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

3D-Printable Elastomers for Real-Time Autonomous Self-Healing in Soft Devices

Photocurable self-healing elastomers are promising candidates for producing complex soft devices that can mend damage. However, the practicality of these materials is limited by reliance on external stimuli, custom synthesis, manual realignment, and multihour healing cycles. This paper introduces a tough 3D-printable hybrid acrylate/thiol-ene elastomer (prepared with commercially available precursors) that exhibits nearly instantaneous damage repair in the absence of external stimuli. This rapid, hydrogen bond-driven self-healing enables meaningful restoration of mechanical properties, including tensile strains up to 344% post-damage. Furthermore, structured herringbone grafts are showcased as a compelling strategy to enable cohesive failure away from healed interfaces, realizing up to 18× increases in toughness from only modest increases in interfacial surface area. Prototype soft robotic devices fabricated using vat photopolymerization demonstrate self-healing within seconds under ambient conditions and without external intervention. These results demonstrate a scalable strategy to provide real-time, autonomous functionality restoration in damaged soft devices.

A Comprehensive Review of Stimuli-Responsive Smart Polymer Materials-Recent Advances and Future Perspectives

Today, smart materials are commonly used in various fields of science and technology, such as medicine, electronics, soft robotics, the chemical industry, the automotive field, and many others. Smart polymeric materials hold good promise for the future due to their endless possibilities. This group of advanced materials can be sensitive to changes or the presence of various chemical, physical, and biological stimuli, e.g., light, temperature, pH, magnetic/electric field, pressure, microorganisms, bacteria, viruses, toxic substances, and many others. This review concerns the newest achievements in the area of smart polymeric materials. The recent advances in the designing of stimuli-responsive polymers are described in this paper.

Network Polymer Properties Engineered Through Polymer Backbone Dispersity and Structure

Dispersity (Ð or Mw/Mn) is an important parameter in material design and as such can significantly impact the properties of polymers. Here, polymer networks with independent control over the molecular weight and dispersity of the linear chains that form the material are developed. Using a RAFT polymerization approach, a library of polymers with dispersity ranging from 1.2-1.9 for backbone chain-length (DP) 100, and 1.4-3.1 for backbone chain-length 200 were developed and transformed to networks through post-polymerization crosslinking to form disulfide linkers. The tensile, swelling, and adhesive properties were explored, finding that both at DP 100 and DP 200 the swelling ratio, tensile strength, and extensibility were superior at intermediate dispersity (1.3-1.5 for DP 100 and 1.6-2.1 for DP 200) compared to materials with either substantially higher or lower dispersity. Furthermore, adhesive properties for materials with chains of intermediate dispersity at DP 200 revealed enhanced performance compared to the very low or high dispersity chains.

Towards high performance and durable soft tactile actuators

Soft actuators are gaining significant attention due to their ability to provide realistic tactile sensations in various applications. However, their soft nature makes them vulnerable to damage from external factors, limiting actuation stability and device lifespan. The susceptibility to damage becomes higher with these actuators often in direct contact with their surroundings to generate tactile feedback. Upon onset of damage, the stability or repeatability of the device will be undermined. Eventually, when complete failure occurs, these actuators are disposed of, accumulating waste and driving the consumption of natural resources. This emphasizes the need to enhance the durability of soft tactile actuators for continued operation. This review presents the principles of tactile feedback of actuators, followed by a discussion of the mechanisms, advancements, and challenges faced by soft tactile actuators to realize high actuation performance, categorized by their driving stimuli. Diverse approaches to achieve durability are evaluated, including self-healing, damage resistance, self-cleaning, and temperature stability for soft actuators. In these sections, current challenges and potential material designs are identified, paving the way for developing durable soft tactile actuators.

Practical Applications of Self-Healing Polymers Beyond Mechanical and Electrical Recovery

Self-healing polymeric materials, which can repair physical damage, offer promising prospects for protective applications across various industries. Although prolonged durability and resource conservation are key advantages, focusing solely on mechanical recovery may limit the market potential of these materials. The unique physical properties of self-healing polymers, such as interfacial reduction, seamless connection lines, temperature/pressure responses, and phase transitions, enable a multitude of innovative applications. In this perspective, the diverse applications of self-healing polymers beyond their traditional mechanical strength are emphasized and their potential in various sectors such as food packaging, damage-reporting, radiation shielding, acoustic conservation, biomedical monitoring, and tissue regeneration is explored. With regards to the commercialization challenges, including scalability, robustness, and performance degradation under extreme conditions, strategies to overcome these limitations and promote successful industrialization are discussed. Furthermore, the potential impacts of self-healing materials on future research directions, encompassing environmental sustainability, advanced computational techniques, integration with emerging technologies, and tailoring materials for specific applications are examined. This perspective aims to inspire interdisciplinary approaches and foster the adoption of self-healing materials in various real-life settings, ultimately contributing to the development of next-generation materials.

