3D Printing of Hydrogels for Stretchable Ionotronic Devices

In the booming development of flexible electronics represented by electronic skins, soft robots, and human–machine interfaces, 3D printing of hydrogels, an approach used by the biofabrication community, is drawing attention from researchers working on hydrogel-based stretchable ionotronic devices. Such devices can greatly benefit from the excellent patterning capability of 3D printing in three dimensions, as well as the free design complexity and easy upscale potential. Compared to the advanced stage of 3D bioprinting, 3D printing of hydrogel ionotronic devices is in its infancy due to the difficulty in balancing printability, ionic conductivity, shape fidelity, stretchability, and other functionalities. In this review, a guideline is provided on how to utilize the power of 3D printing in building high-performance hydrogel-based stretchable ionotronic devices mainly from a materials’ point of view, highlighting the systematic approach to balancing the printability, printing quality, and performance of printed devices. Various 3D printing methods for hydrogels are introduced, and then the ink design principles, balancing printing quality, printed functions, such as elastic conductivity, self-healing ability, and device (e.g., flexible sensors, shape-morphing actuators, soft robots, electroluminescent devices, and electrochemical biosensors) performances are discussed. In conclusion, perspectives on the future directions of this exciting field are presented.     

Magnetic Assembly of Soft Robots with Hard Components

This paper describes the modular magnetic assembly of reconfigurable, pneumatically actuated robots composed of soft and hard components and materials. The soft components of these hybrid robots are actuators fabricated from silicone elastomers using soft lithography, and the hard components are acrylonitrile–butadiene–styrene (ABS) structures made using 3D printing. Neodymium–iron–boron (NdFeB) ring magnets are embedded in these components to make and maintain the connections between components. The reversibility of these magnetic connections allows the rapid reconfiguration of these robots using components made of different materials (soft and hard) that also have different sizes, structures, and functions; in addition, it accelerates the testing of new designs, the exploration of new capabilities, and the repair or replacement of damaged parts. This method of assembling soft actuators to build soft machines addresses some limitations associated with using soft lithography for the direct molding of complex 3D pneumatic networks. Combining the self‐aligning property of magnets with pneumatic control makes it possible for a teleoperator to modify the structures and capabilities of these robots readily in response to the requirements of different tasks.     

Combining 3D Printing with Electrospinning for Rapid Response and Enhanced Designability of Hydrogel Actuators

Porous structures have emerged as a breakthrough of shape‐morphing hydrogels to achieve a rapid response. However, these porous actuators generally suffer from a lack of complexity and diversity in obtained 3D shapes. Herein, a simple yet versatile strategy is developed to generate shape‐morphing hydrogels with both fast deformation and enhanced designability in 3D shapes by combining two promising technologies: electrospinning and 3D printing. Elaborate patterns are printed on mesostructured stimuli‐responsive electrospun membranes, modulating in‐plane and interlayer internal stresses induced by swelling/shrinkage mismatch, and thus guiding morphing behaviors of electrospun membranes to adapt to changes of the environment. With this strategy, a series of fast deformed hydrogel actuators are constructed with various distinctive responsive behaviors, including reversible/irreversible formations of 3D structures, folding of 3D tubes, and formations of 3D structures with multi low‐energy states. It is worth noting that although poly(N‐isopropyl acrylamide) is chosen as the model system in the present research, our strategy is applicable to other stimuli‐responsive hydrogels, which enriches designs of rapid deformed hydrogel actuators.     

