3D printing for soft robotics – a review

Soft robots have received an increasing attention due to their advantages of high flexibility and safety for human operators but the fabrication is a challenge. Recently, 3D printing has been used as a key technology to fabricate soft robots because of high quality and printing multiple materials at the same time. Functional soft materials are particularly well suited for soft robotics due to a wide range of stimulants and sensitive demonstration of large deformations, high motion complexities and varied multi-functionalities. This review comprises a detailed survey of 3D printing in soft robotics. The development of key 3D printing technologies and new materials along with composites for soft robotic applications is investigated. A brief summary of 3D-printed soft devices suitable for medical to industrial applications is also included. The growing research on both 3D printing and soft robotics needs a summary of the major reported studies and the authors believe that this review article serves the purpose.     

Self‐Healing Hydrogels

Over the past few years, there has been a great deal of interest in the development of hydrogel materials with tunable structural, mechanical, and rheological properties, which exhibit rapid and autonomous self‐healing and self‐recovery for utilization in a broad range of applications, from soft robotics to tissue engineering. However, self‐healing hydrogels generally either possess mechanically robust or rapid self‐healing properties but not both. Hence, the development of a mechanically robust hydrogel material with autonomous self‐healing on the time scale of seconds is yet to be fully realized. Here, the current advances in the development of autonomous self‐healing hydrogels are reviewed. Specifically, methods to test self‐healing efficiencies and recoveries, mechanisms of autonomous self‐healing, and mechanically robust hydrogels are presented. The trends indicate that hydrogels that self‐heal better also achieve self‐healing faster, as compared to gels that only partially self‐heal. Recommendations to guide future development of self‐healing hydrogels are offered and the potential relevance of self‐healing hydrogels to the exciting research areas of 3D/4D printing, soft robotics, and assisted health technologies is highlighted.     

Ferromagnetic Liquid Metal Putty-Like Material with Transformed Shape and Reconfigurable Polarity

It is remarkably desirable and challenging to design reconfigurable ferromagnetic materials with high electrical conductivity. This has attracted great attention due to promising applications in many fields such as emerging flexible electronics and soft robotics. However, the shape and magnetic polarity of existing ferromagnetic materials with low conductivity are both hard to be reconfigured, and the magnetization of insulative ferrofluids is easily lost once the external magnetic field is removed. A novel reconfigurable ferromagnetic liquid metal (LM) putty-like material (FM-LMP) with high electrical conductivity and transformed shape, which is prepared through homogenously mixing neodymium–iron–boron microparticles into the gallium-based LM matrix, and turning this liquid-like suspension into the solid-like putty-like material by magnetization, is reported to achieve this. The induction magnetic field of FM-LMP is mainly attributed to the magnetic alignment of the dispersed ferromagnetic microparticles, which can be conveniently demagnetized by mechanical disordering and reversibly reconfigured through microparticle realignment by applying a weak magnetic field. FM-LMP with a low fraction of microparticles can be used as printable conductive ink for paper electronics, which are further exploited for applications including magnetic switching, flexible erasable magnetic recording paper, and self-sensing paper-based soft robotics using magnetic actuation.     

Soft Robotic Grippers

Advances in soft robotics, materials science, and stretchable electronics have enabled rapid progress in soft grippers. Here, a critical overview of soft robotic grippers is presented, covering different material sets, physical principles, and device architectures. Soft gripping can be categorized into three technologies, enabling grasping by: a) actuation, b) controlled stiffness, and c) controlled adhesion. A comprehensive review of each type is presented. Compared to rigid grippers, end‐effectors fabricated from flexible and soft components can often grasp or manipulate a larger variety of objects. Such grippers are an example of morphological computation, where control complexity is greatly reduced by material softness and mechanical compliance. Advanced materials and soft components, in particular silicone elastomers, shape memory materials, and active polymers and gels, are increasingly investigated for the design of lighter, simpler, and more universal grippers, using the inherent functionality of the materials. Embedding stretchable distributed sensors in or on soft grippers greatly enhances the ways in which the grippers interact with objects. Challenges for soft grippers include miniaturization, robustness, speed, integration of sensing, and control. Improved materials, processing methods, and sensing play an important role in future research.     

