Carmel Majidi

Hyperelastic pressure sensing with a liquid-embedded elastomer

A hyperelastic pressure transducer is fabricated by embedding silicone rubber with microchannels of conductive liquid eutectic gallium–indium. Pressing the surface of the elastomer with pressures in the range of 0–100 kPa will deform the cross-section of underlying channels and change their electric resistance by as much as 50%. Microchannels with dimensions as small as 25 µm are obtained with a maskless, soft lithography process that utilizes direct laser exposure. Change in electrical resistance is measured as a function of the magnitude and area of the surface pressure as well as the cross-sectional geometry, depth and relative lateral position of the embedded channel. These experimentally measured values closely match closed-form theoretical predictions derived from plane strain elasticity and contact mechanics.

Effective elastic modulus of isolated gecko setal arrays

SUMMARY Conventional pressure sensitive adhesives (PSAs) are fabricated from soft viscoelastic materials that satisfy Dahlquists criterion for tack with a Youngs modulus (E) of 100 kPa or less at room temperature and 1 Hz. In contrast, the adhesive on the toes of geckos is made of β-keratin, a stiff material with E at least four orders of magnitude greater than the upper limit of Dahlquists criterion. Therefore, one would not expect aβ -keratin structure to function as a PSA by deforming readily to make intimate molecular contact with a variety of surface profiles. However, since the gecko adhesive is a microstructure in the form of an array of millions of high aspect ratio shafts (setae), the effective elastic modulus (Eeff) is much lower than E of bulkβ -keratin. In the first test of the Eeff of a gecko setal adhesive, we measured the forces resulting from deformation of isolated arrays of tokay gecko (Gekko gecko) setae during vertical compression, and during tangential compression at angles of +45° and -45°. We tested the hypothesis that Eeff of gecko setae falls within Dahlquists criterion for tack, and evaluated the validity of a model of setae as cantilever beams. Highly linear forces of deformation under all compression conditions support the cantilever model. Eeff of setal arrays during vertical and +45° compression (along the natural path of drag of the setae) were 83±4.0 kPa and 86±4.4 kPa (means ± s.e.m.), respectively. Consistent with the predictions of the cantilever model, setae became significantly stiffer when compressed against the natural path of drag: Eeff during -45° compression was 110±4.7 kPa. Unlike synthetic PSAs, setal arrays act as Hookean elastic solids; setal arrays function as a bed of springs with a directional stiffness, assisting alignment of the adhesive spatular tips with the contact surface during shear loading.

A non-differential elastomer curvature sensor for softer-than-skin electronics

We extend soft lithography microfabrication and design methods to introduce curvature sensors that are elastically soft (modulus 0.1‐1 MPa) and stretchable (100‐1000% strain). In contrast to existing curvature sensors that measure differential strain, sensors in this new class measure curvature directly and allow for arbitrary gauge factor and film thickness. Moreover, each sensor is composed entirely of a soft elastomer (PDMS (polydimethylsiloxane) or Ecoflex ® ) and conductive liquid (eutectic gallium indium, eGaIn) and thus remains functional even when stretched to several times its natural length. The electrical resistance in the embedded eGaIn microchannel is measured as a function of the bending curvature for a variety of sensor designs. In all cases, the experimental measurements are in reasonable agreement with closed-form algebraic approximations derived from elastic plate theory and Ohm’s law. (Some figures in this article are in colour only in the electronic version)

iSkin: Flexible, Stretchable and Visually Customizable On-Body Touch Sensors for Mobile Computing

We propose iSkin, a novel class of skin-worn sensors for touch input on the body. iSkin is a very thin sensor overlay, made of biocompatible materials, and is flexible and stretchable. It can be produced in different shapes and sizes to suit various locations of the body such as the finger, forearm, or ear. Integrating capacitive and resistive touch sensing, the sensor is capable of detecting touch input with two levels of pressure, even when stretched by 30% or when bent with a radius of 0.5cm. Furthermore, iSkin supports single or multiple touch areas of custom shape and arrangement, as well as more complex widgets, such as sliders and click wheels. Recognizing the social importance of skin, we show visual design patterns to customize functional touch sensors and allow for a visually aesthetic appearance. Taken together, these contributions enable new types of on-body devices. This includes finger-worn devices, extensions to conventional wearable devices, and touch input stickers, all fostering direct, quick, and discreet input for mobile computing.

Liquid-Phase Gallium–Indium Alloy Electronics with Microcontact Printing

Liquid-phase electronic circuits are patterned on an elastomer substrate with a microcontact printer. The printer head dips into a pool of a liquid-phase gallium-indium alloy, e.g., eutectic gallium-indium (EGaIn) or gallium-indium-tin (Galinstan), and deposits a single drop on a silicone elastomer substrate. After patterned deposition, the liquid-phase circuit is sealed with an additional layer of silicone elastomer. We also demonstrate patterned deposition of the liquid-phase GaIn alloy with a molded polydimethylsiloxane stamp that is manually inked and pressed into an elastomer substrate. As with other liquid-phase electronics produced through needle injection or masked deposition, the circuit is elastically deformable and can be stretched to several times its natural length without losing electronic functionality. In contrast to existing fabrication techniques, microcontact printing and stamp lithography can be used to produce circuits with any planar geometric feature, including electrodes with large planar area, intersecting and closed-loop wires, and combs with multiple terminal electrodes. In air, the surface of the coalesced droplets oxidize to form a thin oxide skin that preserves the shape of the circuit during sealing. This first demonstration of soft-lithography fabrication with liquid-phase GaIn alloy expands the space of allowable circuit geometries and eliminates the need for mold or mask fabrication.

