An extreme toughening mechanism for soft materials

Network design for soft materials: addressing elasticity and fracture resistance challenges

Soft materials, such as elastomers and gels, feature crosslinked polymer chains that provide stretchable and elastic mechanical properties. These properties are derived from entropic elasticity, which limits energy dissipation and makes the material susceptible to fracture. To address this issue, network designs that dissipate energy through the plastic zone have been introduced to enhance toughness; however, this approach compromises elasticity, preventing the material from fully recovering its original shape after deformation. In this review, we describe the trade-off between fracture resistance and elasticity, exploring network designs that overcome this limitation to achieve both high toughness and low hysteresis. The development of soft materials that are both elastic and fracture-resistant holds significant promise for applications in stretchable electronics, soft robotics, and biomedical devices. By analyzing successful network designs, we identify strategies to further improve these materials and discuss potential enhancements based on existing limitations.

Hydrogel-Gated MXene-Graphene Field-Effect Transistor for Selective Detection and Screening of SARS-CoV-2 and E. coli Bacteria

Field-effect transistor (FET) biosensors have significantly attracted interest across various disciplines because of their high sensitivity, time-saving, and label-free characteristics. However, it remains a grand challenge to interface the FET biosensor with complex liquid media. Unlike standard liquid electrolytes containing purified protein content, directly exposing FET biosensors to complex biological fluids introduces significant sensing noise, which is caused by the abundance of nonspecific proteins, viruses, and bacteria that adsorb to the biosensor surfaces. In this work, we leverage the hydrogel encapsulation on an MXene-graphene-based FET, which selectively allows the permeation of viruses (e.g., SARS-CoV-2) and bacteria (e.g., E. coli), leading to the high-specificity detection of those biomarkers. The results demonstrated that hydrogel encapsulation could successfully detect the SARS-CoV-2 biomarker at 1 fg/mL while preventing the diffusion of E. coli biomarkers, and the obtained signal output amplitude is twice that of sensors without hydrogel encapsulation, demonstrating significant advantages over conventional bare sensors.

Crosslinking degree variations enable programming and controlling soft fracture via sideways cracking

Large deformations of soft materials are customarily associated with strong constitutive and geometrical nonlinearities that originate new modes of fracture. Some isotropic materials can develop strong fracture anisotropy, which manifests as modifications of the crack path. Sideways cracking occurs when the crack deviates to propagate in the loading direction, rather than perpendicular to it. This fracture mode results from higher resistance to propagation perpendicular to the principal stretch direction. It has been argued that such fracture anisotropy is related to deformation-induced anisotropy resulting from the microstructural stretching of polymer chains and, in strain-crystallizing elastomers, strain-induced crystallization mechanisms. However, the precise variation of the fracture behavior with the degree of crosslinking remains to be understood. Leveraging experiments and computational simulations, here we show that the tendency of a crack to propagate sideways in the two component Elastosil P7670 increases with the degree of crosslinking. We explore the mixing ratio for the synthesis of the elastomer that establishes the transition from forward to sideways fracturing. To assist the investigations, we construct a novel phase-field model for fracture where the critical energy release rate is directly related to the crosslinking degree. Our results demonstrate that fracture anisotropy can be modulated during the synthesis of the polymer. Then, we propose a roadmap with composite soft structures with low and highly crosslinked phases that allow for control over fracture, arresting and/or directing the fracture. The smart combination of the phases enables soft structures with enhanced fracture tolerance and reduced stiffness. By extending our computational framework as a virtual testbed, we capture the fracture performance of the composite samples and enable predictions based on more intricate composite unit cells. Overall, our work offers promising avenues for enhancing the fracture toughness of soft polymers.

Thermally Conductive Elastomer Composites with High Toughness, Softness, and Resilience Enabled by Regulating Interfacial Structure and Dynamics

The emerging applications of thermally conductive elastomer composites in modern electronic devices for heat dissipation require them to maintain both high toughness and resilience under thermomechanical stresses. However, such a combination of thermal conductivity and desired mechanical characteristics is extremely challenging to achieve in elastomer composites. Here this long-standing mismatch is resolved via regulating interfacial structure and dynamics response. This regulation is realized both by tuning the molecular weight of the dangling chains in the polymer networks and by silane grafting of the fillers, thereby creating a broad dynamic-gradient interfacial region comprising of entanglements. These entanglements can provide the slipping topological constraint that allows for tension equalization between and along the chains, while also tightening into rigid knots to prevent chain disentanglement upon stretching. Combined with ultrahigh loading of aluminum-fillers (90 wt%), this design provides a low Young's modulus (350.0 kPa), high fracture toughness (831.5 J m-2), excellent resilience (79%) and enhanced thermal conductivity (3.20 W m-1 k-1). This work presents a generalizable preparation strategy toward engineering soft, tough, and resilient high-filled elastomer composites, suitable for complex environments, such as automotive electronics, and wearable devices.

Molecular control via dynamic bonding enables material responsiveness in additively manufactured metallo-polyelectrolytes

Metallo-polyelectrolytes are versatile materials for applications like filtration, biomedical devices, and sensors, due to their metal-organic synergy. Their dynamic and reversible electrostatic interactions offer high ionic conductivity, self-healing, and tunable mechanical properties. However, the knowledge gap between molecular-level dynamic bonds and continuum-level material properties persists, largely due to limited fabrication methods and a lack of theoretical design frameworks. To address this critical gap, we present a framework, combining theoretical and experimental insights, highlighting the interplay of molecular parameters in governing material properties. Using stereolithography-based additive manufacturing, we produce durable metallo-polyelectrolytes gels with tunable mechanical properties based on metal ion valency and polymer charge sparsity. Our approach unveils mechanistic insights into how these interactions propagate to macroscale properties, where higher valency ions yield stiffer, tougher materials, and lower charge sparsity alters material phase behavior. This work enhances understanding of metallo-polyelectrolytes behavior, providing a foundation for designing advanced functional materials.

