a coordination adaptable network (PETMP-AIM-Cu) with high mechanical rigidity (Young's modulus of 1.9 GPa and elongation <2% before fracturing) as well as excellent variable stiffness property (soft-rigid switching ability σ as high as 3 268 000 when ΔT = 90 °C). Combining PETMP-AIM-Cu with a self-healing elastomer based on dynamic disulfide bonds (LP-PDMS), we fabricated a new pneumatic actuator which shows high load capacity at room temperature, but can also easily deform upon heating and thus can be actuated pneumatically. Benefiting from the excellent self-healing ability of PETMP-AIM-Cu and LP-PDMS, the entire pneumatic actuator can still be actuated after being cut and healed. Such a variable-stiffness and healable pneumatic actuator would be useful for complex environmental applications.

Dynamic Response and Deformative Mechanism of the Shape Memory Polymer Filled with Low-Melting-Point Alloy under Different Dynamic Loads

Low-melting-point alloy (LMPA) was used as an additive to prepare epoxy-resin-based shape memory polymer composites (LMPA/EP SMP), and dynamic mechanical analyzer (DMA) tests were performed to demonstrate the shape memory effect, storage modulus, and stiffness of the composites under different load cases. The composites exhibited an excellent shape recovery ratio and shape fixity ratio, and a typical turning point was observed in the storage modulus curves, which was attributed to the melting of the LMPA. In order to investigate the dynamic deformation mechanism at high strain rates, split Hopkinson pressure bar (SHPB) experiments were performed to study the influence of the strain rate and plastic work on the dynamic mechanical response of LMPA/EP composites. The results showed that there was a saturated tendency for the flow stress with increasing strain rate, and the composites exhibited a typical brittle failure mode at high strain rate. Moreover, an obvious melting phenomenon of the LMPA was observed by SEM tests, which was due to the heat generated by the plastic work at high strain rate. The fundamental of the paper provided an effective approach to modulate the stiffness and evaluate the characteristics of SMP composites.

Stretchable and conformable variable stiffness device through an electrorheological fluid

Stiffness variations extend creatures' functions and capabilities to deal with complex environments. In this study, we proposed an electrorheological fluid-based variable stiffness device, named VSERF, made up of soft materials. Our device is soft, thin, and stretchable so that it can conform to surfaces with complex morphologies. The stiffness of the VSERF device can be continuously, independently, and reversibly adjusted by applying an electric field. It achieves 14.8-times compressive stiffness variation and 3.5-times tangential stiffness variation when the electric field intensity increases from 0 V mm^-1 to 750 V mm^-1. The VSERF device is able to return to its initial shape after removing the external force and electric field, allowing it to be reused. The effects of stretching and bending on the device's capability of stiffness variations are investigated experimentally and the results show that the stiffness variation is unaffected by a stretching strain of up to 20% and a bending curvature of up to 50 m^-1. Finally, we show that the VSERF device is capable of conforming to complex surfaces (coral stones, pencils, and 3D printed cubes) in its inactive state, hanging on them with a weight of up to 80 g (19 times of its own weight) in its active state, and detaching when the electric field is removed. The device's short-term and long-term stabilities are experimentally investigated as well. The demonstration of the VSERF's attaching and detaching ability shows that the stiffness-variation device's adaptability to complex environments can be improved.

Self-Reporting Joule Heating Modulated Stiffness of Polymeric Nanocomposites for Shape Reconfiguration

Shape reconfigurable devices, e.g., foldable phones, have emerged with the development of flexible electronics. But their rigid frames limit the feasible shapes for the devices. To achieve freely changeable shapes yet keep the rigidity of devices for user-friendly operations, stiffness-tunable materials are desired, especially under electrical control. However, current such systems are multilayer with at least a heater layer and a structural layer, leading to complex fabrication, high cost, and loss of reprocessability. Herein, we fabricate covalent adaptable networks-carbon nanotubes (CAN-CNT) composites to realize Joule heating controlled stiffness. The nanocomposites function as stiffness-tunable matrices, electric heaters, and softening sensors all by themselves. The self-reporting of softening is used to regulate the power control, and the sensing mechanism is investigated by simulating the CNT-polymer chain interactions at the nanoscale during the softening process. The nanocomposites not only have adjustable mechanical and thermodynamic properties but also are easy to fabricate at low cost and exhibit reprocessability and recyclability benefiting from the dynamic exchange reactions of CANs. Shape and stiffness control of flexible display systems are demonstrated with the nanocomposites as framing material, where freely reconfigurable shapes are realized to achieve convenient operation, wearing, or storage, fully exploiting their flexible potential.

