Soft and deformable electronics and actuators have attracted high research interests toward practical applications. This work focuses on two goals: (1) applying the concept of elastic instability in the structural design for soft systems; and (2) exploring rapid and low-cost schemes for their facile fabrications. Specifically, Kirigami, curved serpentines, auxetics, bistable and multistable structures, have all been utilized in different electronics and actuator systems to obtain unique and desirable properties, such as ultrahigh deformability, omnidirectional stretchability, and impact-resistant mechanics in this work.
First, a construct inspired by Kirigami designs has been developed to make highly deformable micro-supercapacitor patches with high areal coverages of electrode and electrolyte materials. These patches are fabricated in simple and efficient steps by a laser assisted graphitic conversion and cutting process, utilizing different laser power and scanning speeds on a laser cutter. The Kirigami cuts significantly increase the structural compliance such that individual segments in the patches can buckle, rotate, bend and twist to accommodate large overall deformations with only a small strain in active electrode areas. Electrochemical testing results have proved that electrochemical performances are preserved under large deformations up to 282.5% of overall structural elongations.
A time- and cost-effective fabrication approach to construct stretchable electronics with the “island-bridge” constructs has been established without using photomasks. A low-cost commercially available vinyl cutter is used to define patterns by adjusting the cutting force and depth on the blade. Metal interconnects and pads can be patterned via the “tunnel cut” process and the flexible overall structure can be defined via the “through cut” process. The capabilities of the proposed method is shown by two demonstration devices, a skin-mounted module for monitoring breathing and a water-resistant supercapacitor array with omni-directionally stretchable capability. These devices can accommodate large deformations through the buckling and post-buckling instability without affecting their functions.
Finally, a class of magnetically powered, untethered soft actuators has been built based on a bioinspired “flesh-and-bone” construct. This construct has both key attributes of fast actuation and compliant impact-resistant mechanics and it also renders a simple fabrication process using generic 3D printers and off-the-shelf neodymium magnets as well as silicone elastomers. Actuators of diverse shapes of elastomeric “fleshes” and different placements of magnetic “bones” have displayed several distinct types of tasks, including auxetic expansion and shrinking, out-of-plane transformations, transition among multiple stable states, and manipulation of small objects.