4D Printing of Hydrogels: A Review

3D printing permits the construction of objects by layer‐by‐layer deposition of material, resulting in precise control of the dimensions and properties of complex printed structures. Although 3D printing fabricates inanimate objects, the emerging technology of 4D printing allows for animated structures that change their shape, function, or properties over time when exposed to specific external stimuli after fabrication. Among the materials used in 4D printing, hydrogels have attracted growing interest due to the availability of various smart hydrogels. The reversible shape‐morphing in 4D printed hydrogel structures is driven by a stress mismatch arising from the different swelling degrees in the parts of the structure upon application of a stimulus. This review provides the state‐of‐the‐art of 4D printing of hydrogels from the materials perspective. First, the main 3D printing technologies employed are briefly depicted, and, for each one, the required physico‐chemical properties of the precursor material. Then, the hydrogels that have been printed are described, including stimuli‐responsive hydrogels, non‐responsive hydrogels that are sensitive to solvent absorption/desorption, and multimaterial structures that are totally hydrogel‐based. Finally, the current and future applications of this technology are presented, and the requisites and avenues of improvement in terms of material properties are discussed.     

3D Printing of Multifunctional Hydrogels

3D printing technology has been widely explored for the rapid design and fabrication of hydrogels, as required by complicated soft structures and devices. Here, a new 3D printing method is presented based on the rheology modifier of Carbomer for direct ink writing of various functional hydrogels. Carbomer is shown to be highly efficient in providing ideal rheological behaviors for multifunctional hydrogel inks, including double network hydrogels, magnetic hydrogels, temperature‐sensitive hydrogels, and biogels, with a low dosage (at least 0.5% w/v) recorded. Besides the excellent printing performance, mechanical behaviors, and biocompatibility, the 3D printed multifunctional hydrogels enable various soft devices, including loadable webs, soft robots, 4D printed leaves, and hydrogel Petri dishes. Moreover, with its unprecedented capability, the Carbomer‐based 3D printing method opens new avenues for bioprinting manufacturing and integrated hydrogel devices.     

Stimuli-Responsive Peptide Self-Assembly to Construct Hydrogels with Actuation and Shape Memory Behaviors

Hydrogel actuators, capable of generating reversible deformation in response to external stimulus, are widely considered as new emerging intelligent materials for applications in soft robots, smart sensors, artificial muscles, and so on. Peptide self-assembly is widely applied in the construction of intelligent hydrogel materials due to their excellent stimulus response. However, hydrogel actuators based on peptide self-assembly are rarely reported and explored. In this study, a pH-responsive peptide (MA-FIID) is designed and introduced into a poly(N-isopropyl acrylamide) backbone (PNIPAM) to construct bilayer and heterogeneous hydrogel actuators based on the assembly and disassembly of peptide molecules under different pH conditions. These peptide-containing hydrogel actuators can perform controllable bending, bucking, and complex deformation under pH stimulation. Meanwhile, the Hofmeister effect of PNIPAM hydrogels endows these peptide-containing hydrogels with enhanced mechanical strength, ionic stimulus response (CaCl₂), and excellent shape-memory property. This work broadens the application of supramolecular self-assembly in the construction of intelligent hydrogels, and also provides new inspirations for peptide self-assembly to construct smart materials.     

Highly Elastic,Transparent, and Conductive 3D‐Printed Ionic Composite Hydrogels

Despite extensive progress to engineer hydrogels for a broad range of technologies, practical applications have remained elusive due to their (until recently) poor mechanical properties and lack of fabrication approaches, which constrain active structures to simple geometries. This study demonstrates a family of ionic composite hydrogels with excellent mechanical properties that can be rapidly 3D‐printed at high resolution using commercial stereolithography technology. The new material design leverages the dynamic and reversible nature of ionic interactions present in the system with the reinforcement ability of nanoparticles. The composite hydrogels combine within a single platform tunable stiffness, toughness, extensibility, and resiliency behavior not reported previously in other engineered hydrogels. In addition to their excellent mechanical performance, the ionic composites exhibit fast gelling under near‐UV exposure, remarkable conductivity, and fast osmotically driven actuation. The design of such ionic composites, which combine a range of tunable properties and can be readily 3D‐printed into complex architectures, provides opportunities for a variety of practical applications such as artificial tissue, soft actuators, compliant conductors, and sensors for soft robotics.     