Hard- and Soft-Coded Strain Stiffening in Metamaterials via Out-of-Plane Buckling Using Highly Entangled Active Hydrogel Elements

Metamaterials show elaborate mechanical behavior such as strain stiffening, which stems from their unit cell design. However, the stiffening response is typically programmed in the design step and cannot be adapted postmanufacturing. Here, we show hydrogel metamaterials with highly programmable strain-stiffening responses by exploiting the out-of-plane buckling of integrated pH-switchable hydrogel actuators. The stiffening upon reaching a certain extension stems from the initially buckled active hydrogel beams. At low strain, the beams do not contribute to the mechanical response under tension until they straighten with a resulting step-function increase in stiffness. In the hydrogel actuator design, the acrylic acid concentration hard-codes the configuration of the metamaterial and range of possible stiffening onsets, while the pH soft-codes the exact stiffening onset point after fabrication. The utilization of out-of-plane buckling to realize subsequent stiffening without the need to deform the passive structure extends the application of hydrogel actuators in mechanical metamaterials. Our concept of out-of-plane buckled active elements that stiffen only under tension enables strain-stiffening metamaterials with high programmability before and after fabrication.

Fibrin clot fracture under cyclic fatigue and variable rate loading

Fibrin clot is a vital class of fibrous materials, governing the mechanical response of blood clots. Fracture behavior of fibrin clots under complex physiological load is relevant for hemostasis and thrombosis. But how they fracture under cyclic and variable rate loading has not been reported. Here we conduct cyclic fatigue and monotonic variable rate loading tests on fibrin clots to characterize their fracture properties in terms of fatigue threshold and rate-dependent fracture toughness. We demonstrate that the fracture behavior of fibrin clots is sensitive to the amplitude of cyclic load and the loading rate. The cyclic fatigue tests show the fatigue threshold of fibrin clots at 1.66 J/m2, compared to the overall fracture toughness 15.8 J/m2. Furthermore, we rationalize the fatigue threshold using a semi-empirical model parameterized by 3D morphometric quantification to account for the hierarchical molecular structure of fibrin fibers. The variable loading tests reveal rate dependence of the overall fracture toughness of fibrin clots. Our analysis with a viscoelastic fracture model suggests the viscoelastic origin of the rate-dependent fracture toughness. The toughening mechanism of fibrin clots is further compared with biological tissues and hydrogels. This study advances the understanding and modeling of fatigue and fracture of blood clots and would motivate further investigation on the mechanics of fibrous materials. STATEMENT OF SIGNIFICANCE: Fibrin clot is a soft fibrous gel, exhibiting nonlinear mechanical responses under complex physiological loads. It is the main load-bearing constituent of blood clots where red blood cells, platelets and other cells are trapped. How the fibrin clot fractures under complex mechanical loads is critical for hemostasis and thrombosis. We study the fracture behavior of fibrin clots under cyclic fatigue and monotonic variable rate loads. We characterize the fatigue-threshold and viscous energy dissipation of fibrin clots. We compare the toughness enhancement of fibrin clots with hydrogels. The findings offer new insights into the fatigue and fracture of blood clots and fibrous materials, which could improve design guidelines for bioengineered materials.

A double-well potential model for glass transition in a glassy hydrogel undergoing bi-stable interactions with water

The key mechanisms for achieving ultra-high mechanical properties of glassy hydrogels have not been fully understood, and it is commonly believed that their glass transitions are the crucial reasons due to the existence of significant bi-stable interactions between polymer macromolecules and water molecules. In this study, a double-well potential model is formulated to describe the mechanical properties of glassy hydrogels undergoing glass transition, by combining phase evolution theory and a rubber elasticity model. Bi-stable interactions between polymer macromolecules and water molecules (for both the trapped and free water) have been characterized using this double-well potential model, and various parameters are studied, including depth of well (for elasticity), distance between two wells (for yielding), and energy difference between two wells (for transition probability). Furthermore, constitutive stress-strain relationships are developed to explore the working principles for achieving ultra-high mechanical properties of these glassy hydrogels. Finally, the effectiveness of the proposed models is verified using finite element analysis (FEA) and also the experimental results reported in the literature, thus providing physical and mechanical insights into the ultra-high mechanical properties of glassy hydrogels.

Simultaneous Polymerization Acceleration and Mechanical Enhancement for Printing a Biomimetic PEDOT Adhesive by Coordinative and Orthogonal Ruthenium Photochemistry

Conductive hydrogels are promising material candidates in fields ranging from flexible sensors and electronic skin applications to personalized medical monitoring. However, developing intrinsically conductive polymer hydrogels (ICPHs) with high mechanical properties and excellent printability is still challenging. Here, we introduce a simultaneous polymerization acceleration and mechanical enhancement (SPAME) strategy to construct PEDOT-based ICPHs via the rational design of coordinative and orthogonal ruthenium photochemistry (CORP). This orthogonal photochemistry triggers the oxidative polymerization of EDOT and the coupling of phenols within seconds under blue light irradiation. Benefiting from the bifunctional EDTA-Fe design, the photoreleased Fe(III) accelerated the EDOT polymerization and shortened the preparation time of ICPHs to a few seconds. At the same time, the addition of EDTA-Fe enhanced their mechanical properties, and both the critical strains and maximum stresses of the hydrogel doubled. Furthermore, the introduction of phenol residues in PAA-Ph significantly shortened the gelation time from several minutes to about 7 s. Thus, this fast and controllable CORP chemistry is compatible with standard printing techniques for engineering hydrogels for complex multifunctional structures for multifunctional bioelectronics and devices.