Soft Ultrathin Electronics Innervated Adaptive Fully Soft Robots

Soft robots outperform the conventional hard robots on significantly enhanced safety, adaptability, and complex motions. The development of fully soft robots, especially fully from smart soft materials to mimic soft animals, is still nascent. In addition, to date, existing soft robots cannot adapt themselves to the surrounding environment, i.e., sensing and adaptive motion or response, like animals. Here, compliant ultrathin sensing and actuating electronics innervated fully soft robots that can sense the environment and perform soft bodied crawling adaptively, mimicking an inchworm, are reported. The soft robots are constructed with actuators of open‐mesh shaped ultrathin deformable heaters, sensors of single‐crystal Si optoelectronic photodetectors, and thermally responsive artificial muscle of carbon‐black‐doped liquid‐crystal elastomer (LCE‐CB) nanocomposite. The results demonstrate that adaptive crawling locomotion can be realized through the conjugation of sensing and actuation, where the sensors sense the environment and actuators respond correspondingly to control the locomotion autonomously through regulating the deformation of LCE‐CB bimorphs and the locomotion of the robots. The strategy of innervating soft sensing and actuating electronics with artificial muscles paves the way for the development of smart autonomous soft robots.     

Hydroprinted Liquid‐Alloy‐Based Morphing Electronics for Fast‐Growing/Tender Plants: From Physiology Monitoring to Habit Manipulation

Monitoring physiological signals and manipulating growth habits of living plants in real time are important for botany research, biohybrid plant robots, and precision agriculture. Although emerging epidermal electronics that can conveniently acquire vital signals of living organisms exhibit a high potential for such scenarios, it is a significant challenge to adapt such devices for plants, because they are fragile and usually have complex surfaces that can change significantly during rapid growth. A gentle fabrication process is critical in order to employ compliant electronic systems to adapt to this highly dynamic situation. In this study, a hydroprinted liquid‐alloy‐based morphing electronics (LAME) process is employed for fast‐growing plants that will sense physiological signals and even function as a biohybrid to determine plant behavior on demand. Besides various surfaces of inorganic targeting substrates, pinning liquid alloy circuits onto the complex plant epidermis is enhanced by introducing high‐surface‐energy liquid. Functionally, the new developed LAME can be used to monitor leaf moisture content and length, and manipulate leaf and bean sprout orientation. This study lays the foundation for a new form of morphing electronics for botany or biohybrid plant robots, potentially impacting the next generation of precision agriculture and smart hybrid robots.     

Magnetic Shape Memory Polymers with Integrated Multifunctional Shape Manipulation

Shape-programmable soft materials that exhibit integrated multifunctional shape manipulations, including reprogrammable, untethered, fast, and reversible shape transformation and locking, are highly desirable for a plethora of applications, including soft robotics, morphing structures, and biomedical devices. Despite recent progress, it remains challenging to achieve multiple shape manipulations in one material system. Here, a novel magnetic shape memory polymer composite is reported to achieve this. The composite consists of two types of magnetic particles in an amorphous shape memory polymer matrix. The matrix softens via magnetic inductive heating of low-coercivity particles, and high-remanence particles with reprogrammable magnetization profiles drive the rapid and reversible shape change under actuation magnetic fields. Once cooled, the actuated shape can be locked. Additionally, varying the particle loadings for heating enables sequential actuation. The integrated multifunctional shape manipulations are further exploited for applications including soft magnetic grippers with large grabbing force, reconfigurable antennas, and sequential logic for computing.     