Anti-Freezing, Non-Drying, Localized Stiffening, and Shape-Morphing Organohydrogels

Artificial shape-morphing hydrogels are emerging toward various applications, spanning from electronic skins to healthcare. However, the low freezing and drying tolerance of hydrogels hinder their practical applications in challenging environments, such as subzero temperatures and arid conditions. Herein, we report on a shape-morphing system of tough organohydrogels enabled by the spatially encoded rigid structures and its applications in conformal packaging of “island–bridge” stretchable electronics. To validate this method, programmable shape morphing of Fe (III) ion-stiffened Ca-alginate/polyacrylamide (PAAm) tough organohydrogels down to −50 °C, with long-term preservation of their 3D shapes at arid or even vacuum conditions, was successfully demonstrated, respectively. To further illustrate the potency of this approach, the as-made organohydrogels were employed as a material for the conformal packaging of non-stretchable rigid electronic components and highly stretchable liquid metal (galinstan) conductors, forming a so-called “island–bridge” stretchable circuit. The conformal packaging well addresses the mechanical mismatch between components with different elastic moduli. As such, the as-made stretchable shape-morphing device exhibits a remarkably high mechanical durability that can withstand strains as high as 1000% and possesses long-term stability required for applications under challenging conditions.

Self-Sensing Actuators Based on a Stiffness Variable Reversible Shape Memory Polymer Enabled by a Phase Change Material

Soft actuators with integrated mechanical and actuation properties and self-sensing ability are still a challenge. Herein, a stiffness variable polyolefin elastomer (POE) with a reversible shape memory effect is prepared by introducing a typical phase change material, i.e., paraffin wax (PW). It is found that the variable stiffness of POE induced by PW can balance the reversible strain and load-bearing capability of actuators. Especially, carbon nanotubes (CNTs) are concentrated in a thin surface layer by spraying and hot pressing in the soft state of POE/PW blends, providing signal transductions for the strain and temperature perception for actuators. Taking advantage of tunable reversible deformation and mechanical transformation of the POE/PW actuator, different biomimetic robotics, including grippers with high load-bearing capability (weight-lifting ratio > 146), walking robots that can sense angles of joints, and high-temperature warning robots are demonstrated. A scheme combining the variable stiffness and electrical properties provides a versatile strategy to integrate actuation performance and self-sensing ability, inspiring the development of multifunctional composite designs for soft robotics.

A micromechanical model for phase-change composites

Phase-change composites have a wide range of tunable mechanical properties caused by temperature-driven phase transition, and have been widely applied in many cutting-edge fields like soft robotics. Previous studies on the effective mechanical properties of phase-change composites mostly use experimental methods, and there have been few theoretical approaches. In this work, we develop a micromechanical framework capable of tracking the effective mechanical properties of phase-change composites throughout the entire phase transition. The phase-change materials embedded in the composites are modelled as inclusions, and the non-phase-change materials are modelled as the matrix. This allows us to determine the effective mechanical properties of phase-change composites via the energy equivalency approach. Moreover, since the new phase will be generated inside the phase-change inclusions in the form of sub-inclusions during the phase transition, the inclusions are modelled as two-phase composites, and their effective mechanical properties are then determined using the Mori–Tanaka method. Finally, by comparing theoretical predictions with experimental data, the accuracy and reliability of the present model are verified. We believe that the proposed model can serve as a powerful tool for evaluating the effective mechanical properties of phase-change composites and provide theoretical guidelines for the design of advanced devices with tunable mechanical performance.

Shape morphing mechanical metamaterials through reversible plasticity

Biological organisms such as the octopus can reconfigure their shape and properties to perform diverse tasks. However, soft machines struggle to achieve complex configurations, morph into shape to support loads, and go between multiple states reversibly. Here, we introduce a multifunctional shape-morphing material with reversible and rapid polymorphic reconfigurability. We couple elastomeric kirigami with an unconventional reversible plasticity mechanism in metal alloys to rapidly (<0.1 seconds) morph flat sheets into complex, load-bearing shapes, with reversibility and self-healing through phase change. This kirigami composite overcomes trade-offs in deformability and load-bearing capacity and eliminates power requirements to sustain reconfigured shapes. We demonstrate this material through integration with onboard control, motors, and power to create a soft robotic morphing drone, which autonomously transforms from a ground to air vehicle and an underwater morphing machine, which can be reversibly deployed to collect cargo.