3D Printing of Double Network Granular Elastomers with Locally Varying Mechanical Properties

Fast advances in the design of soft actuators and robots demand for new soft materials whose mechanical properties can be changed over short length scales. Elastomers can be formulated as highly stretchable or rather stiff materials and hence, are attractive for these applications. They are most frequently cast such that their composition cannot be changed over short length scales. A method that allows to locally change the composition of elastomers on hundreds of micrometer lengths scales is direct ink writing (DIW). Unfortunately, in the absence of rheomodifiers, most elastomer precursors cannot be printed through DIW. Here, 3D printable double network granular elastomers (DNGEs) whose ultimate tensile strain and stiffness can be varied over an unprecedented range are introduced. The 3D printability of these materials is leveraged to produce an elastomer finger containing rigid bones that are surrounded by a soft skin. Similarly, the rheological properties of the microparticle-based precursors are leveraged to cast elastomer slabs with locally varying stiffnesses that deform and twist in a predefined fashion. These DNGEs are foreseen to open up new avenues in the design of the next generation of smart wearables, strain sensors, prosthesis, soft actuators, and robots.

Soft Self-Healing Robot Driven by New Micro Two-Way Shape Memory Alloy Spring

Soft robotic bodies are susceptible to mechanical fatigue, punctures, electrical breakdown, and aging, which can result in the degradation of performance or unexpected failure. To overcome these challenges, a soft self-healing robot is created using a thermoplastic methyl thioglycolate-modified styrene-butadiene-styrene (MG-SBS) elastomer tube fabricated by melt-extrusion, to allow the robot to self-heal autonomously at room temperature. After repeated damage and being separated into several parts, the robot is able to heal its stiffness and elongation to break to enable almost complete recovery of robot performance after being allowed to heal at room temperature for 24 h. The self-healing capability of the robot is examined across the material scale to robot scale by detailed investigations of the healing process, healing efficiency, mechanical characterization of the robot, and assessment of dynamic performance before and after healing. The self-healing robot is driven by a new micro two-way shape-memory alloy (TWSMA) spring actuator which achieved a crawling speed of 21.6 cm/min, equivalent to 1.57 body length per minute. An analytical model of the robot is created to understand the robot dynamics and to act as an efficient tool for self-healing robot design and optimization. This work therefore provides a new methodology to create efficient, robust, and damage-tolerant soft robots.

Research Progress of Self-Healing Polymer for Ultraviolet-Curing Three-Dimensional Printing

Ultraviolet (UV)-curing technology as a photopolymerization technology has received widespread attention due to its advantages of high efficiency, wide adaptability, and environmental friendliness. Ultraviolet-based 3D printing technology has been widely used in the printing of thermosetting materials, but the permanent covalent cross-linked networks of thermosetting materials which are used in this method make it hard to recover the damage caused by the printing process through reprocessing, which reduces the service life of the material. Therefore, introducing dynamic bonds into UV-curable polymer materials might be a brilliant choice which can enable the material to conduct self-healing, and thus meet the needs of practical applications. The present review first introduces photosensitive resins utilizing dynamic bonds, followed by a summary of various types of dynamic bonds approaches. We also analyze the advantages/disadvantages of diverse UV-curable self-healing polymers with different polymeric structures, and outline future development trends in this field.

A review on self-healing featured soft robotics

Soft robots are becoming more popular because they can solve issues stiff robots cannot. Soft component and system design have seen several innovations recently. Next-generation robot-human interactions will depend on soft robotics. Soft material technologies integrate safety at the material level, speeding its integration with biological systems. Soft robotic systems must be as resilient as biological systems in unexpected, uncontrolled situations. Self-healing materials, especially polymeric and elastomeric ones, are widely studied. Since most currently under-development soft robotic systems are composed of polymeric or elastomeric materials, this finding may provide immediate assistance to the community developing soft robots. Self-healing and damage-resilient systems are making their way into actuators, structures, and sensors, even if soft robotics remains in its infancy. In the future, self-repairing soft robotic systems composed of polymers might save both money and the environment. Over the last decade, academics and businesses have grown interested in soft robotics. Despite several literature evaluations of the soft robotics subject, there seems to be a lack of systematic research on its intellectual structure and development despite the rising number of articles. This article gives an in-depth overview of the existing knowledge base on damage resistance and self-healing materials' fundamental structure and classifications. Current uses, problems with future implementation, and solutions to those problems are all included in this overview. Also discussed are potential applications and future directions for self-repairing soft robots.

