Stretchable, Twisted Conductive Microtubules for Wearable Computing, Robotics, Electronics, and Healthcare

Bio-SHARPE: Bioinspired Soft and High Aspect Ratio Pumping Element for Robotic and Medical Applications

The advent of soft robots has solved many issues posed by their rigid counterparts, including safer interactions with humans and the capability to work in narrow and complex environments. While much work has been devoted to developing soft actuators and bioinspired mechatronic systems, comparatively little has been done to improve the methods of actuation. Hydraulically soft actuators (HSAs) are emerging candidates to control soft robots due to their fast responses, low noise, and low hysteresis compared to compressible pneumatic ones. Despite advances, current hydraulic sources for large HSAs are still bulky and require high power availability to drive the pumping plant. To overcome these challenges, this work presents a new bioinspired soft and high aspect ratio pumping element (Bio-SHARPE) for use in soft robotic and medical applications. This new soft pumping element can amplify its input volume to at least 8.6 times with a peak pressure of at least 40 kPa. The element can be integrated into existing hydraulic pumping systems like a hydraulic gearbox. Naturally, an amplification of fluid volume can only come at the sacrifice of pumping pressure, which was observed as a 19.1:1 reduction from input to output pressure. The new concept enables a large soft robotic body to be actuated by smaller fluid reservoirs and pumping plant, potentially reducing their power and weight, and thus facilitating drive source miniaturization. The high amplification ratio also makes soft robotic systems more applicable for human-centric applications such as rehabilitation aids, bioinspired untethered soft robots, medical devices, and soft artificial organs. Details of the fabrication and experimental characterization of the Bio-SHARPE and its associated components are given. A soft robotic squid and an artificial heart ventricle are introduced and experimentally validated.

Integrated Multifunctional Electronic Skins with Low-Coupling for Complicated and Accurate Human-Robot Collaboration

Multifunctional capability and low coupling electronic skin (e-skin) is of great significance in advanced robot systems interacting with the human body or the external environment directly. Herein, a multifunctional e-skin system via vertical integrated different sensing materials and structures is presented. The multifunctional e-skin has capacity sensing the proximity, pressure, temperature, and relative humidity simultaneously, with scope of 100-0 mm, 0-30 N, 20-120 °C and 20-70%, respectively. The sensitivity of the four kinds of sensors can be achieved to 0.72 mm^-1 , 16.34 N^-1 , 0.0032 °C^-1 , and 15.2 pF/%RH, respectively. The cross-coupling errors are less than 1.96%, 1.08%, 2.65%, and 1.64%, respectively, after temperature compensation. To be state-of-the-art, a commercial robot is accurately controlled via the multifunctional e-skin system in the complicated environment. The following and safety controlling exhibit both accuracy and high dynamic features. To improve the sensing performance to the insulating objects, machine learning is employed to classify the conductivity during the object approaching, leading to set the threshold in dynamic. The accuracy for isolating the insulator increases from 18% to 88%. Looking forward, the multifunctional e-skin system has broader applications in human-machine collaboration and industrial safety production technology.

Mechanically Tunable Flexible Photonic Device for Strain Sensing Applications

Flexible photonic devices based on soft polymers enable real-time sensing of environmental conditions in various industrial applications. A myriad of fabrication techniques have been established for producing optical devices, including photo and electron-beam lithography, nano/femtosecond laser writing, and surface imprinting or embossing. However, among these techniques, surface imprinting/embossing is simple, scalable, convenient to implement, can produce nanoscale resolutions, and is cost-effective. Herein, we utilize the surface imprinting method to replicate rigid micro/nanostructures onto a commonly available PDMS substrate, enabling the transfer of rigid nanostructures into flexible forms for sensing at a nanometric scale. The sensing nanopatterned sheets were mechanically extended, and the extension was remotely monitored via optical methods. Monochromatic light (450, 532, and 650 nm) was transmitted through the imprinted sensor under various force/stress levels. The optical response was recorded on an image screen and correlated with the strain created by the applied stress levels. The optical response was obtained in diffraction pattern form from the flexible grating-based sensor and in an optical-diffusion field form from the diffuser-based sensor. The calculated Young's modulus in response to the applied stress, measured through the novel optical method, was found in a reasonable range compared to the reported range of PDMS (360-870 kPa) in the literature.

