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Fibrillar adhesives composed of fibers with non-circular cross-sections and contacts, including squares and rectangles, offer advantages that include a larger real contact area when arranged in arrays and simplicity in fabrication. However, they typically have a lower adhesion strength compared to circular pillars due to a stress concentration at the corner of the non-circular contact. We investigate the adhesion of composite pillars with circular, square and rectangular cross-sections each consisting of a stiff pillar terminated by a thin compliant layer at the tip. Finite element mechanics modeling is used to assess differences in the stress distribution at the interface for the different geometries and the adhesion strength of different shape pillars is measured in experiments. The composite fibrillar structure results in a favorable stress distribution on the adhered interface that shifts the crack initiation site away from the edge for all of the cross-sectional contact shapes studied. The highest adhesion strength achieved among the square and rectangular composite pillars with various tip layer thicknesses is approximately 65 kPa. This is comparable to the highest strength measured for circular composite pillars and is about 6.5× higher than the adhesion strength of a homogenous square or rectangular pillar. The results suggest that a composite fibrillar adhesive structure with a local stress concentration at a corner can achieve comparable adhesion strength to a fibrillar structure without such local stress concentrations if the magnitude of the corner stress concentrations are sufficiently small such that failure does not initiate near the corners, and the magnitude of the peak interface stress away from the edge and the tip layer thickness are comparable. 

Many soft robotic components require highly stretchable, electrically conductive materials for proper operation. Often these conductive materials are used as sensors or as heaters for thermally responsive materials. However, there is a scarcity of stretchable materials that can withstand the high strains typically experienced by soft robots, while maintaining the electrical properties necessary for Joule heating ( e.g. , uniform conductivity). In this work, we present a silicone composite containing both liquid and solid inclusions that can maintain a uniform conductivity while experiencing 200% linear strains. This composite can be cast in thin sheets enabling it to be wrapped around thermally responsive soft materials that increase their volume or stretchability when heated. We show how this material opens up possibilities for electrically controllable shape changing soft robotic actuators, as well as all-silicone actuation systems powered only by electrical stimulus. Additionally, we show that this stretchable composite can be used as an electrode material in other applications, including a strain sensor with a linear response up to 200% strain and near-zero signal noise. 

Variable stiffness in elastomers can be achieved through the introduction of low melting point alloy particles, such as Field's metal (FM), enabling on‐demand switchable elasticity and anisotropy in response to thermal stimulus. Because the FM particles are thermally transitioned between solid and liquid phases, it is beneficial for the composite to be electrically conductive so the stiffness may be controlled via direct Joule heating. While FM is highly conductive, spherical particles contribute to a high percolation threshold. In this paper, it is shown that the percolation threshold of FM particulate composites can be reduced with increasing particles aspect ratio. Increasing the aspect ratio of phase‐changing fillers also increases the rigid‐to‐soft modulus ratio of the composite by raising the elastic modulus in the rigid state while preserving the low modulus in the soft state. The results indicate that lower quantities of high aspect ratio FM particles can be used to achieve both electrical conductivity and stiffness‐switching via a single solution and without introducing additional conductive fillers. This technique is applied to enable a highly stretchable, variable stiffness, and electrically conductive composite, which, when patterned around an inflatable actuator, allows for adaptable trajectories via selective softening of the surface materials.

 

Herein, a new class of robust bicontinuous elastomer–metal foam composites with highly tunable mechanical stiffness is proposed, fabricated, characterized, and demonstrated. The smart composite is a bicontinuous network of two foams, one metallic made of a low melting point alloy (LMPA) and the other elastomeric made of polydimethylsiloxane (PDMS). The stiffness of the composite can be tuned by inducing phase changes in its LMPA component. Below the melting point of the LMPA, Young's modulus of the smart composites is ≈1 GPa, whereas above the melting point of the LMPA it is ≈1 MPa. Thus, a sharp stiffness change of ≈1000× can be realized through the proposed bicontinuous foam composite structure, which is higher than all available robust smart composites. Effective medium theory is also used to predict the Young's modulus of the bicontinuous smart composites, which generates reasonable agreement with experimentally measured Young's modulus of the smart composites. Finally, the use of these smart materials as a smart joint in a robotic arm is also demonstrated.

 

Recently, a novel concept to realize dynamically tunable dry adhesion via subsurface stiffness modulation (SSM) in a composite core–shell structure has been introduced and demonstrated for gripping and release of objects. Here, a variant form of the composite core–shell design is proposed to significantly improve the performance of dynamically tunable dry adhesion in terms of activation time and activation voltage. Specifically, composite pillars with an embedded microfluidic channel filled with a low melting point alloy (LMPA) are fabricated, and the adhesion of the pillars is characterized as a function of LMPA state: either melted or solid. The effects of the thickness and in‐plane pattern of the LMPA channel, as well as the depth at which it is embedded on tunable adhesion are investigated. Experiments show that the effective adhesion strength can be reduced up to 50%, equivalent to a 2× change in dry adhesion when the LMPA is melted. Finite element analysis of the stress distribution change under SSM shows that the experimentally observed tunable adhesion is primarily due to stiffness change close to the interface. In addition, two technology demonstrations of composite pillars picking and releasing objects with fast activation (≈1 s) and low activation voltages (≈1 V) are included.

 

Materials with tunable properties, especially dynamically tunable stiffness, have been of great interest for the field of soft robotics. Herein, a novel design concept of robust three‐component elastomer–particle–fiber composite system with tunable mechanical stiffness and electrical conductivity is introduced. These smart materials are capable of changing their mechanical stiffness rapidly and reversibly when powered with electrical current. One implementation of the composite system demonstrated here is composed of a polydimethylsiloxane (PDMS) matrix, Field's metal (FM) particles, and nickel‐coated carbon fibers (NCCF). It is demonstrated that the mechanical stiffness and the electrical conductivity of the composite are highly tunable and dependent on the volume fraction of the three components and the temperature, and can be reasonably estimated using effective medium theory. Due to its superior electrical conductivity, Joule heating can be used as the activation mechanism to realize ≈20× mechanical stiffness changes in seconds. The performance of the composites is thermally and mechanically robust. The shape memory effect of these composites is also demonstrated. The combination of tunable mechanical and electrical properties makes these composites promising candidates for sensing and actuation applications for soft robotics.

 

Tunable dry adhesion has a range of applications, including transfer printing, climbing robots, and gripping in automated manufacturing processes. Here, a novel concept to achieve dynamically tunable dry adhesion via modulation of the stiffness of subsurface mechanical elements is introduced and demonstrated. A composite post structure, consisting of an elastomer shell and a core with a stiffness that can be tuned via application of electrical voltage, is fabricated. In the nonactivated state, the core is stiff and the effective adhesion strength between the composite post and contact surface is high. Activation of the core via application of electrical voltage reduces the stiffness of the core, resulting in a change in the stress distribution and driving force for delamination at the interface and, thus a reduction in the effective adhesion strength. The adhesion of composite posts with a range of dimensions is characterized and activation of the core is shown to reduce the adhesion by as much as a factor of 6. The experimentally observed reduction in adhesion is primarily due to the change in stiffness of the core. However, the activation of the core also results in heating of the interface and this plays a secondary role in the adhesion change.