Thermal, Viscoelastic and Surface Properties of Oxidized Field's Metal for Additive Microfabrication

Field's metal, a low-melting-point eutectic alloy composed of 51% In, 32.5 Bi% and 16.5% Sn by weight and with a melting temperature of 333 K, is widely used as liquid metal coolant in advanced nuclear reactors and in electro-magneto-hydrodynamic two-phase flow loops. However, its rheological and wetting properties in liquid state make this metal suitable for the formation of droplets and other structures for application in microfabrication. As with other low-melting-point metal alloys, in the presence of air, Field's metal has an oxide film on its surface, which provides a degree of malleability and stability. In this paper, the viscoelastic properties of Field's metal oxide skin were studied in a parallel-plate rheometer, while surface tension and solidification and contact angles were determined using drop shape analysis techniques.

Solid-Liquid Host-Guest Composites: The Marriage of Porous Solids and Functional Liquids

Composite materials can provide remarkable improvements over the individual constituents. Especially, with a liquid component introduced into a solid porous host, solid-liquid host-guest composites have recently come to the forefront with exceptional functions that promise them for a wealth of applications. Combining the unprecedented dynamic, transparent, omniphobic, self-healing, diffusive and adaptive nature of functional liquid with inherent solid host's property, solid-liquid host-guest composites can realize the ease of fabrication, long-term stability, and a broad spectrum of enhanced properties, which cannot be fully met by conventional solid-solid composites or liquid-liquid composites. This review presents the state-of-the-art progress in solid-liquid host-guest composites. Initially, the concept, classification, design strategy, as well as fabrication methods as a path forward to develop the composites are unraveled, and further it is elaborated on how the functionality of porous solid and functional liquid can be harnessed to create composites with a broad range of unique properties, especially, the optical, thermal, electric, mechanical, sorption, and separation properties. With these fascinating properties, a myriad of emerging applications such as optical devices, thermal management, electromagnetic-interference shielding, soft electronics, gas capture and release, and multiphase separations are touched upon, inspiring more frontier researches in materials science, interfacial chemistry, membrane science, engineering, and multidisciplinary. Finally, this review provides the perspective on the future directions of solid-liquid host-guest composites and assesses the challenges and opportunities ahead.

Transient Electrically Driven Stiffness-Changing Materials from Liquid Metal Polymer Composites

Stiffness-changing materials (SCMs) have received lots of interests due to their reversible transition between their soft and rigid states for modern applications. However, the irreversible stiffness transition, slow response, and sustained external stimuli strictly hinder the broad utilizations of SCMs. Here, this work reports electrically driven SCMs based on supercooled liquid metals (LMs). A small voltage (5 V) can successfully initiate the stable and reversible stiffness change of the SCMs in electrolyte solution. Surprisingly, the LM-based SCMs (LM-SCMs) exhibited a significant change in 1000 times difference of moduli (65 kPa versus 79 MPa). Moreover, such a stiffness transition of the LM-SCM was ultrarapidly completed in a few seconds (<30 s). Importantly, after transient stimulation of LM nucleation, the rigidity of the LM-SCM could be maintained when the external stimulus (voltage) was removed, highly different from previously reported SCMs that require sustained energy to maintain their mechanical states. Based on the unique features of LM-SCMs, advanced robotics like smart valves and mechanical paws in seawater were successfully fabricated.

Materials with Electroprogrammable Stiffness

Stiffness is a mechanical property of vital importance to any material system and is typically considered a static quantity. Recent work, however, has shown that novel materials with programmable stiffness can enhance the performance and simplify the design of engineered systems, such as morphing wings, robotic grippers, and wearable exoskeletons. For many of these applications, the ability to program stiffness with electrical activation is advantageous because of the natural compatibility with electrical sensing, control, and power networks ubiquitous in autonomous machines and robots. The numerous applications for materials with electrically driven stiffness modulation has driven a rapid increase in the number of publications in this field. Here, a comprehensive review of the available materials that realize electroprogrammable stiffness is provided, showing that all current approaches can be categorized as using electrostatics or electrically activated phase changes, and summarizing the advantages, limitations, and applications of these materials. Finally, a perspective identifies state-of-the-art trends and an outlook of future opportunities for the development and use of materials with electroprogrammable stiffness.

2D and 3D Structuring of Freestanding Metallic Wires Enabled by Room-Temperature Welding for Soft and Stretchable Electronics

In this work, a facile and cost-effective approach to assemble metallic wires into two-dimensional (2D) and three-dimensional (3D) freestanding geometries by room-temperature welding is demonstrated. The low melting point of gallium (29.8 °C) enables the welding at room temperature without the aid of high-energy sources required for high-melting-point metals and alloys. The welding enables assembly of solid gallium wires into 2D and 3D geometries that could create freestanding architectures with multiple junctions along any inclined direction. These 2D and 3D freestanding metallic structures are freeze-cast in soft elastomers to obtain stretchable and soft devices: a 2D stretchable resistive and capacitive sensor patterned with parallel metal lines, a 2D stretchable capacitive sensor patterned with an interdigitated metal structure with capacitive changes on stretching in both x- and y-axes, and a 3D compressive sensor by assembly of liquid metal helices, which could sense foot pressure compression. We also developed a facile method to interconnect between soft circuits and external electronics, suppressing stress during mechanical deformation.