Self-Healing Polymeric Materials and Composites for Additive Manufacturing

Self-healing polymers have received widespread attention due to their ability to repair damage autonomously and increase material stability, reliability, and economy. However, the processability of self-healing materials has yet to be studied, limiting the application of rich self-healing mechanisms. Additive manufacturing effectively improves the shortcomings of conventional processing while increasing production speed, accuracy, and complexity, offering great promise for self-healing polymer applications. This article summarizes the current self-healing mechanisms of self-healing polymers and their corresponding additive manufacturing methods, and provides an outlook on future developments in the field.

Self-protection soft fluidic robots with rapid large-area self-healing capabilities

Soft fluidic robots have attracted a lot of attention and have broad application prospects. However, poor fluidic power source and easy to damage have been hindering their development, while the lack of intelligent self-protection also brings inconvenience to their applications. Here, we design diversified self-protection soft fluidic robots that integrate soft electrohydrodynamic pumps, actuators, healing electrofluids, and E-skins. We develop high-performance soft electrohydrodynamic pumps, enabling high-speed actuation and large deformation of untethered soft fluidic robots. A healing electrofluid that can form a self-healed film with excellent stretchability and strong adhesion is synthesized, which can achieve rapid and large-areas-damage self-healing of soft materials. We propose multi-functional E-skins to endow robots intelligence, making robots realize a series of self-protection behaviors. Moreover, our robots allow their functionality to be enhanced by the combination of electrodes or actuators. This design strategy enables soft fluidic robots to achieve their high-speed actuation and intelligent self-protection, opening a door for soft robots with physical intelligence.

Dynamic Bonds: Adaptable Timescales for Responsive Materials

Dynamic bonds introduce unique properties such as self-healing, recyclability, shape memory, and malleability to polymers. Significant efforts have been made to synthesize a variety of dynamic linkers, creating a diverse library of materials. In addition to the development of new dynamic chemistries, fine-tuning of dynamic bonds has emerged as a technique to modulate dynamic properties. This Review highlights approaches for controlling the timescales of dynamic bonds in polymers. Particularly, eight dynamic bonds are considered, including urea/urethanes, boronic esters, Thiol-Michael exchange, Diels-Alder adducts, transesterification, imine bonds, coordination bonds, and hydrogen bonding. This Review emphasizes how structural modifications and external factors have been used as tools to tune the dynamic character of materials. Finally, this Review proposes strategies for tailoring the timescales of dynamic bonds in polymer materials through both kinetic effects and modulating bond thermodynamics.

Vat Photopolymerization 3D-Printing of Dynamic Thiol-Acrylate Photopolymers Using Bio-Derived Building Blocks

As an energy-efficient additive manufacturing process, vat photopolymerization 3D-printing has become a convenient technology to fabricate functional devices with high resolution and freedom in design. However, due to their permanently crosslinked network structure, photopolymers are not easily reprocessed or repaired. To improve the environmental footprint of 3D-printed objects, herein, we combine the dynamic nature of hydroxyl ester links, undergoing a catalyzed transesterification at elevated temperature, with an acrylate monomer derived from renewable resources. As a sustainable building block, we synthesized an acrylated linseed oil and mixed it with selected thiol crosslinkers. By careful selection of the transesterification catalyst, we obtained dynamic thiol-acrylate resins with a high cure rate and decent storage stability, which enabled the digital light processing (DLP) 3D-printing of objects with a structure size of 550 µm. Owing to their dynamic covalent bonds, the thiol-acrylate networks were able to relax 63% of their initial stress within 22 min at 180 °C and showed enhanced toughness after thermal annealing. We exploited the thermo-activated reflow of the dynamic networks to heal and re-shape the 3D-printed objects. The dynamic thiol-acrylate photopolymers also demonstrated promising healing, shape memory, and re-shaping properties, thus offering great potential for various industrial fields such as soft robotics and electronics.

