The growing demand for wearable devices, soft robotics, and tissue engineering in recent years has led to an increased effort in the field of soft materials. With the advent of personalized devices, the one-shape-fits-all manufacturing methods may soon no longer be the standard for the rapidly increasing market of soft devices. Recent findings have pushed technology and materials in the area of additive manufacturing (AM) as an alternative fabrication method for soft functional devices, taking geometrical designs and functionality to greater heights. For this reason, this review aims to highlights recent development and advances in AM processable soft materials with self-healing, shape memory, electronic, chromic or any combination of these functional properties. Furthermore, the influence of AM on the mechanical and physical properties on the functionality of these materials is expanded upon. Additionally, advances in soft devices in the fields of soft robotics, biomaterials, sensors, energy harvesters, and optoelectronics are discussed. Lastly, current challenges in AM for soft functional materials and future trends are discussed.

Thermoplastic materials such as PA12 and PA6 have been extensively employed in Selective Laser Sintering (SLS) 3D printing applications due to their printability, processability, and crystalline structure. However, thermoplastic-based materials lack polymer inter-chain bonding, resulting in inferior mechanical and thermal properties and relatively low fatigue behavior. Therefore, 3D printing of high-performance crosslinked thermosets using SLS technology is paramount to pursue as an alternative to thermoplastics. In this work, a thermoset resin was successfully 3D printed using SLS, and its thermal stability of printed parts after a multi-step post-curing process was investigated. Dimensionally stable and high glass transition temperature (T_g: ~300 °C) thermoset parts were fabricated using SLS. The polymer crosslinking mechanism during the printing and curing process was investigated through FTIR spectra, while the mechanical stability of the SLS 3D-printed thermoset was characterized through compression tests. It is found that 100% crosslinked thermoset can be 3D printed with 900% higher compressive strength than printed green parts.

Recent studies have highlighted the effects of various stimuli on the chemical reduction of graphene oxide (GO) through green reductant L-ascorbic acid (L-AA); however, the combination of near ultraviolet (NUV) light to increase the reduction rate has yet to be thoroughly explored. In this study, drop-casted GO films were subjected to chemical reduction through L-AA with various levels of exposure under 405 nm NUV radiation. The structure and uniformity of GO stackings that form the film were characterized through scanning electron microscopy (SEM) and wide-angle x-ray scattering (WAXS). Additionally, WAXS was used to track the removal of oxygen-containing functional groups along with Fourier-transform infrared (FT-IR) spectroscopy and x-ray photoelectron spectroscopy (XPS) as a function of L-AA and NUV light exposure times. XPS results demonstrated that the interaction between L-AA and NUV exposure has a significant effect on the reduction of films. Furthermore, the results that yielded the highest reduction (C-C bond concentration of 60.7%) were the longest L-AA and NUV light exposure times (48 hours and 3 hours, respectively). This report provides a study on the effects of NUV on the green reduction of GO films through L-AA with potential application in solar energy and chemical sensing applications. Graphical abstract