Advances in Liquid Metal-Enabled Flexible and Wearable Sensors

Embedded Hybrid-Dimensional Heterointerface for Filament Modulation in 2D Material-Based Artificial Nociceptor

Nociceptors are key sensory receptors that transmit warning signals to the central nervous system in response to painful stimuli. This fundamental process is emulated in an electronic device by developing a novel artificial nociceptor with an ultrathin, nonstoichiometric gallium oxide (GaOx)-silicon oxide heterostructure. A large-area 2D-GaOx film is printed on a substrate through liquid metal printing to facilitate the production of conductive filaments. This nociceptive structure exhibits a unique short-term temporal response following stimulation, enabling a facile demonstration of threshold-switching physics. The developed heterointerface 2D-GaOx film enables the fabrication of fast-switching, low-energy, and compliance-free 2D-GaOx nociceptors, as confirmed through experiments. The accumulation and extrusion of Ag in the oxide matrix are significant for inducing plastic changes in artificial biological sensors. High-resolution transmission electron microscopy and electron energy loss spectroscopy demonstrate that Ag clusters in the material dispersed under electrical bias and regrouped spontaneously when the bias is removed owing to interfacial energy minimization. Moreover, 2D nociceptors are stable; thus, heterointerface engineering can enable effective control of charge transfer in 2D heterostructural devices. Furthermore, the diffusive 2D-GaOx device and its Ag dynamics enable the direct emulation of biological nociceptors, marking an advancement in the hardware implementation of artificial human sensory systems.

A retrofit sensing strategy for soft fluidic robots

Soft robots are intrinsically capable of adapting to different environments by changing their shape in response to interaction forces. However, sensory feedback is still required for higher level decisions. Most sensing technologies integrate separate sensing elements in soft actuators, which presents a considerable challenge for both the fabrication and robustness of soft robots. Here we present a versatile sensing strategy that can be retrofitted to existing soft fluidic devices without the need for design changes. We achieve this by measuring the fluidic input that is required to activate a soft actuator during interaction with the environment, and relating this input to its deformed state. We demonstrate the versatility of our strategy by tactile sensing of the size, shape, surface roughness and stiffness of objects. We furthermore retrofit sensing to a range of existing pneumatic soft actuators and grippers. Finally, we show the robustness of our fluidic sensing strategy in closed-loop control of a soft gripper for sorting, fruit picking and ripeness detection. We conclude that as long as the interaction of the actuator with the environment results in a shape change of the interval volume, soft fluidic actuators require no embedded sensors and design modifications to implement useful sensing.

Functional micro-/nanostructured gallium-based liquid metal for biochemical sensing and imaging applications

In recent years, liquid metals (LMs) have garnered increasing attention for their expanded applicability, and wide application potential in various research fields. Among them, gallium (Ga)-based LMs exhibit remarkable analytical performance in electrical and optical sensors, thanks to their excellent conductivity, large surface area, biocompatibility, small bandgap, and high elasticity. This review comprehensively summarizes the latest advancements in functional micro-/nanostructured Ga-based LMs for biochemical sensing and imaging applications. Firstly, the electrical, optical, and biocompatible features of Ga-based LM micro-/nanoparticles are briefly discussed, along with the manufacturing and functionalization processes. Subsequently, we demonstrate the utilization of Ga-based LMs in biochemical sensing techniques, encompassing electrochemistry, electrochemiluminescence, optical sensing techniques, and various biomedical imaging. Lastly, we present an insightful perspective on promising research directions and remaining challenges in LM-based biochemical sensing and imaging applications.