Advanced Soft Robotic System for In Situ 3D Bioprinting and Endoscopic Surgery

Three-dimensional (3D) bioprinting technology offers great potential in the treatment of tissue and organ damage. Conventional approaches generally rely on a large form factor desktop bioprinter to create in vitro 3D living constructs before introducing them into the patient's body, which poses several drawbacks such as surface mismatches, structure damage, and high contamination along with tissue injury due to transport and large open-field surgery. In situ bioprinting inside a living body is a potentially transformational solution as the body serves as an excellent bioreactor. This work introduces a multifunctional and flexible in situ 3D bioprinter (F3DB), which features a high degree of freedom soft printing head integrated into a flexible robotic arm to deliver multilayered biomaterials to internal organs/tissues. The device has a master-slave architecture and is operated by a kinematic inversion model and learning-based controllers. The 3D printing capabilities with different patterns, surfaces, and on a colon phantom are also tested with different composite hydrogels and biomaterials. The F3DB capability to perform endoscopic surgery is further demonstrated with fresh porcine tissue. The new system is expected to bridge a gap in the field of in situ bioprinting and support the future development of advanced endoscopic surgical robots.

Effect of Surrounding Solvents on Interfacial Behavior of Gallium-Based Liquid Metal Droplets

Gallium-based liquid metal (GaLM) alloys have been extensively used in applications ranging from electronics to drug delivery systems. To broaden the understanding and applications of GaLMs, this paper discusses the interfacial behavior of eutectic gallium-indium liquid metal (EGaIn) droplets in various solvents. No significant difference in contact angles of EGaIn is observed regardless of the solvent types. However, the presence or absence of a conical tip on EGaIn droplets after dispensing could indirectly support that the interfacial energy of EGaIn is relatively low in non-polar solvents. Furthermore, in the impact experiments, the EGaIn droplet bounces off in the polar solvents of water and dimethyl sulfoxide (DMSO), whereas it spreads and adheres to the substrate in the non-polar solvents of hexane and benzene. Based on the dimensionless We number, it can be stated that the different impact behavior depending on the solvent types is closely related to the interfacial energy of EGaIn in each solvent. Finally, the contact angles and shapes of EGaIn droplets in aqueous buffer solutions with different pH values (4, 7, and 10) are compared. In the pH 10 buffer solution, the EGaIn droplet forms a spherical shape without the conical tip, representing the high surface energy. This is associated with the dissolution of the “interfacial energy-reducing” surface layer on EGaIn, which is supported by the enhanced concentration of gallium ion released from EGaIn in the buffer solution.

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.

Functional Fibers and Fabrics for Soft Robotics, Wearables, and Human-Robot Interface

Soft robotics inspired by the movement of living organisms, with excellent adaptability and accuracy for accomplishing tasks, are highly desirable for efficient operations and safe interactions with human. With the emerging wearable electronics, higher tactility and skin affinity are pursued for safe and user-friendly human-robot interactions. Fabrics interlocked by fibers perform traditional static functions such as warming, protection, and fashion. Recently, dynamic fibers and fabrics are favorable to deliver active stimulus responses such as sensing and actuating abilities for soft-robots and wearables. First, the responsive mechanisms of fiber/fabric actuators and their performances under various external stimuli are reviewed. Fiber/yarn-based artificial muscles for soft-robots manipulation and assistance in human motion are discussed, as well as smart clothes for improving human perception. Second, the geometric designs, fabrications, mechanisms, and functions of fibers/fabrics for sensing and energy harvesting from the human body and environments are summarized. Effective integration between the electronic components with garments, human skin, and living organisms is illustrated, presenting multifunctional platforms with self-powered potential for human-robot interactions and biomedicine. Lastly, the relationships between robotic/wearable fibers/fabrics and the external stimuli, together with the challenges and possible routes for revolutionizing the robotic fibers/fabrics and wearables in this new era are proposed.

Electroluminescent Fabric Woven by Ultrastretchable Fibers for Arbitrarily Controllable Pattern Display

Flexible textile displays can be revolutionary for information transmission at any place and any time. Typically, textile displays are fabricated by traditional rigid electronics that sacrifice mechanical flexibility of devices or by flexible electronics that do not have an appropriate choice to arbitrarily control single pixels. This work reports on an electroluminescent fabric woven by ultrastretchable fibers (electroluminescent fibers up to 400% stretch, electrode fibers up to 250% stretch), which can exhibit the pixel-based arbitrarily controllable pattern display by a mobile phone application. To realize ultrastretchability, we made these fibers by encapsulating liquid metals on a polyurethane core (high elasticity). To realize arbitrary control, the design shows a plain-woven structure comprising ZnS-based electroluminescent fibers and perpendicular electrode fibers. The cross-points between the electroluminescent fiber and the electrode fiber form pixels that can be switched on or off independently and can further form the pixel-based arbitrarily controllable pattern display. By doping with different elements, ZnS-based electroluminescent fibers can emit green, blue, or yellow lights. Meanwhile, the fabrication of these fibers employs dip-coating, a scalable manufacturing method without high temperature or vacuum atmosphere. These fabrics show great potential in a wide range of applications such as wearable electronic devices, healthcare, and fashion design.