Soft and Stretchable Liquid Metal Composites with Shape Memory and Healable Conductivity

Shape memory composites are fascinating materials with the ability to preserve deformed shapes that recover when triggered by certain external stimuli. Although elastomers are not inherently shape memory materials, the inclusion of phase-change materials within the elastomer can impart shape memory properties. When this filler changes the phase from liquid to solid, the effective modulus of the polymer increases significantly, enabling stiffness tuning. Using gallium, a metal with a low melting point (29.8 °C), it is possible to create elastomeric materials with metallic conductivity and shape memory properties. This concept has been used previously in core-shell (gallium-elastomer) fibers and foams, but here, we show that it can also be implemented in elastomeric films containing microchannels. Such microchannels are appealing because it is possible to control the geometry of the filler and create metallically conductive circuits. Stretching the solidified metal fractures the fillers; however, they can heal by body heat to restore conductivity. Such conductive, shape memory sheets with healable conductivity may find applications in stretchable electronics and soft robotics.

3D-Printed Self-Healing Elastomers for Modular Soft Robotics

Advances in materials, designs, and controls are propelling the field of soft robotics at an incredible rate; however, current methods for prototyping soft robots remain cumbersome and struggle to incorporate desirable geometric complexity. Herein, a vat photopolymerizable self-healing elastomer system capable of extreme elongations up to 1000% is presented. The material is formed from a combination of thiol/acrylate mixed chain/step-growth polymerizations and uses a combination of physical processes and dynamic-bond exchange via thioethers to achieve full self-healing capacity over multiple damage/healing cycles. These elastomers can be three dimensional (3D) printed with modular designs capable of healing together to form highly complex and large functional soft robots. Additionally, these materials show reprogrammable resting shapes and compatibility with self-healing liquid metal electronics. Using these capabilities, subcomponents with multiple internal channel systems were printed, healed together, and combined with functional liquid metals to form a high-wattage pneumatic switch and a humanoid-scale soft robotic gripper. The combination of 3D printing and self-healing elastomeric materials allows for facile production of support-free parts with extreme complexity, resulting in a paradigm shift for the construction of modular soft robotics.

Flexible Manipulator with Low-Melting-Point Alloy Actuation and Variable Stiffness

Flexible manipulators offer significant advantages over traditional rigid manipulators in minimally invasive surgery, because they can flexibly navigate around obstacles and pass cramped or tortuous paths. However, due to the inherent low stiffness, the ability to control/obtain higher stiffness when required remains to be further explored. In this article, we propose a flexible manipulator that exploits the phase transformation property of low-melting-point alloy to hydraulically drive and change the stiffness by heating and cooling. A prototype was fabricated, and experiments were conducted to evaluate the motion characteristics, stiffness performance, and rigid-flexible transition efficiency. The experimental results demonstrate that the proposed manipulator can freely adjust heading direction in the three-dimensional space. The experimental results also indicate that it took 9.2-10.3 s for the manipulator to transform from a rigid state to a flexible state and 15.4 s to transform from a flexible state to a rigid state. The lateral stiffness and flexural stiffness of the manipulator were 95.54 and 372.1 Ncm² in the rigid state and 7.26 and 0.78 Ncm² in the flexible state. The gain of the lateral stiffness and flexural stiffness was 13.15 and 477.05, respectively. In the rigid state, the ultimate force without shape deformation was more than 0.98 N in the straight condition (0°) and 1.36 N in the bending condition (90°). By assembling flexible surgical tools, the manipulator can enrich the diagnosis or treatment functions, which demonstrated the potential clinical value of the proposed manipulator.

Progress and Roadmap for Intelligent Self-Healing Materials in Autonomous Robotics

Robots are increasingly assisting humans in performing various tasks. Like special agents with elite skills, they can venture to distant locations and adverse environments, such as the deep sea and outer space. Micro/nanobots can also act as intrabody agents for healthcare applications. Self-healing materials that can autonomously perform repair functions are useful to address the unpredictability of the environment and the increasing drive toward the autonomous operation. Having self-healable robotic materials can potentially reduce costs, electronic wastes, and improve a robot endowed with such materials longevity. This review aims to serve as a roadmap driven by past advances and inspire future cross-disciplinary research in robotic materials and electronics. By first charting the history of self-healing materials, new avenues are provided to classify the various self-healing materials proposed over several decades. The materials and strategies for self-healing in robotics and stretchable electronics are also reviewed and discussed. It is believed that this article encourages further innovation in this exciting and emerging branch in robotics interfacing with material science and electronics.