Phase Transition Liquid Metal Enabled Emerging Biomedical Technologies and Applications

Phase change materials that can absorb or release large amounts of heat during phase transition, play a critical role in many important processes, including heat dissipation, thermal energy storage, and solar energy utilization. In general, phase change materials are usually encapsulated in passive modules to provide assurance for energy management. The shape and mechanical changes of these materials are greatly ignored. An emerging class of phase change materials, liquid metals (LMs) have attracted significant interest beyond thermal management, including in transformable robots, flexible electronics, soft actuators, and biomedicine. Interestingly, the melting point of LM is highly tunable around body temperature, allowing it to experience considerable stiffness change when interacting with human organisms during solid-liquid change, which brings about novel phenomena, applied technologies, and therapeutic methods, such as mechanical destruction of tumors, neural electrode implantation technique, and embolization therapy. This review focuses on the technology, regulation, and application of the phase change process along with diverse changes of LM to facilitate emerging biomedical applications based on the influences of mechanical stiffness change and versatile regulation strategies. Typical applications will also be categorized and summarized. Lastly, the advantages and challenges of using the unique and reversible process for biomedicine will be discussed.

Electronic exoneuron based on liquid metal for the quantitative sensing of the augmented somatosensory system

The increasing demands in augmented somatosensory have promoted quantitative sensing to be an emerging need for athletic training/performance evaluation and physical rehabilitation. Neurons for the somatosensory system in the human body can capture the information of movements in time but only qualitatively. This work presents an electronic Exo-neuron (EEN) that can spread throughout the limbs for realizing augmented somatosensory by recording both muscular activity and joint motion quantitatively without site constraints or drift instability, even in strenuous activities. Simply based on low-cost liquid metal and clinically used adhesive elastomer, the EEN could be easily fabricated in large areas for limbs. It is thin (~120 μm), soft, stretchable (>500%), and conformal and further shows wide applications in sports, rehabilitation, health care, and entertainment.

Wearable Sensors for Respiration Monitoring: A Review

This paper provides an overview of flexible and wearable respiration sensors with emphasis on their significance in healthcare applications. The paper classifies these sensors based on their operating frequency distinguishing between high-frequency sensors, which operate above 10 MHz, and low-frequency sensors, which operate below this level. The operating principles of breathing sensors as well as the materials and fabrication techniques employed in their design are addressed. The existing research highlights the need for robust and flexible materials to enable the development of reliable and comfortable sensors. Finally, the paper presents potential research directions and proposes research challenges in the field of flexible and wearable respiration sensors. By identifying emerging trends and gaps in knowledge, this review can encourage further advancements and innovation in the rapidly evolving domain of flexible and wearable sensors.

Stretchable Sensors: Novel Human Motion Monitoring Wearables

A human body monitoring system remains a significant focus, and to address the challenges in wearable sensors, a nanotechnology-enhanced strategy is proposed for designing stretchable metal-organic polymer nanocomposites. The nanocomposite comprises reduced graphene oxide (rGO) and in-situ generated silver nanoparticles (AgNPs) within elastic electrospun polystyrene-butadiene-polystyrene (SBS) fibers. The resulting Sandwich Structure Piezoresistive Woven Nanofabric (SSPWN) is a tactile-sensitive wearable sensor with remarkable performance. It exhibits a rapid response time (less than three milliseconds) and high reproducible stability over 5500 cycles. The nanocomposite also demonstrates exceptional thermal stability due to effective connections between rGO and AgNPs, making it suitable for wearable electronic applications. Furthermore, the SSPWN is successfully applied to human motion monitoring, including various areas of the hand and RGB sensing shoes for foot motion monitoring. This nanotechnology-enhanced strategy shows promising potential for intelligent healthcare, health monitoring, gait detection, and analysis, offering exciting prospects for future wearable electronic products.

Shaping a Soft Future: Patterning Liquid Metals

This review highlights the unique techniques for patterning liquid metals containing gallium (e.g., eutectic gallium indium, EGaIn). These techniques are enabled by two unique attributes of these liquids relative to solid metals: 1) The fluidity of the metal allows it to be injected, sprayed, and generally dispensed. 2) The solid native oxide shell allows the metal to adhere to surfaces and be shaped in ways that would normally be prohibited due to surface tension. The ability to shape liquid metals into non-spherical structures such as wires, antennas, and electrodes can enable fluidic metallic conductors for stretchable electronics, soft robotics, e-skins, and wearables. The key properties of these metals with a focus on methods to pattern liquid metals into soft or stretchable devices are summari.