Mechanically driven strategies to improve electromechanical behaviour of printed stretchable electronic systems

Stretchable electronics promise to extend the application range of conventional electronics by enabling them to keep their electrical functionalities under system deformation. Within this framework, development of printable silver-polymer composite inks is making possible to realize several of the expected applications for stretchable electronics, which range from seamless sensors for human body measurement (e.g. health patches) to conformable injection moulded structural electronics. However, small rigid electric components are often incorporated in these devices to ensure functionality. Under mechanical loading, these rigid elements cause strain concentrations and a general deterioration of the system's electrical performance. This work focuses on different strategies to improve electromechanical performance by investigating the deformation behaviour of soft electronic systems comprising rigid devices through Finite Element analyses. Based on the deformation behaviour of a simple stretchable device under tensile loading, three general strategies were proposed: local component encapsulation, direct component shielding, and strain dispersion. The FE behaviour achieved using these strategies was then compared with the experimental results obtained for each design, highlighting the reasons for their different resistance build-up. Furthermore, crack formation in the conductive tracks was analysed under loading to highlight its link with the evolution of the system electrical performance.

Advances in Rational Design and Materials of High-Performance Stretchable Electromechanical Sensors

Stretchable and wearable sensor technology has attracted significant interests and created high technological impact on portable healthcare and smart human-machine interfaces. Wearable electromechanical systems are an important part of this technology that has recently witnessed tremendous progress toward high-performance devices for commercialization. Over the past few years, great attention has been paid to simultaneously enhance the sensitivity and stretchability of the electromechanical sensors toward high sensitivity, ultra-stretchability, low power consumption or self-power functionalities, miniaturisation as well as simplicity in design and fabrication. This work presents state-of-the-art advanced materials and rational designs of electromechanical sensors for wearable applications. Advances in various sensing concepts and structural designs for intrinsic stretchable conductive materials as well as advanced rational platforms are discussed. In addition, the practical applications and challenges in the development of stretchable electromechanical sensors are briefly mentioned and highlighted.

Fluidic Fabric Muscle Sheets for Wearable and Soft Robotics

Conformable robotic systems are attractive for applications in which they may actuate structures with large surface areas, provide forces through wearable garments, or enable autonomous robotic systems. We present a new family of soft actuators that we refer to as Fluidic Fabric Muscle Sheets (FFMS). They are composite fabric structures that integrate fluidic transmissions based on arrays of elastic tubes. These sheet-like actuators can strain, squeeze, bend, and conform to hard or soft objects of arbitrary shapes or sizes, including the human body. We show how to design and fabricate FFMS actuators via facile apparel engineering methods, including computerized sewing techniques that determine the stress and strain distributions that can be generated. We present a simple mathematical model that proves effective for predicting their performance. FFMS can operate at frequencies of 5 Hz or more, achieve engineering strains exceeding 100%, and exert forces >115 times their weight. They can be safely used in intimate contact with the human body even when delivering stresses exceeding 10⁶ Pascals. We demonstrate their versatility for actuating a variety of bodies or structures, and in configurations that perform multiaxis actuation, including bending and shape change. As we also show, FFMS can be used to exert forces on body tissues for wearable and biomedical applications. We demonstrate several potential use cases, including a miniature steerable robot, a glove for grasp assistance, garments for applying compression to the extremities, and devices for actuating small body regions or tissues via localized skin stretch.

Fiber Optic Shape Sensing for Soft Robotics

While soft material actuators can undergo large deformations to execute very complex motions, what is critically lacking in soft material robotic systems is the ability to collect high-resolution shape information for sophisticated functions such as environmental mapping, collision detection, and full state feedback control. This work explores the potential of a nearly commercial fiber optic shape sensor (FOSS) and presents the first demonstrations of a monolithic, multicore FOSS integrated into the structure of a fiber-reinforced soft actuator. In this pilot study, we report an open loop sensorized soft actuator capable of submillimeter position feedback that can detect the soft actuator's shape, environmental shapes, collision locations, and material stiffness properties.