Coaxial 4D Printing of Vein-Inspired Thermoresponsive Channel Hydrogel Actuators

Although significant progress has been made in coaxial printing of vascularized tissue models, this technique has not yet been used to fabricate stimulus-responsive scaffolds capable of shape change over time. Here, a new method of direct ink printing (DIP) is proposed with a coaxial nozzle, coaxial 4D printing, enabling the manufacturing of thermoresponsive constructs embedded with a network of interconnected channels. In this approach, a poly(N-isopropylacrylamide) (PNIPAAm)-based thermoink is coaxially extruded into either core/sheath microfibers or microtubes. PNIPAAm renders a hydrogel temperature-sensitive and endows it with a shape-morphing property both at the micro- and macroscale. Specifically, the lumen diameter of the microtubes can be controlled by temperature by 30%. The macrostructural soft actuators can undergo programmed and reversible temperature-dependent shape changes due to the structural anisotropy of the hydrogel. The permeability tests demonstrate that the hydrogel can possess enough strength to maintain the hollow channels without breaking. In vitro tests confirm the biocompatibility of the material with EA.hy926 cells, paving the avenue for new perfusable soft robots, or active implants. Finally, microalgae Chlamydomonas reinhardtii is combined with the hydrogels to fabricate materials having functions of both living microorganisms and stimuli-responsive polymers toward creating engineered living materials (ELMs) with a vein-like geometry.     

Tough Hydrogels with Programmable and Complex Shape Deformations by Ion Dip‐Dyeing and Transfer Printing

Stimuli‐responsive hydrogels with high mechanical strength, programmable deformation, and simple preparation are essential for their practical applications. Here the preparation of tough hydrogels with programmable and complex shape deformations is reported. Janus hydrogels with different compositions and hydrophilic natures on the two surfaces are first prepared, and they exhibit reversible bending/unbending upon swelling/deswelling processes. More impressively, the deformation rate and extent of the hydrogels can further be easily controlled through an extremely simple and versatile ion dip‐dyeing (IDD) and/or ion transfer printing (ITP) method. By selectively printing proper patterns on 1D gel strips, 2D gel sheets and 3D gel structures, the transformations from 1D to 2D, 2D to 3D, and 3D to more complicated 3D shapes can be achieved after swelling the ion‐patterned hydrogels in water. The swelling‐deformable Janus and ion‐patterned hydrogels with high mechanical strengths and programmable deformations can find many practical applications, such as soft machines.     

Fast‐Response,Stiffness‐Tunable Soft Actuator by Hybrid Multimaterial 3D Printing

Soft robots have the appealing advantages of being highly flexible and adaptive to complex environments. However, the low‐stiffness nature of the constituent materials makes soft robotic systems incompetent in tasks requiring relatively high load capacity. Despite recent attempts to develop stiffness‐tunable soft actuators by employing variable stiffness materials and structures, the reported stiffness‐tunable actuators generally suffer from limitations including slow responses, small deformations, and difficulties in fabrication with microfeatures. This work presents a paradigm to design and manufacture fast‐response, stiffness‐tunable (FRST) soft actuators via hybrid multimaterial 3D printing. The integration of a shape memory polymer layer into the fully printed actuator body enhances its stiffness by up to 120 times without sacrificing flexibility and adaptivity. The printed Joule‐heating circuit and fluidic cooling microchannel enable fast heating and cooling rates and allow the FRST actuator to complete a softening–stiffening cycle within 32 s. Numerical simulations are used to optimize the load capacity and thermal rates. The high load capacity and shape adaptivity of the FRST actuator are finally demonstrated by a robotic gripper with three FRST actuators that can grasp and lift objects with arbitrary shapes and various weights spanning from less than 10 g to up to 1.5 kg.     