Flexible and Stretchable Elastomer Composites Based on Lightweight Liquid Metal Foam Spheres with Pod-like Contacts

Liquid metal (LM) is increasingly employed as a conductive filler in soft and flexible elastomer composites owing to its favorable conductivity and liquid fluidity. However, the high density of LM inevitably increases the weight of composites, which brings limitations in large-area and weight-sensitive applications. This work reports a flexible and stretchable elastomer composite composed of pod-like contacting lightweight LM foam spheres and polydimethylsiloxane matrix (LMS/PDMS). The lightweight LMS reduces the amount of LM used in the preparation process while imparting good electrical conductivity and deformability to the composite. The different contact modes of LMS endow the final composites with diverse strain sensitivity. The mechanism of interfacial contact conduction between the LMS with different melting points has been systematically studied, and the result shows that the liquid-solid contact mode of LMS further improves the strain sensitivity of the composite. Moreover, the composite also has satisfactory electrothermal properties and the temperature can quickly reach 70 °C within 30 s, showing good applicability in electric heating. Finally, the composites containing LMS with different contact modes can be developed as multifunctional sensors to detect human activities, temperature variation, and even underwater vibration, demonstrating the great potential in next-generation sensors and electronics.

Functionality of Flexible Pressure Sensors in Cardiovascular Health Monitoring: A Review

As the highest percentage of global mortality is caused by several cardiovascular diseases (CVD), maintenance and monitoring of a healthy cardiovascular condition have become the primary concern of each and every individual. Simultaneously, recent progress and advances in wearable pressure sensor technology have provided many pathways to monitor and detect underlying cardiovascular illness in terms of irregularities in heart rate, blood pressure, and blood oxygen saturation. These pressure sensors can be comfortably attached onto human skin or can be implanted on the surface of vascular grafts for uninterrupted monitoring of arterial blood pressure. While the traditional monitoring systems are time-consuming, expensive, and not user-friendly, flexible sensor technology has emerged as a promising and dynamic practice to collect important health information at a comparatively low cost in a reliable and user-friendly way. This Review explores the importance and necessity of cardiovascular health monitoring while emphasizing the role of flexible pressure sensors in monitoring patients' health conditions to avoid adverse effects. A comprehensive discussion on the current research progress along with the real-time impact and accessibility of pressure sensors developed for cardiovascular health monitoring applications has been provided.

Emerging Liquid Metal Biomaterials: From Design to Application

Liquid metals (LMs) as emerging biomaterials possess unique advantages including their favorable biosafety, high fluidity, and excellent electrical and thermal conductivities, thus providing a unique platform for a wide range of biomedical applications ranging from drug delivery, tumor therapy, and bioimaging to biosensors. The structural design and functionalization of LMs endow them with enhanced functions such as enhanced targeting ability and stimuli responsiveness, enabling them to achieve better and even multifunctional synergistic therapeutic effects. Herein, the advantages of LMs in biomedicine are presented. The design of LM-based biomaterials with different scales ranging from micro-/nanoscale to macroscale and various components is explored in-depth to promote the understanding of structure-property relationships, guiding their performance optimization and applications. Furthermore, the related advanced progress in the development of LM-based biomaterials in biomedicine is summarized. Current challenges and prospects of LMs in the biomedical field are also discussed.

Influence of microstructural alterations of liquid metal and its interfacial interactions with rubber on multifunctional properties of soft composite materials