Fabrication and Functionality Integration Technologies for Small-Scale Soft Robots

Small-scale soft robots are attracting increasing interest for visible and potential applications owing to their safety and tolerance resulting from their intrinsic soft bodies or compliant structures. However, it is not sufficient that the soft bodies merely provide support or system protection. More importantly, to meet the increasing demands of controllable operation and real-time feedback in unstructured/complicated scenarios, these robots are required to perform simplex and multimodal functionalities for sensing, communicating, and interacting with external environments during large or dynamic deformation with the risk of mismatch or delamination. Challenges are encountered during fabrication and integration, including the selection and fabrication of composite/materials and structures, integration of active/passive functional modules with robust interfaces, particularly with highly deformable soft/stretchable bodies. Here, methods and strategies of fabricating structural soft bodies and integrating them with functional modules for developing small-scale soft robots are investigated. Utilizing templating, 3D printing, transfer printing, and swelling, small-scale soft robots can be endowed with several perceptual capabilities corresponding to diverse stimulus, such as light, heat, magnetism, and force. The integration of sensing and functionalities effectively enhances the agility, adaptability, and universality of soft robots when applied in various fields, including smart manufacturing, medical surgery, biomimetics, and other interdisciplinary sciences.

Manta Ray Inspired Soft Robot Fish with Tough Hydrogels as Structural Elements

The design of soft robots capable of navigation underwater has received tremendous research interest due to the robots' versatile applications in marine explorations. Inspired by marine animals such as jellyfish, scientists have developed various soft robotic fishes by using elastomers as the major material. However, elastomers have a hydrophobic network without embedded water, which is different from the gel-state body of the prototypes and results in high contrast to the surrounding environment and thus poor acoustic stealth. Here, we demonstrate a manta ray-inspired soft robot fish with tailored swimming motions by using tough and stiff hydrogels as the structural elements, as well as a dielectric elastomer as the actuating unit. The switching between actuated and relaxed states of this unit under wired power leads to the flapping of the pectoral fins and swimming of the gel fish. This robot fish has good stability and swims with a fast speed (∼10 cm/s) in freshwater and seawater over a wide temperature range (4-50 °C). The high water content (i.e., ∼70 wt %) of the robot fish affords good optical and acoustic stealth properties under water. The excellent mechanical properties of the gels also enable easy integration of other functional units/systems with the robot fish. As proof-of-concept examples, a temperature sensing system and a soft gripper are assembled, allowing the robot fish to monitor the local temperature, raise warning signals by lighting, and grab and transport an object on demand. Such a robot fish should find applications in environmental detection and execution tasks under water. This work should also be informative for the design of other soft actuators and robots with tough hydrogels as the building blocks.

Recent advances in biomimetic soft robotics: fabrication approaches, driven strategies and applications

Compared to traditional rigid-bodied robots, soft robots are constructed using physically flexible/elastic bodies and electronics to mimic nature and enable novel applications in industry, healthcare, aviation, military, etc. Recently, the fabrication of robots on soft matter with great flexibility and compliance has enabled smooth and sophisticated 'multi-degree-of-freedom' 3D actuation to seamlessly interact with humans, other organisms and non-idealized environments in a highly complex and controllable manner. Herein, we summarize the fabrication approaches, driving strategies, novel applications, and future trends of soft robots. Firstly, we introduce the different fabrication approaches to prepare soft robots and compare and systematically discuss their advantages and disadvantages. Then, we present the actuator-based and material-based driving strategies of soft robotics and their characteristics. The representative applications of soft robotics in artificial intelligence, medicine, sensors, and engineering are summarized. Also, some remaining challenges and future perspectives in soft robotics are provided. This work highlights the recent advances of soft robotics in terms of functional material selection, structure design, control strategies and biomimicry, providing useful insights into the development of next-generation functional soft robotics.

Advances in Digital Light Processing of Hydrogels

Hydrogels, three-dimensional (3D) networks of hydrophilic polymers formed in water, are a significant type of soft matter used in fundamental and applied sciences. Hydrogels are of particular interest for biomedical applications, owing to their soft elasticity and good biocompatibility. However, the high water content and soft nature of hydrogels often make it difficult to process them into desirable solid forms. The development of 3D printing (3DP) technologies has provided opportunities for the manufacturing of hydrogels, by adopting a freeform fabrication method. Owing to its high printing speed and resolution, vat photopolymerization 3DP has recently attracted considerable interest for hydrogel fabrication, with digital light processing (DLP) becoming a widespread representative technique. Whilst acknowledging that other types of vat photopolymerization 3DP have also been applied for this purpose, we here only focus on DLP and its derivatives. In this review, we first comprehensively outline the most recent advances in both materials and fabrication, including the adaptation of novel hydrogel systems and advances in processing (e.g., volumetric printing and multimaterial integration). Secondly, we summarize the applications of hydrogel DLP, including regenerative medicine, functional microdevices, and soft robotics. To the best of our knowledge, this is the first time that either of these specific review focuses has been adopted in the literature. More importantly, we discuss the major challenges associated with hydrogel DLP and provide our perspectives on future trends. To summarize, this review aims to aid and inspire other researchers investigatng DLP, photocurable hydrogels, and the research fields related to them.