The Effect of Encapsulation Geometry on the Performance of Stretchable Interconnects

The stretchability of electronic devices is typically obtained by tailoring the stretchable interconnects that link the functional units together. The durability of the interconnects against environmental conditions, such as deformation and chemicals, is therefore important to take into account. Different approaches, including encapsulation, are commonly used to improve the endurance of stretchable interconnects. In this paper, the geometry of encapsulation layer is initially investigated using finite element analysis. Then, the stretchable interconnects with a narrow-to-wide layout are screen-printed using silver flake ink as a conductor on a thermoplastic polyurethane (TPU) substrate. Printed ultraviolet (UV)-curable screen-printed dielectric ink and heat-laminated TPU film are used for the encapsulation of the samples. The electromechanical tests reveal a noticeable improvement in performance of encapsulated samples compared to non-protected counterparts in the case of TPU encapsulation. The improvement is even greater with partial coverage of the encapsulation layer. A device with a modified encapsulation layer can survive for 10,000 repetitive cycles at 20% strain, while maintaining the electrical and mechanical performance.

Development of Flexible Robot Skin for Safe and Natural Human⁻Robot Collaboration

For industrial manufacturing, industrial robots are required to work together with human counterparts on certain special occasions, where human workers share their skills with robots. Intuitive human–robot interaction brings increasing safety challenges, which can be properly addressed by using sensor-based active control technology. In this article, we designed and fabricated a three-dimensional flexible robot skin made by the piezoresistive nanocomposite based on the need for enhancement of the security performance of the collaborative robot. The robot skin endowed the YuMi robot with a tactile perception like human skin. The developed sensing unit in the robot skin showed the one-to-one correspondence between force input and resistance output (percentage change in impedance) in the range of 0–6.5 N. Furthermore, the calibration result indicated that the developed sensing unit is capable of offering a maximum force sensitivity (percentage change in impedance per Newton force) of 18.83% N⁻¹ when loaded with an external force of 6.5 N. The fabricated sensing unit showed good reproducibility after loading with cyclic force (0–5.5 N) under a frequency of 0.65 Hz for 3500 cycles. In addition, to suppress the bypass crosstalk in robot skin, we designed a readout circuit for sampling tactile data. Moreover, experiments were conducted to estimate the contact/collision force between the object and the robot in a real-time manner. The experiment results showed that the implemented robot skin can provide an efficient approach for natural and secure human–robot interaction.

Flexible corner cube retroreflector array for temperature and strain sensing

Optical sensors for detecting temperature and strain play a crucial role in the analysis of environmental conditions and real-time remote sensing. However, the development of a single optical device that can sense temperature and strain simultaneously remains a challenge. Here, a flexible corner cube retroreflector (CCR) array based on passive dual optical sensing (temperature and strain) is demonstrated. A mechanical embossing process was utilised to replicate a three-dimensional (3D) CCR array in a soft flexible polymer film. The fabricated flexible CCR array samples were experimentally characterised through reflection measurements followed by computational modelling. As fabricated samples were illuminated with a monochromatic laser beam (635, 532, and 450 nm), a triangular shape reflection was obtained at the far-field. The fabricated flexible CCR array samples tuned retroreflected light based on external stimuli (temperature and strain as an applied force). For strain and temperature sensing, an applied force and temperature, in the form of weight suspension, and heat flow was applied to alter the replicated CCR surface structure, which in turn changed its optical response. Directional reflection from the heated flexible CCR array surface was also measured with tilt angle variation (max. up to 10°). Soft polymer CCRs may have potential in remote sensing applications, including measuring the temperature in space and in nuclear power stations.

A flexible corner cube retroreflector (CCR) array based passive dual sensing is demonstrated to measure external stimuli (temperature/mechanical force as weight suspension).

Soft Material-Enabled, Flexible Hybrid Electronics for Medicine, Healthcare, and Human-Machine Interfaces

Flexible hybrid electronics (FHE), designed in wearable and implantable configurations, have enormous applications in advanced healthcare, rapid disease diagnostics, and persistent human-machine interfaces. Soft, contoured geometries and time-dynamic deformation of the targeted tissues require high flexibility and stretchability of the integrated bioelectronics. Recent progress in developing and engineering soft materials has provided a unique opportunity to design various types of mechanically compliant and deformable systems. Here, we summarize the required properties of soft materials and their characteristics for configuring sensing and substrate components in wearable and implantable devices and systems. Details of functionality and sensitivity of the recently developed FHE are discussed with the application areas in medicine, healthcare, and machine interactions. This review concludes with a discussion on limitations of current materials, key requirements for next generation materials, and new application areas.