Liquid metal (LM)-based polymer composites are currently new breakthrough and emerging classes of soft multifunctional materials (SMMs) having immense transformative potential for soft technological applications. Currently, room-temperature LMs, mostly eutectic gallium‑indium and Galinstan alloys are used to integrate with soft polymer due to their outstanding properties such as high conductivity, fluidity, low adhesion, high surface tension, low cytotoxicity, etc. The microstructural alterations and interfacial interactions controlling the efficient integration of LMs with rubber are the most critical aspects for successful implementation of multifunctionality in the resulting material. In this review article, a fundamental understanding of microstructural alterations of LMs to the formation of well-defined percolating networks inside an insulating rubber matrix has been established by exploiting several existing theoretical and experimental studies. Furthermore, effects of the chemical modifications of an LM surface and its interfacial interactions on the compatibility between solid rubber and fluid filler phase have been discussed. The presence of thin oxide layer on the LM surface and the effects and challenges it poses to the adequate functionalization of these materials have been discussed. Plausible applications of SMMs in different soft matter technologies, like soft robotics, flexible electronics, soft actuators, sensors, etc. have been provided. Finally, the current technical challenges and further prospective to the development of SMMs using non‑silicone rubbers have been critically discussed. This review is anticipated to infuse a new impetus to the associated research communities for the development of next generation SMMs.

Mechanically Active Materials and Devices for Bio-Interfaced Pressure Sensors-A Review

Pressures generated by external forces or by internal body processes represent parameters of critical importance in diagnosing physiological health and in anticipating injuries. Examples span intracranial hypertension from traumatic brain injuries, high blood pressure from poor diet, pressure-induced skin ulcers from immobility, and edema from congestive heart failure. Pressures measured on the soft surfaces of vital organs or within internal cavities of the body can provide essential insights into patient status and progression. Challenges lie in the development of high-performance pressure sensors that can softly interface with biological tissues to enable safe monitoring for extended periods of time. This review focuses on recent advances in mechanically active materials and structural designs for classes of soft pressure sensors that have proven uses in these contexts. The discussions include applications of such sensors as implantable and wearable systems, with various unique capabilities in wireless continuous monitoring, minimally invasive deployment, natural degradation in biofluids, and/or multiplexed spatiotemporal mapping. A concluding section summarizes challenges and future opportunities for this growing field of materials and biomedical research.

Construction of liquid metal-based soft microfluidic sensors via soft lithography

Background

Liquid metal (LM) can be integrated into microfluidic channel, bringing new functionalities of microfluidics and opening a new window for soft microfluidic electronics, due to the superior advantages of the conductivity and deformability of LMs. However, patterning the LMs into microfluidic channels requires either selective surface wetting or complex fabrication process.

Results

In this work, we develop a method to pattern the LMs onto the soft elastomer via soft lithographic process for fabrication of soft microfluidic sensors without the surface modification, bulky facilities, and complicated processes. The combination of the interfacial hydrogen bond and surface tension enables the LM patterns transfer to the soft elastomer. The transferred LM patterns with an ellipse-like cross-section further improve the stability under the mechanical deformation. Three proof-of-concept experiments were conducted to demonstrate the utilization of this method for development of thermochromic sensors, self-powered capacity sensors and flexible biosensor for glucose detection.

Conclusions

In summary, the proposed method offers a new patterning method to obtain soft microfluidic sensors and brings new possibilities for microfluidics-related wearable devices.

Graphical Abstract

Supplementary Information

The online version contains supplementary material available at 10.1186/s12951-022-01471-0.

Acoustic Wave-Driven Liquid Metal Expansion

In this paper, we report a volume expansion phenomenon of a liquid metal droplet naturally oxidized in an ambient environment by applying an acoustic wave. An oxidized gallium-based liquid metal droplet was placed on a paper towel, and a piezo-actuator was attached underneath it. When a liquid metal droplet was excited by acoustic wave, the volume of liquid metal was expanded due to the inflow of air throughout the oxide crack. The liquid metal without the oxide layer cannot be expanded with an applied acoustic wave. To confirm the effect of the expansion of the oxidized liquid metal droplet, we measured an expansion ratio, which was calculated by comparing the expanded size in the x (horizontal), y (vertical) axis to the initial size of the liquid metal droplet, using a high-speed camera. For various volumes of the droplet, when we applied various voltages in the range of 5~8 Vrms with 18.5~24.5 kHz using the piezo-actuator, we obtained a maximum expansion ratio of 2.4 in the x axis and 3.8 in the y axis, respectively. In addition, we investigated that the time to reach the maximum expansion in proportion to the volume size of liquid metal differed by five times from 4 s to 20 s, and that the time to maintain the maximum expansion differed from 23 s to 2.5 s, which was inversely proportional to the volume size. We also investigated the expansion ratios depending on the exposure time to the atmosphere. Finally, a circuit containing LED, which can be turned on by expanded liquid metal droplet, was demonstrated.

