Ultra-sensitive and resilient compliant strain gauges for soft machines.

Soft machines are a promising design paradigm for human-centric devices1,2 and systems required to interact gently with their environment3,4. To enable soft machines to respond intelligently to their surroundings, compliant sensory feedback mechanisms are needed. Specifically, soft alternatives to strain gauges-with high resolution at low strain (less than 5 per cent)-could unlock promising new capabilities in soft systems. However, currently available sensing mechanisms typically possess either high strain sensitivity or high mechanical resilience, but not both. The scarcity of resilient and compliant ultra-sensitive sensing mechanisms has confined their operation to laboratory settings, inhibiting their widespread deployment. Here we present a versatile and compliant transduction mechanism for high-sensitivity strain detection with high mechanical resilience, based on strain-mediated contact in anisotropically resistive structures (SCARS). The mechanism relies upon changes in Ohmic contact between stiff, micro-structured, anisotropically conductive meanders encapsulated by stretchable films. The mechanism achieves high sensitivity, with gauge factors greater than 85,000, while being adaptable for use with high-strength conductors, thus producing sensors resilient to adverse loading conditions. The sensing mechanism also exhibits high linearity, as well as insensitivity to bending and twisting deformations-features that are important for soft device applications. To demonstrate the potential impact of our technology, we construct a sensor-integrated, lightweight, textile-based arm sleeve that can recognize gestures without encumbering the hand. We demonstrate predictive tracking and classification of discrete gestures and continuous hand motions via detection of small muscle movements in the arm. The sleeve demonstration shows the potential of the SCARS technology for the development of unobtrusive, wearable biomechanical feedback systems and human-computer interfaces.

Investigating Changes in Muscle Coordination During Cycling with Soft Wearable Strain Sensors Sensitive to Muscle Deformation.

Continuous monitoring of muscle coordination can provide valuable information regarding an individual's performance during physical activities. For example, changes in muscle coordination can indicate muscle fatigue during exhaustive exercise or can be used to track the rehabilitation progress of patients post-injury. Traditional methods to evaluate coordination often focus solely on measuring muscle activation with electromyography, ignoring timing changes of the resultant force produced by the activated muscle. Setups designed to evaluate force directly to study muscle coordination are often limited by either hyper-constrained settings or cost-prohibitive hardware. In this paper, we employ wearable, ultra-sensitive soft strain sensors that track muscle deformation for estimating changes in muscle coordination during cycling at different cadences and to exhaustion. The results were compared to muscle activation timing measured by electromyography and peak force timing measured by a cycle ergometer. We demonstrate that with an increase in cadence, the soft strain sensor and ergometer timing metrics align more closely than those measured by electromyography. We also demonstrate how muscle coordination is altered with the onset of fatigue during cycling to exhaustion.

Toward Soft Wearable Strain Sensors for Muscle Activity Monitoring.

The force-generating capacity of skeletal muscle is an important metric in the evaluation and diagnosis of musculoskeletal health. Measuring changes in muscle force exertion is essential for tracking the progress of athletes during training, for evaluating patients' recovery after muscle injury, and also for assisting the diagnosis of conditions such as muscular dystrophy, multiple sclerosis, or Parkinson's disease. Traditional hardware for strength evaluation requires technical training for operation, generates discrete time points for muscle assessment, and is implemented in controlled settings. The ability to continuously monitor muscle force without restricting the range of motion or adapting the exercise protocol to suit specific hardware would allow for a richer dataset that can help unlock critical features of muscle health and strength evaluation. In this paper, we employ wearable, ultra-sensitive soft strain sensors for tracking changes in muscle deformation during contractions. We demonstrate the sensors' sensitivity to isometric contractions, as well as the sensors' capacity to track changes in peak torque over the course of an isokinetic fatiguing protocol for the knee extensors. The wearable soft system was able to efficiently estimate peak joint torque reduction caused by muscle fatigue (mean NRMSE = 0.15±0.03 ).

Fabrication Process of Silicone-based Dielectric Elastomer Actuators.

This contribution demonstrates the fabrication process of dielectric elastomer transducers (DETs). DETs are stretchable capacitors consisting of an elastomeric dielectric membrane sandwiched between two compliant electrodes. The large actuation strains of these transducers when used as actuators (over 300% area strain) and their soft and compliant nature has been exploited for a wide range of applications, including electrically tunable optics, haptic feedback devices, wave-energy harvesting, deformable cell-culture devices, compliant grippers, and propulsion of a bio-inspired fish-like airship. In most cases, DETs are made with a commercial proprietary acrylic elastomer and with hand-applied electrodes of carbon powder or carbon grease. This combination leads to non-reproducible and slow actuators exhibiting viscoelastic creep and a short lifetime. We present here a complete process flow for the reproducible fabrication of DETs based on thin elastomeric silicone films, including casting of thin silicone membranes, membrane release and prestretching, patterning of robust compliant electrodes, assembly and testing. The membranes are cast on flexible polyethylene terephthalate (PET) substrates coated with a water-soluble sacrificial layer for ease of release. The electrodes consist of carbon black particles dispersed into a silicone matrix and patterned using a stamping technique, which leads to precisely-defined compliant electrodes that present a high adhesion to the dielectric membrane on which they are applied.

High-Resolution, Large-Area Fabrication of Compliant Electrodes via Laser Ablation for Robust, Stretchable Dielectric Elastomer Actuators and Sensors.

A key element in stretchable actuators, sensors, and systems based on elastomer materials are compliant electrodes. While there exist many methodologies for fabricating electrodes on dielectric elastomers, very few succeed in achieving high-resolution patterning over large areas. We present a novel approach for the production of mechanically robust, high-resolution compliant electrodes for stretchable silicone elastomer actuators and sensors. Cast, 2-50 µm thick poly(dimethylsiloxane) (PDMS)-carbon composite layers are patterned by laser ablation and subsequently bonded to a PDMS membrane by oxygen plasma activation. The technique affords great design flexibility and high resolution and readily scales to large-area arrays of devices. We validate our methodology by producing arrays of actuators and sensors on up to A4-size substrates, reporting on microscale dielectric elastomer actuators (DEA) generating area strains of over 25%, and interdigitated capacitive touch sensors with high sensitivity yet insensitivity to substrate stretching. We demonstrate the ability to cofabricate highly integrated multifunctional transducers using the same process flow, showing the methodology's promise in realizing sophisticated and reliable complex stretchable devices with fine features over large areas.