High-Resolution 3D Printing for Electronics

The ability to form arbitrary 3D structures provides the next level of complexity and a greater degree of freedom in the design of electronic devices. Since recent progress in electronics has expanded their applicability in various fields in which structural conformability and dynamic configuration are required, high-resolution 3D printing technologies can offer significant potential for freeform electronics. Here, the recent progress in novel 3D printing methods for freeform electronics is reviewed, with providing a comprehensive study on 3D-printable functional materials and processes for various device components. The latest advances in 3D-printed electronics are also reviewed to explain representative device components, including interconnects, batteries, antennas, and sensors. Furthermore, the key challenges and prospects for next-generation printed electronics are considered, and the future directions are explored based on research that has emerged recently.

Carbon Nanotube Composites with Bottlebrush Elastomers for Compliant Electrodes

Wearable electronics and biointerfacing technology require materials that are both compliant and conductive. The typical design strategy exploits polymer composites containing conductive particles, but the addition of a hard filler generally leads to a substantial increase in modulus that is not well-matched to biological tissue. Here, we report a new class of supersoft, conductive composites comprising carbon nanotubes (CNT) embedded in bottlebrush polymer networks. By virtue of the bottlebrush polymer architecture, these materials are several orders of magnitude softer than comparable composites in the literature involving linear polymer networks. For example, a CNT content of 0.25 wt % yields a shear modulus of 66 kPa while maintaining a typical conductivity for a CNT composite (ca. 10-2 S/m). An added benefit of this bottlebrush matrix chemistry is the presence of dynamic polyester bonds that facilitate thermal (re)processing. This unique strategy of designing soft composites provides new opportunities to tailor the structure and properties of sustainable advanced materials.

Processing of Self-Healing Polymers for Soft Robotics

Soft robots are, due to their softness, inherently safe and adapt well to unstructured environments. However, they are prone to various damage types. Self-healing polymers address this vulnerability. Self-healing soft robots can recover completely from macroscopic damage, extending their lifetime. For developing healable soft robots, various formative and additive manufacturing methods have been exploited to shape self-healing polymers into complex structures. Additionally, several novel manufacturing techniques, noted as (re)assembly binding techniques that are specific to self-healing polymers, have been created. Herein, the wide variety of processing techniques of self-healing polymers for robotics available in the literature is reviewed, and limitations and opportunities discussed thoroughly. Based on defined requirements for soft robots, these techniques are critically compared and validated. A strong focus is drawn to the reversible covalent and (physico)chemical cross-links present in the self-healing polymers that do not only endow healability to the resulting soft robotic components, but are also beneficial in many manufacturing techniques. They solve current obstacles in soft robots, including the formation of robust multi-material parts, recyclability, and stress relaxation. This review bridges two promising research fields, and guides the reader toward selecting a suitable processing method based on a self-healing polymer and the intended soft robotics application.

Progress in Utilizing Dynamic Bonds to Fabricate Structurally Adaptive Self-Healing, Shape Memory, and Liquid Crystal Polymers

Stimuli-responsive structurally dynamic polymers are capable of mimicking the biological systems to adapt themselves to the surrounding environmental changes and subsequently exhibiting a wide range of responses ranging from self-healing to complex shape-morphing. Dynamic self-healing polymers (SHPs), shape-memory polymers (SMPs) and liquid crystal elastomers (LCEs), which are three representative examples of stimuli-responsive structurally dynamic polymers, have been attracting broad and growing interest in recent years because of their potential applications in the fields of electronic skin, sensors, soft robots, artificial muscles, and so on. We review recent advances and challenges in the developments towards dynamic SHPs, SMPs and LCEs, focusing on the chemistry strategies and the dynamic reaction mechanisms that enhance the performances of the materials including self-healing, reprocessing and reprogramming. We compare and discuss the different dynamic chemistries and their mechanisms on the enhanced functions of the materials, where three summary tables are presented: a library of dynamic bonds and the resulting characteristics of the materials. Finally, we provide a critical outline of the unresolved issues and future perspectives on the emerging developments. This article is protected by copyright. All rights reserved.