Biohybrid Design Gets Personal: New Materials for Patient-Specific Therapy

Precision medicine requires materials and devices that can sense and adapt to dynamic physiological and pathological conditions. This motivates the design and manufacture of biohybrid materials that mimic the responsive behaviors demonstrated by natural biological systems. Two parallel approaches to biohybrid design are presented—biomimetics and biointegration. Biohybrid hydrogels that mimic the form and function of natural materials, or that integrate living cells or bioactive moieties, can respond to a range of environmental stimuli in parallel, including heat, light, pH, hydration, enzymes, and electric, mechanical, and magnetic forces. A range of examples that illustrate the tremendous potential of this nascent discipline are presented, and ongoing technical challenges related to manufacturing, storage, transport, and external noninvasive control of these materials that will need to be overcome in the coming years are outlined. The ethical, educational, and regulatory challenges that will govern translation of biohybrid design into medical applications are also discussed. Personalized medical therapies that target the precise needs of patients are a critically needed and expanding market. Biohybrid design offers the unique ability to manufacture materials and devices that match the dynamic and patient-specific in vivo environment, promising to generate more effective and safe therapies that enable personalized care.     

Soft Matter Technology at KIT: Chemical Perspective from Nanoarchitectures to Microstructures

Bioinspiration has emerged as an important design principle in the rapidly growing field of materials science and especially its subarea, soft matter science. For example, biological cells form hierarchically organized tissues that not only are optimized and designed for durability, but also have to adapt to their external environment, undergo self‐repair, and perform many highly complex functions. Being able to create artificial soft materials that mimic those highly complex functions will enable future materials applications. Herein, soft matter technologies that are used to realize bioinspired material structures are described, and potential pathways to integrate these into a comprehensive soft matter research environment are addressed. Solutions become available because soft matter technologies are benefitting from the synergies between organic synthesis, polymer chemistry, and materials science.     

Kirigami-Based Light-Induced Shape-Morphing and Locomotion

The development of stimuli-responsive soft actuators, a task largely undertaken by material scientists, has become a major driving force in pushing the frontiers of microrobotics. Devices made of soft active materials are oftentimes small in size, remotely and wirelessly powered/controlled, and capable of adapting themselves to unexpected hurdles. However, nowadays most soft microscale robots are rather simple in terms of design and architecture, and it remains a challenge to create complex 3D soft robots with stimuli-responsive properties. Here, it is suggested that kirigami-based techniques can be useful for fabricating complex 3D robotic structures that can be activated with light. External stress fields introduce out-of-plane deformation of kirigami film actuators made of liquid crystal networks. Such 2D-to-3D structural transformations can give rise to mechanical actuation upon light illumination, thus allowing the realization of kirigami-based light-fuelled robotics. A kirigami rolling robot is demonstrated, where a light beam controls the multigait motion and steers the moving direction in 2D. The device is able to navigate along different routes and moves up a ramp with a slope of 6°. The results demonstrate a facile technique to realize complex and flexible 3D structures with light-activated robotic functions.     

Design of untethered soft material micromachine for life-like locomotion

Living organisms composed of composite materials with complex structures support autonomous and intelligent behaviors, such as motility, perception and response to changes of the environment. By studying the biological structures and their environmental interactions, researchers are now using these natural systems as models for building soft material machines. In this review, we discuss materials and machine engineering principles to achieve life-like locomotion and functionalities in untethered soft micromachines. Through the various mechanochemical or physical mechanisms, we show how molecular motion can be collectively amplified into versatile macroscopic deformation by materials engineering across multiple length scales. In controlled ways, mobile micromachines are made to crawl, roll or jump and adaptive to various terrains, typically inspired by the terrestrial animals while propulsion of swimming micromachines are guided by aquatic organisms. Besides, out-of-equilibrium behaviors of living systems, such as cell cycling, have stimulated the design of autonomous movement. Furthermore, we review the recent efforts on robotic locomotion intelligence to achieve adaptive, functional locomotion and navigation in complex environment. We finally provide a critical perspective for the field of soft micromachines, and highlight the key challenges of different material systems that need to be overcome to realize practical use.     