Liquid Metal Foaming via Decomposition Agents

As an emerging functional material, the liquid metal has demonstrated its encouraging potential in several areas with practical trials, while its global uniformity including high density and limited macroscopic interface might become a barrier for some tough application scenarios. Here, we proposed the concept of liquid metal foaming via decomposition agents, aiming to develop a generalized way to make porous foam metallic fluid, which would pave the way in achieving more structured features and adaptability of liquid metals. By introducing a greenness strategy with the help of an ecofriendly foaming agent, we realized a series of designed targeted liquid metal foams (LMFs). Compared with common liquid metals, LMFs possess many excellent properties, such as abundant interfaces, tunable conductivity, and adjustable stiffness, due to the controllable regulation of their porous structure. According to these unique characteristics, diversified values of LMFs were obtained. Benefiting from the naturally enriched interface in LMFs, the hydrogen evolution of LMFs in neutral deionized water was more efficient and more productive. Additionally, the compact LMF-air battery with high performance was originally manufactured. Moreover, the tunable LMF-enabled four-dimensional (4D) electromagnetic shielding materials possess excellent shielding performance. This material could open up broad vistas for the application of LMs.

Phase change mediated mechanically transformative dynamic gel for intelligent control of versatile devices

Traditional devices, including conventional rigid electronics and machines, as well as emerging wearable electronics and soft robotics, almost all have a single mechanical state for particular service purposes. Nonetheless, dynamic materials with interchangeable mechanical states, which enable more diverse and versatile applications, are urgently necessary for intelligent and adaptive application cases in the future electronic and robot fields. Here, we report a gel-like material composed of a crosslinking polymer network impregnated with a phase changing molten liquid, which undergoes an exceptional stiffness transition in response to a thermal stimulus. Vice versa, the material switches from a soft gel state to a rigid solid state with a dramatic stiffness change of 10⁵ times (601 MPa versus 4.5 kPa) benefiting from the liquid-solid phase change of the crystalline polymer once cooled. Such reversibility of the phase and mechanical transition upon thermal stimuli enables the dynamic gel mechanical transformation, demonstrating potential applications in an adhesive thermal interface gasket (TIG) to facilitate thermal transport, a high-temperature warning sensor and an intelligent gripper. Overall, this dynamic gel with a tunable stiffness change paves a new way to design and fabricate adaptive smart materials toward intelligent control of versatile devices.

Versatile Soft Robot Gripper Enabled by Stiffness and Adhesion Tuning via Thermoplastic Composite

Within the field of robotics, stiffness tuning technologies have potential for a variety of applications-perhaps most notably for robotic grasping. Many stiffness tuning grippers have been developed that can grasp fragile or irregularly shaped objects without causing damage and while still accommodating large loads. In addition to limiting gripper deformation when lifting an object, increasing gripper stiffness after contact formation improves load sharing at the interface and enhances adhesion. In this study, we present a novel stiffness and adhesion tuning gripper, enabled by the thermally induced phase change of a thermoplastic composite material embedded within a silicone contact pad. The gripper operates by bringing the pad into contact with an object while in its heated, soft state, and then allowing the pad to cool and stiffen to form a strong adhesive bond before lifting the object. Pull-off tests conducted using the gripper show that transitioning from a soft to stiff state during grasping enables up to 6 × increase in adhesion strength. Additionally, a finite element model is developed to simulate the behavior of the gripper. Finally, pick-and-place demonstrations are performed, which highlight the gripper's ability to delicately grasp objects of various shapes, sizes, and weights.

Controlled Assembly of Liquid Metal Inclusions as a General Approach for Multifunctional Composites

Soft composites that use droplets of gallium-based liquid metal (LM) as the dispersion phase have the potential for transformative impact in multifunctional material engineering. However, it is unclear whether percolation pathways of LM can support high electrical conductivity in a wide range of matrix materials. This issue is addressed through an approach to LM composite synthesis that focuses on the interrelated effects of matrix curing/solidification and droplet formation. The combined influence of LM concentration, particle size, and sedimentation is explored. By developing this approach, the functionalities that have been demonstrated with LM composites can be generalized to other matrix materials that impart additional functionality. Specifically, composites are synthesized using a biodegradable/reprocessable plastic (polycaprolactone), a hydrogel (poly(vinyl alcohol)), and a processable rubber (a styrene-ethylene-butylene-styrene derivative) to demonstrate wide applicability. This method enables synthesis of composites: i) with high stretchability and negligible electromechanical coupling (>600% strain); ii) with Joule-heated healing and reprocessability; iii) with electrical and mechanical self-healing; and iv) that can be printed. This approach to controlled assembly represents a widely applicable technique for creating new classes of LM composites with unprecedented multifunctionality.