Design and calibration of 3D printed soft deformation sensors for soft actuator control

Soft actuators made from compliant materials are superior to conventional rigid robots in terms of flexibility, adaptability and safety. However, an inherent drawback of soft actuator is the low actuation precision. Implementing closed loop control is a possible solution, but the soft actuator shape can hardly be measured directly by commercially available sensors, which either are too stiff for integration or cause performance degradation of the actuator. Although 3D printing has been applied to print bendable sensors from conductive materials, they either have larger stiffness than the soft actuator or are made from specially designed materials that are difficult to reproduce. In this study, easily accessible commercial soft conductive material is applied to directly 3D print soft sensors on soft actuators. Different configurations of the printed sensors are studied to investigate how the sensor design affects the performance. The best sensor configuration is selected to provide shape feedback using its changing resistance during deformation. Compared with a commercial flexible bending sensor, the printed sensor has less influences on the soft actuator performance and enjoys higher shape estimation accuracy. Closed loop shape control of the actuator using feedback from the 3D printed sensor is then designed, implemented and compared with the control results using image feedback. A gripper consisting of three individually controlled soft actuators demonstrates the applications of the soft sensor.     

Actuation of Three-Dimensional-Printed Nanocolloidal Hydrogel with Structural Anisotropy

Polymer hydrogels exhibit actuation properties that result in reversible shape transformations and have promising applications in soft robotics, drug delivery systems, sensors, and microfluidic devices. Actuation occurs due to differential hydrogel swelling and is generally achieved by modulating hydrogel composition. Here a different approach to hydrogel actuation that originates solely from its structural anisotropy is reported. For 3D-printed single-layer hydrogels formed by cellulose nanocrystals (CNCs) and gelatin methacryloyl it is shown that shear-induced orientation of CNCs results in anisotropic mechanical and swelling properties of the hydrogel. Upon swelling in water, planar hydrogels acquire multiple complex 3D shapes that are achieved by i) varying CNC orientation with respect to the shape on the hydrogel sheet and ii) patterning the hydrogel with the regions of shear-mediated and random CNC orientation. This study shows the capability to generate multiple shapes from the same hydrogel actuator based on the degree of its structural anisotropy. In addition, it introduces a biocompatible nanocolloidal ink with shear-thinning and self-healing properties for additive manufacturing of hydrogel actuators.     

Highly Conductive MXene/PEDOT:PSS-Integrated Poly(N-Isopropylacrylamide) Hydrogels for Bioinspired Somatosensory Soft Actuators

Sophisticated sensing and actuation capabilities of many living organisms in nature have inspired scientists to develop biomimetic somatosensory soft robots. Herein, the design and fabrication of homogeneous and highly conductive hydrogels for bioinspired somatosensory soft actuators are reported. The conductive hydrogels are synthesized by in situ copolymerization of conductive surface-functionalized MXene/Poly(3,4-ethylenedioxythiophene)/poly(styrenesulfonate) ink with thermoresponsive poly(N-isopropylacrylamide) hydrogels. The resulting hydrogels are found to exhibit high conductivity (11.76 S m⁻¹), strain sensitivity (GF of 9.93), broad working strain range (≈560% strain), and high stability after over 300 loading–unloading cycles at 100% strain. Importantly, shape-programmable somatosensory hydrogel actuators with rapid response, light-driven remote control, and self-sensing capability are developed by chemically integrating the conductive hydrogels with a structurally colored polymer. As the proof-of-concept illustration, structurally colored hydrogel actuators are applied for devising light-driven programmable shape-morphing of an artificial octopus, an artificial fish, and a soft gripper that can simultaneously monitor their own motions via real-time resistance variation. This work is expected to offer new insights into the design of advanced somatosensory materials with self-sensing and actuation capabilities, and pave an avenue for the development of soft-matter-based self-regulatory intelligence via built-in feedback control that is of paramount significance for intelligent soft robotics and automated machines.     