Directed Assembly of Liquid Metal–Elastomer Conductors for Stretchable and Self-Healing Electronics

Growing interest in soft robotics, stretchable electronics, and electronic skins has created demand for soft, compliant, and stretchable electrodes and interconnects. Here, dielectrophoresis (DEP) is used to assemble, align, and sinter eutectic gallium indium (EGaIn) microdroplets in uncured poly(dimethylsiloxane) (PDMS) to form electrically conducting microwires. There are several noteworthy aspects of this approach. 1) Generally, EGaIn droplets in silicone at loadings approaching 90 wt% remain insulating and form a conductive network only when subjected to sintering. Here, DEP facilitates assembly of EGaIn droplets into conductive microwires at loadings as low as 10 wt%. 2) DEP is done in silicone for the first time, enabling the microwires to be cured in a stretchable matrix. 3) Liquid EGaIn droplets sinter during DEP to form a stretchable metallic microwire that retains its shape after curing the silicone. 4) Use of liquid metal eliminates the issue of compliance mismatch observed in soft polymers with solid fillers. 5) The silicone–EGaIn “ink” can be assembled by DEP within the crevices of severely damaged wires to create stretchable interconnects that heal the damage mechanically and electrically. The DEP process of this unique set of materials is characterized and the interesting attributes enabled by such liquid microwires are demonstrated.     

Extreme Toughening of Soft Materials with Liquid Metal

Soft and tough materials are critical for engineering applications in medical devices, stretchable and wearable electronics, and soft robotics. Toughness in synthetic materials is mostly accomplished by increasing energy dissipation near the crack tip with various energy dissipation techniques. However, bio‐materials exhibit extreme toughness by combining multi‐scale energy dissipation with the ability to deflect and blunt an advancing crack tip. Here, we demonstrate a synthetic materials architecture that also exhibits multi‐modal toughening, whereby embedding a suspension of micron sized and highly deformable liquid metal (LM) droplets inside a soft elastomer, the fracture energy dramatically increases by up to 50x (from 250 ± 50 J m^‐2 to 11,900 ± 2600 J m^‐2) over an unfilled polymer. For some LM‐embedded elastomer (LMEE) compositions, the toughness is measured to be 33,500 ± 4300 J m^‐2, which far exceeds the highest value previously reported for a soft elastic material. This extreme toughening is achieved by (i) increasing energy dissipation, (ii) adaptive crack movement, and (iii) effective elimination of the crack tip. Such properties arise from the deformability of the LM inclusions during loading, providing a new mechanism to not only prevent crack initiation, but also resist the propagation of existing tears for ultra tough, soft materials.     

Effect of magnetostriction on fracture of a soft ferromagnetic medium with a crack-like flaw

The magnetic‐induction field in the vicinity of an elliptical inclusion embedded in an infinite soft ferromagnetic medium is determined based on complex potential theory. By using a constitutive relation of magnetostriction for isotropic materials, the stress field in the vicinity of an elliptical flaw is obtained. Furthermore, the stress field at the tip of a slender elliptical crack is determined for the case in which only an external magnetic field perpendicular to the major axis of the ellipse is applied at infinity. The results indicate that the stress field in the neighbourhood of the tip is governed by the magnetostriction and permeability of the soft ferromagnetic material. The induction magnetostrictive modulus is a key parameter in determining which of the two mechanisms, i.e., magnetostriction and magnetic‐force‐induced deformation, is dominant in determining the stress field in the neighbourhood of the tip of a crack‐like flaw. With regard to the influence of the magnetic field on the apparent toughness of a soft ferromagnetic body with a crack‐like flaw, soft ferromagnetic materials can be roughly divided into two categories: one possesses a large induction magnetostrictive modulus and the other has a small modulus. An approximate criterion for categorizing the materials is presented. For the benefit of engineering design, the expressions of the stress‐intensity factor for these two categories of soft ferromagnetic materials are presented. The results show that the stress‐intensity factor is affected not only by the flaw geometry, but also by the permeability of the medium inside the flaw.     

Autonomous Motility of Polymer Films

Adaptive soft materials exhibit a diverse set of behaviors including reconfiguration, actuation, and locomotion. These responses however, are typically optimized in isolation. Here, the interrelation between these behaviors is established through a state space framework, using Nylon 6 thin films in a humidity gradient as an experimental testbed. It is determined that the dynamic behaviors are a result of not only a response to but also an interaction with the applied stimulus, which can be tuned via control of the environment and film characteristics, including size, permeability, and coefficient of hygroscopic expansion to target a desired behavior such as multimodal locomotion. Using these insights, it is demonstrated that films simultaneously harvest energy and information from the environment to autonomously move down a stimulus gradient. Improved understanding of the coupling between an adaptive material and its environment aids the development of materials that integrate closed loop autonomous sensing, actuation, and locomotion.     