Liquid metal nanocomposites

Liquid metal (LM) has attracted tremendous interest over the past decade for its enabling combination of high electrical and thermal conductivity and low mechanical compliance and viscosity. Efforts to harness LM in electronics, robotics, and biomedical applications have largely involved methods to encapsulate the liquid so that it can support functionality without leaking or smearing. In recent years, there has been increasing interest in LM "nanocomposites" in which either liquid metal is mixed with metallic nanoparticles or nanoscale droplets of liquid metal are suspended within a soft polymer matrix. Both of these material systems represent an important step towards utilizing liquid metal for breakthrough applications. In this minireview, we present a brief overview of recent progress over the past few years in methods to synthesize LM nanomaterials and utilize them as transducers for sensing, actuation, and energy harvesting. In particular, we focus on techniques for stable synthesis of LM nanodroplets, suspension of nanodroplets within various matrix materials, and methods for incorporating metallic nanoparticles within an LM matrix.

A Super-Stretchable Liquid Metal Foamed Elastomer for Tunable Control of Electromagnetic Waves and Thermal Transport

It is remarkably desirable and challenging to design a stretchable conductive material with tunable electromagnetic-interference (EMI) shielding and heat transfer for applications in flexible electronics. However, the existing materials sustained a severe attenuation of performances when largely stretched. Here, a super-stretchable (800% strain) liquid metal foamed elastomer composite (LMF-EC) is reported, achieving super-high electrical (≈104 S cm-1) and thermal (17.6 W mK-1) conductivities under a large strain of 400%, which also exhibits unexpected stretching-enhanced EMI shielding effectiveness of 85 dB due to the conductive network elongation and reorientation. By varying the liquid and solid states of LMF, the stretching can enable a multifunctional reversible switch that simultaneously regulates the thermal, electrical, and electromagnetic wave transport. Novel flexible temperature control and a thermoelectric system based on LMF-EC is furthermore developed. This work is a significant step toward the development of smart electromagnetic and thermal regulator for stretchable electronics.

Hybrid Metallic Foam with Superior Elasticity, High Electrical Conductivity, and Pressure Sensitivity

Growing interest has been received in metallic foams for their combined features of metals and porous structures. Coating metals on polymers have been the most prevalent method to fabricate hybrid metallic foams to inherit both the merits of metals and the mechanical flexibility of polymers. However, direct coating metals on foams is challenging and requires tedious synthesis, such as electrolysis and chemical reduction. This work reported a facile strategy to build hybrid metallic foams via in situ foaming of liquid metals (LM) and polyurethane. The fluidity and incompatibility of LM with porous polyurethane allow the coating of LM on polymers. LM-Foams exhibit high electrical conductivity (3.9 × 10⁴ S/m), low density (ρ < 1 g/cm³), phenomenal elasticity (recover at 95% strain), and excellent mechanical stability (stable with 1000 compressive cycles). Interestingly, the ease of deformation for fluidic fillers in elastic polyurethane generates additional resistive change under pressure, showing unique sensory behaviors which were not observed in conventional conductive foams, such as high response sensitivity (gauge factor >25), short response time (202 ms), and outstanding electrical stability. The nonuniform size distribution of pores leads LM-Foams to show unusual position-dependent sensitivity, enabling advanced applications as password pads and electrical protection foams.

Recent advances in soft functional materials: preparation, functions and applications

Synthetic materials and biomaterials with elastic moduli lower than 10 MPa are generally considered as soft materials. Research studies on soft materials have been boosted due to their intriguing features such as light-weight, low modulus, stretchability, and a diverse range of functions including sensing, actuating, insulating and transporting. They are ideal materials for applications in smart textiles, flexible devices and wearable electronics. On the other hand, benefiting from the advances in materials science and chemistry, novel soft materials with tailored properties and functions could be prepared to fulfil the specific requirements. In this review, the current progress of soft materials, ranging from materials design, preparation and application are critically summarized based on three categories, namely gels, foams and elastomers. The chemical, physical and electrical properties and the applications are elaborated. This review aims to provide a comprehensive overview of soft materials to researchers in different disciplines.