Development of Thermoinks for 4D Direct Printing of Temperature-Induced Self-Rolling Hydrogel Actuators

4D printing has emerged as an important technique for fabricating 3D objects from programmable materials capable of time-dependent reshaping. In the present investigation, novel 4D thermoinks composed of laponite (LAP), an interpenetrating network of poly(N-isopropylacrylamide) (PNIPAAm), and alginate (ALG) are developed for direct printing of shape-morphing structures. This approach consists of the design and fabrication of 3D honeycomb-patterned hydrogel discs self-rolling into tubular constructs under the stimulus of temperature. The shape morphing behavior of hydrogels is due to shear-induced anisotropy generated via 3D printing. The compositionally tunable hydrogel discs can be programmed to exhibit different actuation behaviors at different temperatures. Upon immersion in 12 °C water, singly crosslinked sheets roll up into a tubular construct. When transferred to 42 °C water, the tubes first rapidly unfold and then slightly curve up in the opposite direction. Through a dual photocrosslinking of PNIPAAm, it is possible to inverse temperature-dependent shape morphing and induce self-folding at higher and unrolling at lower temperatures. The extensive self-assembling motion is essential to developing thermal actuators with broad applications in, e.g., soft robotics and active implantology, whereas controllable self-rolling of planar hydrogels is of the highest interest to biomedical engineering as it allows for effective fabrication of hollow tubes.     

Microstructured Actuation of Liquid Crystal Polymer Networks

Smart microstructured materials enable functions such as actuation, detection, transportation, and sensing with potential applications ranging from robotics and photonics to biomedical devices. Of the many materials systems, liquid crystal polymer networks (LCN) are fascinating owing to their ability to exhibit reversible macroscopic deformation driven by a molecular order–disorder phase transition. LCN have been increasingly explored for their utility in the design and fabrication of smart actuating devices capable of complex shape changes or motions upon external stimulation of humidity, heat, light, and other stimuli, and recent studies in this field show that their actuation complexity can be enriched and actuation performance enhanced by having some sort of microstructures. Herein, the recent progress in microstructured actuation of LCN materials with substructures in scale ranging from micrometer to millimeter is reported, placing the emphasis on the main approaches to generating a microstructure in LCN, which include patterned LC director fields, patterned chain crosslinking in LCN with uniaxial orientation of mesogens, 3D/4D printing, and replica molding. The potential applications in microstructured 3D actuators and devices as well as functional LCN surfaces are also highlighted, with an outlook on important issues and future trends in smart microstructured LCN materials and actuators.     

3D-Printed Electrostatic Microactuators for Flexible Microsystems

Developing small-scale, lightweight, and flexible devices with integrated microactuators is one of the critical challenges in wearable haptic devices, soft robotics, and microrobotics. In this study, a novel fabrication process that leverages the benefits of 3D printing with two-photon polymerization and flexible printed circuit boards (FPCBs) is presented. This method enables flexible microsystems with 3D-printed electrostatic microactuators, which are demonstrated in a flexible integrated micromirror array and a legged microrobot with a mass of 4 mg. 3D electrostatic actuators on FPCBs are robust enough to actuate the micromirrors while the device is deformed, and they are easily integrated with off-the-shelf electronics. The crawling robot is one of the lightest legged microrobots actuated without external fields, and the legs actuated with 3D electrostatic actuators enable a locomotion speed of 0.27 body length per second. The proposed fabrication framework opens up a pathway toward a variety of highly integrated flexible microsystems.     

3D Printed Actuators: Reversibility,Relaxation, and Ratcheting

Additive manufacturing strives to combine any combination of materials into 3D functional structures and devices, ultimately opening up the possibility of 3D printed machines. It remains difficult to actuate such devices, thus limiting the scope of 3D printed machines to passive devices or necessitating the incorporation of external actuators that are manufactured differently. Here, 3D printed hybrid thermoplast/conducter bilayers are explored, which can be actuated by differential heating caused by externally controllable currents flowing through their conducting faces. The functionality of such actuators is uncovered and it is shown that they allow to 3D print, in one pass, simple flexible robotic structures that propel forward under step‐wise applied voltages. Moreover, exploiting the thermoplasticity of the nonconducting plastic parts at elevated temperatures, it is shown that how strong driving leads to irreversible deformations—a form of 4D printing—which also enlarges the range of linear response of the actuators. Finally, it is shown that how to leverage such thermoplastic relaxations to accumulate plastic deformations and obtain very large deformations by alternatively driving both layers of a bilayer; this is called ratcheting. The strategy is scalable and widely applicable, and opens up a new approach to reversible actuation and irreversible 4D printing of arbitrary structures and machines.     