Rubber-Like Soft Lattice Structure for Anti-Ballooning in Fluidic Elastic Soft Robots

Additive manufacturing of lattice structures provides materials with enhanced strength, stiffness, and lightweight properties. While most research focuses on stiff, low-stretch materials like metals and acrylonitrile butadiene styrene, herein, the tensile behavior of soft, elastomeric lattice structures is explored. Soft-material 3D-printing advancements have enabled increased usage of directly printed soft robots. Traditional fluidic elastic actuators, however, face limitations due to the ballooning effect of soft polymers, causing potential explosions or leakages. To mitigate this, the study proposes using a soft lattice structure to reinforce soft inflatable robots, thereby reducing the ballooning effect and increasing design freedom. Herein, soft lattices are fabricated using Agilus30 in a Stratasys J735 printer and their behaviors under compression and stretching are compared. It is indicated in the results that lattice reinforcement maintains the soft robot's shape under higher pressure and allows tunability of stiffness with variable internal pressure. The implementation of this method in non-convex soft robots successfully demonstrates its anti-ballooning effect.     

Liquid Metal–Based Soft Microfluidics

Motivated by the increasing demand of wearable and soft electronics, liquid metal (LM)‐based microfluidics has been subjected to tremendous development in the past decade, especially in electronics, robotics, and related fields, due to the unique advantages of LMs that combines the conductivity and deformability all‐in‐one. LMs can be integrated as the core component into microfluidic systems in the form of either droplets/marbles or composites embedded by polymer materials with isotropic and anisotropic distribution. The LM microfluidic systems are found to have broad applications in deformable antennas, soft diodes, biomedical sensing chips, transient circuits, mechanically adaptive materials, etc. Herein, the recent progress in the development of LM‐based microfluidics and their potential applications are summarized. The current challenges toward industrial applications and future research orientation of this field are also summarized and discussed.     

Covalent Bonding of Thermoplastics to Rubbers for Printable,Reel‐to‐Reel Processing in Soft Robotics and Microfluidics

The lamination of mechanically stiff structures to elastic materials is prevalent in biological systems and popular in many emerging synthetic systems, such as soft robotics, microfluidics, stretchable electronics, and pop‐up assemblies. The disparate mechanical and chemical properties of these materials have made it challenging to develop universal synthetic procedures capable of reliably adhering to these classes of materials together. Herein, a simple and scalable procedure is described that is capable of covalently laminating a variety of commodity (“off‐the‐shelf”) thermoplastic sheets to silicone rubber films. When combined with laser printing, the nonbonding sites can be “printed” onto the thermoplastic sheets, enabling the direct fabrication of microfluidic systems for actuation and liquid handling applications. The versatility of this approach in generating thin, multifunctional laminates is demonstrated through the fabrication of milliscale soft actuators and grippers with hinged articulation and microfluidic channels with built‐in optical filtering and pressure‐dependent geometries. This method of fabrication offers several advantages, including technical simplicity, process scalability, design versatility, and material diversity. The concepts and strategies presented herein are broadly applicable to the soft robotics, microfluidics, and advanced and additive manufacturing communities where hybrid rubber/plastic structures are prevalent.     

Soft Actuators for Small‐Scale Robotics

This review comprises a detailed survey of ongoing methodologies for soft actuators, highlighting approaches suitable for nanometer‐ to centimeter‐scale robotic applications. Soft robots present a special design challenge in that their actuation and sensing mechanisms are often highly integrated with the robot body and overall functionality. When less than a centimeter, they belong to an even more special subcategory of robots or devices, in that they often lack on‐board power, sensing, computation, and control. Soft, active materials are particularly well suited for this task, with a wide range of stimulants and a number of impressive examples, demonstrating large deformations, high motion complexities, and varied multifunctionality. Recent research includes both the development of new materials and composites, as well as novel implementations leveraging the unique properties of soft materials.