Flexible Tactile Sensing Microfibers Based On Liquid Metals

High-performance and intelligent fibers are indispensable parts of wearable electronics in the future. This work mainly demonstrates the preparation of flexible intelligent liquid metal (LM) fibers with three core-sheath structures. An ultra-thin (10-50 μm), conductive, and highly flexible LM was deposited on the fiber core [carbon/polyethylene terephthalate (C/PET)--150-500 μm] along the fiber direction and then deposited on a polymer-protective layer [polyvinyl alcohol/epoxy resin (PVA/EP)--10 μm]. Four kinds of LM intelligent fibers were manufactured, including the C-LM-PVA fiber, C-LM-EP fiber, PET-LM-PVA fiber, and PET-LM-EP fiber. These LM intelligent fibers (diameter, 150-600 μm) were demonstrated with a high conductivity of 7.839 × 10⁴ S·m^-1. The changes in resistance in different torsion directions were measured, and these smart LM fibers could also be used as electrical heaters or thermoelectric generators, which released heat (36-36.9 °C/1-1.5 V) into the environment. Then, these multifunctional LM fibers were applied as high-performance strain sensors and bending sensors. These flexible LM conductive fibers could be successfully utilized in intelligent wearable fabrics and were expected to be widely utilized in artificial muscle and sensor fields.

Force-Sensitive Interface Engineering in Flexible Pressure Sensors: A Review

Flexible pressure sensors have received extensive attention in recent years due to their great importance in intelligent electronic devices. In order to improve the sensing performance of flexible pressure sensors, researchers are committed to making improvements in device materials, force-sensitive interfaces, and device structures. This paper focuses on the force-sensitive interface engineering of the device, which listing the main preparation methods of various force-sensitive interface microstructures and describing their respective advantages and disadvantages from the working mechanisms and practical applications of the flexible pressure sensor. What is more, the device structures of the flexible pressure sensor are investigated with the regular and irregular force-sensitive interface and accordingly the influences of different device structures on the performance are discussed. Finally, we not only summarize diverse practical applications of the existing flexible pressure sensors controlled by the force-sensitive interface but also briefly discuss some existing problems and future prospects of how to improve the device performance through the adjustment of the force-sensitive interface.

Emerging Role of Liquid Metals in Sensing

Low melting point metals and alloys are the group of materials that combine metallic and liquid properties, simultaneously. The fascinating characteristics of liquid metals (LMs) including softness and high electrical and thermal conductivity, as well as their unique interfacial chemistry, have started to dominate various research disciplines. Utilization of LMs as responsive interfaces, enabling sensing in a flexible and versatile manner, is one of the most promising traits demonstrated for LMs. In the context of LMs-enabled sensors, gallium (Ga) and its alloys have emerged as multipurpose functional materials with many compelling physical and chemical properties. Responsiveness to different stimuli and easy-to-functionalize interfaces of Ga-based LMs make them ideal candidates for a variety of sensing applications. However, despite the vast capabilities of Ga-based LMs in sensing, applications of these materials for developing different sensors have not been fully explored. In the present review, we provide a comprehensive overview regarding the applications of Ga-based LMs in a wide range of sensing approaches that cover different physical and chemical sensors. The unique features of Ga-based LMs, which make them promising materials for sensing, are discussed in subsections followed by relevant case studies. Finally, challenges as well as the prospected future and developing motifs are highlighted for each type of LM-based sensors.

