3D-Architected low melting point alloys foam microstructure-reinforced polymer composite with superior stiffness-switchable for soft actuator

Stiffness variable materials have aroused extensive research interest in smart devices, especially in soft actuators. However, achieving materials with high stiffness switch range remains challenging. Here, a novel three-dimensional (3D) lightweight Field's metal (FM) foam was developed. Meanwhile, the polymer composite (SUFF) with superior stiffness switchable capacity was fabricated by embedding FM foam into a kind of designed stiffness variable polymer. The SUFF shows outstanding conductivity under relatively low FM volume fraction of 20.6%. Impressively, because of the extremely high modulus and fast transition of FM foam, the stiffness switch ratio of the SUFF are able to reach an ultra-high value of 6987.5-folds. Apart from its exceptional stiffness switchable capacity, the SUFF also possesses remarkable shape memory and self-healing characteristics. Next, the SUFF was then fastened to a soft actuator as the stiffness changing units. The obtained actuator was able to exhibit a short heating–cooling cycle time of 44 s while using 10 A of current and 4°C water for cooling. Moreover, the actuator can reach remarkable values of 973 mN/mm and 4729 mN, respectively, for its stiffness and net force. Then, a soft robot gripper made up of three obtained actuators mounted on a base demonstrates its excellent load and stiffness switchable ability. It can lift a variety of objects with various forms with weights up to more than 3 kg. This study might provide a reference for application of stiffness variable materials in soft actuators. Highlights The FM foam were designed and synthetized by lost-wax casting method. The polymer composite exhibits large stiffness switching range. The polymer composite achieves 6987.5-folds rigid/soft stiffness ratio. A 3D-printing soft actuator was fabricated using obtained polymer composite. The assembled robotic gripper can lift weights up to more than 3 kg.