To advance soft robotics, skin-integrated electronics, and biomedical devices, researchers have developed a 3D printed material that is soft and stretchable — traits needed for matching the properties of tissues and organs — and that self-assembles. Their approach employs a process that eliminates many drawbacks of previous fabrication methods, such as less conductivity or device failure.

Liquid metal-based stretchable conductors suffer from inherent complexity and challenges posed by the post-fabrication activation process, the researchers said. The secondary activation methods include stretching, compressing, shear friction, mechanical sintering, and laser activation, all of which can lead to challenges in fabrication and can cause the liquid metal to leak, resulting in device failure.

In the new method, the researchers combine liquid metal, a conductive polymer mixture called PEDOT:PSS and hydrophilic polyurethane that enables the liquid metal to transform into particles. When the composite soft material is printed and heated, the liquid metal particles on its bottom surface self-assemble into a conductive pathway. (Image credit: Marzia Momin)

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