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Material extrusion (MEX) of soft, multifunctional composites consisting of liquid metal (LM) droplets can enable highly tailored properties for a range of applications from soft robotics to stretchable electronics. However, an understanding of how LM ink rheology and print process parameters can reconfigure LM droplet shape during MEX processing for in-situ control of properties and function is currently limited. Herein, the material (ink viscosity, and LM droplet size) and process (nozzle velocity, height from print bed, and extrusion rate) parameters are determined which control LM microstructure during MEX of these composites. The interplay and interdependence of these parameters is evaluated and nearly spherical LM droplets are transformed into highly elongated ellipsoidal shapes with an average aspect ratio of 12.4 by systematically tuning each individual parameter. Material and process relationships are established for the LM ink which show that an ink viscosity threshold should be fulfilled to program the LM microstructure from spherical to an ellipsoidal shape during MEX. Additionally, the thin oxide layer on the LM droplets is found to play a unique and critical role in the reconfiguration and retention of droplet shape. Finally, two quantitative design maps based on material and process parameters are presented to guide MEX additive manufacturing strategies for tuning liquid droplet architecture in LM-polymer inks. The insights gained from this study enable informed design of materials and manufacturing to control microstructure of emerging multifunctional soft composites. 

Abstract Ultrasound is a safe, noninvasive diagnostic technique used to measure internal structures such as blood vessels and the velocity of blood flow in the human body. The ability to continuously measure blood flow in major cerebral arteries would enable the early detection of medical problems such as stroke. However, current ultrasound technology consists of rigid, hand-held probes that are arduous to use, sensitive to movement, and are primarily designed for intermittent, instead of continuous use. Here, we describe the design of a wearable ultrasound patch for continuously measuring blood flow velocity through the middle cerebral artery (MCA) that can be assessed from the temple region of the head. The wearable ultrasound patch is composed of an array of piezoelectric elements that are wired together using flexible electrical conductors and encapsulated in an elastic substrate. To improve ultrasound energy transfer, a soft and conformal composite matching layer is introduced. The matching layer consists of gallium-based liquid metal (LM) microdroplets dispersed in a silicone elastomer. The acoustic impedance of the matching layer can be tuned by varying the volume loading of LM. The wearable ultrasound patch will provide new opportunities to continuously measure blood flow velocity and ultimately enable early detection of medical problems such as stroke. 

Octopus-inspired switchable adhesives are integrated with sensing, processing, and control for robust underwater manipulation.