4D Printing of Multi-Stimuli Responsive Protein-Based Hydrogels for Autonomous Shape Transformations

Stimuli responsive hydrogels that can change shape in response to applied external stimuli are appealing for soft robotics, biomedical devices, drug delivery, and actuators. However, existing 3D printed shape morphing materials are non-biodegradable, which limits their use in biomedical applications. Here, 3D printed protein-based hydrogels are developed and applied for programmable structural changes under the action of temperature, pH, or an enzyme. Key to the success of this strategy is the use of methacrylated bovine serum albumin (MA–BSA) as a biodegradable building block to Pickering emulsion gels in the presence of N-isopropylacrylamide or 2-dimethylaminoethyl methacrylate. These shear-thinning gels are ideal for direct ink write (DIW) 3D printing of multi-layered stimuli-responsive hydrogels. While poly(N-isopropylacrylamide) and poly(dimethylaminoethyl methacrylate) introduce temperature and pH-responsive properties into the printed objects, a unique feature of this strategy is an enzyme-triggered shape transformation based on the degradation of the bovine serum albumin network. To highlight this technique, protein-based hydrogels that reversibly change shape based on environmental temperature and pH are fabricated, and irreversibly altered by enzymatic degradation, which demonstrates the complexity that can be introduced into 4D printed systems.     

Liquid-Phase Super Photoactuator through the Synergetic Effects of a Janus Structure and Solvent/Thermal/Photo Responses

Azobenzene actuator has attracted wide research attention in the fields of soft robots, artificial muscles, etc., owing to the typical photoresponsive material based on its reversible trans–cis isomerization. However, it remains challenging to enhance the actuation performance of azobenzene actuators through simple methods and can work in complex and variable environments. In contrast to complex molecular functional design, this study presents a Janus azobenzene inverse opal actuator: one side of a monodomain azobenzene polymer and the other side of a polydomain azobenzene inverse opal structure. The proposed design can significantly enhance the photoactuation performance in the liquid phase based on the synergetic effects of the Janus structure and the plastic influence of solvent/thermal/photo responses on the polymer segment. Promising applications of photo-driven ring rolling in the liquid phase are demonstrated. The results of this study are of great significance for the design and fabrication of novel-type azobenzene actuators in the liquid phase.     

Photocurable 3D Printing of High Toughness and Self-Healing Hydrogels for Customized Wearable Flexible Sensors

Currently, most customized hydrogels can only be processed via extrusion-based 3D printing techniques, which is limited by printing efficiency and resolution. Here, a simple strategy for the rapid fabrication of customized hydrogels using a photocurable 3D printing technique is presented. This technique has been rarely used because the presence of water increases the molecular distance between the polymer chains and reduces the monomer polymerization rate, resulting in the failure of rapid solid-liquid separation during printing. Although adding cross-linkers to printing inks can effectively accelerate 3D cross-linked network formation, chemical cross-linking may result in reduced toughness and self-healing ability of the hydrogel. Therefore, an interpenetrated-network hydrogel based on non-covalent interactions is designed to form physical cross-links, affording fast solid-liquid separation. Poly(acrylic acid (AA)-N-vinyl-2-pyrrolidone (NVP)) and carboxymethyl cellulose (CMC) are cross-linked via Zn²⁺-ligand coordination and hydrogen bonding; the resulting mixed AA-NVP/CMC solution is used as the printing ink. The printed poly(AA-NVP/CMC) hydrogel exhibited high tensile toughness (3.38 MJ m⁻³) and superior self-healing ability (healed stress: 81%; healed strain: 91%). Some objects like manipulator are successfully customized by photocurable 3D printing using hydrogels with high toughness and complex structures. This high-performance hydrogel has great potential for application in flexible wearable sensors.