This article proposes an approach of 3D printing structures consisting of stretchable hydrogels bonded with UV curable polymers.

Stretchable strain sensor detects a wide range of strain variation and is therefore a key component in various applications. Unlike traditional ones made of elastomers doped with conductive components or fabricated with liquid conductors, ionically conductive hydrogel-based strain sensors remain conductive under large deformations and are biocompatible. However, dehydration is a challenging issue for the latter. Researchers have developed hydrogel-elastomer-based strain sensors where an elastomer matrix encapsulates a hydrogel circuit to prevent its dehydration. However, the reported multi-step approaches are generally time-consuming. Our group recently reported a multimaterial 3D printing approach that enables fast fabrication of such sensors, yet requires a self-built digital-light-processing-based multimaterial 3D printer. Here, we report a simple projection lithography method to fabricate hydrogel-elastomer-based stretchable strain sensors within 5 minutes. This method only requires a UV projector/lamp with photomasks; the chemicals are commercially available; the protocols for preparing the polymer precursors are friendly to users without chemistry background. Moreover, the manufacturing flexibility allows users to readily pattern the sensor circuit and attach the sensor to a 3D printed soft pneumatic actuator to enable strain sensing on the latter. The proposed approach paves a simple and versatile way to fabricate hydrogel-elastomer-based stretchable strain sensors and flexible electronic devices. Graphical Abstract

Soft biomaterials have a wide range of applications in many areas. However, one material can only cover a specific range of mechanical performance such as the elastic modulus and stretchability. In order to improve the mechanical performance of soft biomaterials, lattice structures are embedded to reinforce the biomaterials. In this paper, rectangular and triangular lattice structures formed by modified horseshoe microstructures are used because their mechanical properties are tunable and can be tailored precisely to match the desired properties by adjusting four geometrical parameters, the length L, radius R, width w and arc angle θ₀. A theoretical design framework for the modified horseshoe lattice structures is developed to predict the dependence of the mechanical behaviors on geometrical parameters. Both experiments and finite element simulations on lattice structures are conducted to validate the theoretical models. Results show that a wide range of design space for the elastic modulus (a few kPa to hundreds of MPa), stretchability (strain up to 180%) and Poisson ratio (ranging from −0.5 to 1.2) can be achieved. Experiments on lattice–hydrogel composites are also conducted to verify the reinforcement effect of lattice structures on the hydrogel. This work provides a theoretical method to predict the mechanical behaviors of the lattice structures and aid the rational design of reinforced biomaterials, which has applications in tissue engineering, drug delivery and intraocular lenses.