Complex multiphase organohydrogels with programmable mechanics toward adaptive soft-matter machines

Many biological organisms can tune their mechanical properties to adapt to environments in multistable modes, but the current synthetic materials, with bistable states, have a limited ability to alter mechanical stiffness. Here, we constructed programmable organohydrogels with multistable mechanical states by an on-demand modular assembly of noneutectic phase transition components inside microrganogel inclusions. The resultant multiphase organohydrogel exhibits precisely controllable thermo-induced stepwise switching (i.e., triple, quadruple, and quintuple switching) mechanics and a self-healing property. The organohydrogel was introduced into the design of soft-matter machines, yielding a soft gripper with adaptive grasping through stiffness matching with various objects under pneumatic-thermal hybrid actuation. Meanwhile, a programmable adhesion of octopus-inspired robotic tentacles on a wide range of surface morphologies was realized. These results demonstrated the applicability of these organohydrogels in lifelike soft robotics in unconstructed and human body environments.

Highly Stretchable Conductor by Self-Assembling and Mechanical Sintering of a 2D Liquid Metal on a 3D Polydopamine-Modified Polyurethane Sponge

A highly stretchable conductor was fabricated through dip-coating a new liquid metal (LM) electric ink on a polydopamine (PDA)-modified three-dimensional (3D) polyurethane sponge (PUS) followed by mechanical sintering. The LM was first sonicated to nanodroplets to reduce the consumption of LM and then modified by 3-mercaptopropionic acid (LMNPS-MPA) to improve the interfacial adhesion between LM and PUS. The denser and even distribution of LMNPS-MPA self-assembling on PDA-treated PUS (PUS-PDA) was successfully prepared via hydrogen bonding interactions. Mechanical sintering of 3D PUS-PDA coated by a two-dimensional (2D) LM layer was then conducted to obtain a continuous conductive network. Comparing with those of the reported 3D conductors, the resulting PUS-PDA-LM composite conductor shows both high electrical conductivity (478 S cm^-1) under a low LM consumption of 10 vol% and excellent conductivity stability with the relative resistance change, ΔR/R₀, of 2% at 50% strain under stretching deformation. The as-prepared PUS-PDA-LM composites were then successfully applied as flexible and stretchable light-emitting diode (LED) arrays with excellent conductivity and conductivity stability at different deformations. We believe that the 3D stretchable PUS-PDA-LM conductor has many potential applications in flexible sensors, flexible circuits, rollable displays, etc.

Ultrastretchable Elastic Shape Memory Fibers with Electrical Conductivity

Herein, elastomeric fibers that have shape memory properties due to the presence of a gallium core that can undergo phase transition from solid to liquid in response to mild heating are described. The gallium is injected into the core of a hollow fiber formed by melt processing. This approach provides a straightforward method to create shape memory properties from any hollow elastic fiber. Solidifying the core changes the effective fiber modulus from 4 to 1253 MPa. This increase in stiffness can preserve the fiber in a deformed shape. The elastic energy stored in the polymer shell during deformation drives the fiber to relax back to its original geometry upon melting the solid gallium core, allowing for shape memory. Although waxes are used previously for this purpose, the use of gallium is compelling because of its metallic electrical and thermal conductivity. In addition, the use of a rigid metallic core provides perfect fixity of the shape memory fiber. Notably, the use of gallium-with a melting point above room temperature but below body temperature-allows the user to melt and deform local regions of the fiber by hand and thereby tune the effective modulus and shape of the fiber.

Mechanically transformative electronics, sensors, and implantable devices

Traditionally, electronics have been designed with static form factors to serve designated purposes. This approach has been an optimal direction for maintaining the overall device performance and reliability for targeted applications. However, electronics capable of changing their shape, flexibility, and stretchability will enable versatile and accommodating systems for more diverse applications. Here, we report design concepts, materials, physics, and manufacturing strategies that enable these reconfigurable electronic systems based on temperature-triggered tuning of mechanical characteristics of device platforms. We applied this technology to create personal electronics with variable stiffness and stretchability, a pressure sensor with tunable bandwidth and sensitivity, and a neural probe that softens upon integration with brain tissue. Together, these types of transformative electronics will substantially broaden the use of electronics for wearable and implantable applications.