Sliding-induced adhesion of stiff polymer microfibre arrays. I. Macroscale behaviour

Gecko-inspired microfibre arrays with 42 million polypropylene fibres cm−2 (each fibre with elastic modulus 1 GPa, length 20 μm and diameter 0.6 μm) were fabricated and tested under pure shear loading conditions, after removing a preload of less than 0.1 N cm−2. After sliding to engage fibres, 2 cm2 patches developed up to 4 N of shear force with an estimated contact region of 0.44 cm2. The control unfibrillated surface had no measurable shear force. For comparison, a natural setal patch tested under the same conditions on smooth glass showed approximately seven times greater shear per unit estimated contact region. Similar to gecko fibre arrays, the synthetic patch maintains contact and increases shear force with sliding. The high shear force observed (approx. 210 nN per fibre) suggests that fibres are in side contact, providing a larger true contact area than would be obtained by tip contact. Shear force increased over the course of repeated tests for synthetic patches, suggesting deformation of fibres into more favourable conformations.

Soft curvature sensors for joint angle proprioception

We introduce a curvature sensor composed of a thin, transparent elastomer film (polydimethylsiloxane, PDMS) embedded with a microchannel of conductive liquid (eutectic Gallium Indium, eGaIn) and a sensing element. Bending the sensor exerts pressure on the embedded microchannel via the sensing element. Deformation of the cross-section of the microchannel leads to a change in electrical resistance. We demonstrate the functionality of the sensor through testing on a finger joint. The film is wrapped around a finger with the sensing element positioned on top of the knuckle. Finger bending both stretches the elastomer and exerts pressure on the sensing element, leading to an enhanced change in the electrical resistance. Because the sensor is soft (elastic modulus E ∼ 1 MPa) and stretchable (>350%), it conforms to the host bending without interfering with the natural mechanics of motion. This sensor represents the first use of liquid-embedded elastomer electronics to monitor human or robotic motion.

Wearable tactile keypad with stretchable artificial skin

A hyperelastic, thin, transparent pressure sensitive keypad is fabricated by embedding a silicone rubber film with conductive liquid-filled microchannels. Applying pressure to the surface of the elastomer deforms the cross-section of underlying microchannels and changes the electrical resistance across the affected channels. Perpendicular conductive channels form a quasi-planar network within an elastomeric matrix that registers the location, intensity and duration of applied pressure. Pressing channel intersections of the keypad triggers one of twelve keys, allowing the user to write any combination of alphabetic letters. A 5% change in channel output voltage must be achieved to trigger a key. It is found that approximately 100 kPa of pressure is necessary to produce a 5% change in voltage across a conductive microchannel that is 20 microns in height and 200 microns in width. Sensitivity of the keypad is tunable via channel geometry and choice of elastomeric material.

Methods to pattern liquid metals

This highlight describes emerging methods to pattern metals that are liquid at room temperature. The ability to pattern liquid metals is important for fabricating metallic components that are soft, stretchable, conformal, and in some cases, shape-reconfigurable. Applications include electrodes, antennas, micro-mirrors, plasmonic structures, sensors, switches, and interconnects. Gallium (Ga) and its liquid metal alloys are attractive alternatives to toxic mercury. This family of alloys spontaneously forms a surface oxide that dominates the rheological and wetting properties of the metal. These properties pose challenges using conventional fabrication methods, but present new opportunities for patterning innovations. For example, Ga-based liquid metals may be injected, imprinted, or 3D printed on either soft or hard substrates. The use of a liquid metal also enables rapid and facile room temperature processing. The patterning techniques organize into four categories: (i) patterning enabled by lithography, (ii) injection, (iii) subtractive techniques, and (iv) additive techniques. Although many of these approaches take advantage of the surface oxide that forms on Ga and its alloys, some of the approaches may also be suitable for patterning other soft-conductors (e.g., conductive inks, pastes, elastomeric composites).

Soft-matter capacitors and inductors for hyperelastic strain sensing and stretchable electronics

We introduce a family of soft-matter capacitors and inductors composed of microchannels of liquid-phase gallium‐indium‐tin alloy (galinstan) embedded in a soft silicone elastomer (Ecoflex R 00-30). In contrast to conventional (rigid) electronics, these circuit elements remain electronically functional even when stretched to several times their natural length. As the surrounding elastomer stretches, the capacitance and inductance of the embedded liquid channels change monotonically. Using a custom-built loading apparatus, we experimentally measure relative changes in capacitance and inductance as a function of stretch in three directions. These experimental relationships are consistent with theoretical predictions that we derive with finite elasticity kinematics. (Some figures may appear in colour only in the online journal)