Development and Testing of Woven FRP Flexure Hinges for Pressure-Actuated Cellular Structures with Regard to Morphing Wing Applications

Shape-variable structures can change their geometry in a targeted way and thus adapt their outer shape to different operating conditions. The potential applications in aviation are manifold and far-reaching. The substitution of conventional flaps in high-lift systems or even the deformation of entire wing profiles is conceivable. All morphing approaches have to deal with the same challenge: A conflict between minimizing actuating forces on the one hand, and maximizing structural deflections and resistance to external forces on the other. A promising concept of shape variability to face this challenging conflict is found in biology. Pressure-actuated cellular structures (PACS) are based on the movement of nastic plants. Firstly, a brief review of the holistic design approach of PACS is presented. The aim of the following study is to investigate manufacturing possibilities for woven flexure hinges in closed cellular structures. Weaving trials are first performed on the material level and finally on a five-cell PACS cantilever. The overall feasibility of woven fiber reinforced plastics (FRP)-PACS is proven. However, the results show that the materials selection in the weaving process substantially influences the mechanical behavior of flexure hinges. Thus, the optimization of manufacturing parameters is a key factor for the realization of woven FRP-PACS.

Design of Ethylene-Vinyl Acetate Copolymer Fiber with Two-Way Shape Memory Effect

One-dimensional shape memory polymer fibers (SMPFs) have obvious advantages in mechanical properties, dispersion properties, and weavability. In this work, a method for fabricating semi-crystallization ethylene-vinyl acetate copolymer (EVA) fiber with two-way shape memory effect by melt spinning and ultraviolet (UV) curing was developed. Here, the effect of crosslink density on its performance was systematically analyzed by gel fraction measurement, tensile tests, DSC, and TMA analysis. The results showed that the crosslink density and shape memory properties of EVA fiber could be facilely adjusted by controlling UV curing time. The resulting EVA fiber with cylindrical structure had a diameter of 261.86 ± 13.07 μm, and its mechanical strength and elongation at break were 64.46 MPa and 114.33%, respectively. The critical impact of the crosslink density and applied constant stress on the two-way shape memory effect were analyzed. Moreover, the single EVA fiber could lift more than 143 times its own weight and achieve 9% reversible actuation strain. The reversible actuation capability was significantly enhanced by a simple winding design of the single EVA fiber, which provided great potential applications in smart textiles, flexible actuators, and artificial muscles.

A hybrid material that reversibly switches between two stable solid states

Most types of solid matter have a single stable solid state for a particular set of conditions. Nonetheless, materials with distinct, interchangeable solid states would be advantageous for several technological applications. Here, we describe a material composed of a polymer impregnated with a supercooled salt solution, termed as sal-gel, that assumes two distinct but stable and reversible solid states under the same conditions for a range of temperatures (-90 to 58 °C) and pressure. On transient stimulation of nucleation, the material switches from a clear and soft solid to a white and hard state, which can be 10⁴ times stiffer than the original (15 kPa versus 385 MPa). This hard solid becomes soft again by transient heating, demonstrating the reversibility of the transition. This concept, exploiting the robust physical metastability of a liquid state, is extended to sugar alcohols, resulting in a stimuli-responsive and non-evaporating sug-gel. These 'two-in-one' solid materials may find potential uses in soft robotics and adhesive applications.

Design and Manufacturing of Tendon-Driven Soft Foam Robots

A design and manufacturing method is described for creating a motor tendon–actuated soft foam robot. The method uses a castable, light, and easily compressible open-cell polyurethane foam, producing a structure capable of large (~70% strain) deformations while requiring low torques to operate (<0.2 N·m). The soft robot can change shape, by compressing and folding, allowing for complex locomotion with only two actuators. Achievable motions include forward locomotion at 13 mm/s (4.3% of body length per second), turning at 9◦/s, and end-over-end flipping. Hard components, such as motors, are loosely sutured into cavities after molding. This reduces unwanted stiffening of the soft body. This work is the first demonstration of a soft open-cell foam robot locomoting with motor tendon actuators. The manufacturing method is rapid (~30 min per mold), inexpensive (under $3 per robot for the structural foam), and flexible, and will allow a variety of soft foam robotic devices to be produced.

Arbitrarily 3D Configurable Hygroscopic Robots with a Covalent-Noncovalent Interpenetrating Network and Self-Healing Ability

Soft materials that can reversibly transform shape in response to moisture have applications in diverse areas such as soft robotics and biomedicine. However, the design of a structurally transformable or mechanically self-healing version of such a humidity-responsive material, which can arbitrarily change shape and reconfigure its 3D structures remains challenging. Here, by drawing inspiration from a covalent-noncovalent network, an elaborately designed biopolyester is developed that features a simple hygroscopic actuation mechanism, straightforward manufacturability at low ambient temperature (≤35 °C), fast and stable response, robust mechanical properties, and excellent self-healing ability. Diverse functions derived from various 3D shapes that can grasp, swing, close-open, lift, or transport an object are further demonstrated. This strategy of easy-to-process 3D structured self-healing actuators is expected to combine with other actuation mechanisms to extend new possibilities in diverse practical applications.