Finite Element Modeling of Magnitude and Location of Brain Micromotion Induced Strain for Intracortical Implants

Micromotion-induced stress remains one of the main determinants of life of intracortical implants. This is due to high stress leading to tissue injury, which in turn leads to an immune response coupled with a significant reduction in the nearby neural population and subsequent isolation of the implant. In this work, we develop a finite element model of the intracortical probe-tissue interface to study the effect of implant micromotion, implant thickness, and material properties on the strain levels induced in brain tissue. Our results showed that for stiff implants, the strain magnitude is dependent on the magnitude of the motion, where a micromotion increase from 1 to 10 μm induced an increase in the strain by an order of magnitude. For higher displacement over 10 μm, the change in the strain was relatively smaller. We also showed that displacement magnitude has no impact on the location of maximum strain and addressed the conflicting results in the literature. Further, we explored the effect of different probe materials [i.e., silicon, polyimide (PI), and polyvinyl acetate nanocomposite (PVAc-NC)] on the magnitude, location, and distribution of strain. Finally, we showed that strain distribution across cortical implants was in line with published results on the size of the typical glial response to the neural probe, further reaffirming that strain can be a precursor to the glial response.

Supported Cu/W/Mo/Ni—Liquid Metal Catalyst with Core-Shell Structure for Photocatalytic Degradation

Room-temperature liquid metal is a very ideal material for the design of catalytic materials. At low temperatures, the liquid metal enters the liquid state. It provides an opportunity to utilize the liquid phase in the catalysis, which is far superior to the traditional solid-phase catalyst. Aiming at the low performance and narrow application scope of the existing single-phase liquid metal catalyst, this paper proposed a type of liquid metal/metal oxide core-shell composite multi-metal catalyst. The Ga2O3 core-shell heterostructure was formed by chemical modification of liquid metals with different nano metals Cu/W/Mo/Ni, and it was applied to photocatalytic degrading organic contaminated raw liquor. The effects of different metal species on the rate of catalytic degradation were explored. The selectivity and stability of the LM/MO core-shell composite catalytic material were clarified, and it was found that the Ni-LM catalyst could degrade methylene blue and Congo red by 92% and 79%, respectively. The catalytic mechanism and charge transfer mechanism were revealed by combining the optical band gap value. Finally, we provided a theoretical basis for the further development of liquid metal photocatalytic materials in the field of new energy environments.

Temperature-Stress Bimodal Sensing Conductive Hydrogel-Liquid Metal by Facile Synthesis for Smart Wearable Sensor

Conductive hydrogels have attracted great attention due to their promising applications in wearable sensors. However, developing conductive hydrogels with excellent sensor properties and multiple stimuli responsiveness for smart wearable devices is still a challenge. This paper presents a facile synthetic method of a crosslinked chitosan quaternary ammonium salt and liquid metal (CHACC-LM) composite hydrogel with temperature-stress bimodal sensing for smart wearable sensor. LM as liquid fillers toughen the hydrogel matrix (stress: 1.11 MPa) and enhance the hydrogel extensibility (strain: 233%). The CHACC-LM hydrogel exhibits conductivity , excellent antibacterial properties (> 99%), an electrical self-healing property, and strain sensitivity (GF = 1.6). In addition, the CHACC-LM hydrogel can be used as wearable flexible sensors with the ability of monitoring human activities directly and the distinguished ability of discerning subtle motions (handwriting). It also shows sensitivity in the external environment such as low temperature, thermal response, and water solution. Importantly, the composite hydrogel simultaneous response to different stress and temperature stimuli. Furthermore, the CHACC-LM hydrogel can be used for gesture recognition and to control the manipulator in human-computer interaction. All these properties provide a great scope for researchers to achieve practical advances in smart wearable sensors.

Recent advances in liquid-metal-based wearable electronics and materials

Soft wearable electronics are rapidly developing through exploration of new materials, fabrication approaches, and design concepts. Although there have been many efforts for decades, a resurgence of interest in liquid metals (LMs) for sensing and wiring functional properties of materials in soft wearable electronics has brought great advances in wearable electronics and materials. Various forms of LMs enable many routes to fabricate flexible and stretchable sensors, circuits, and functional wearables with many desirable properties. This review article presents a systematic overview of recent progresses in LM-enabled wearable electronics that have been achieved through material innovations and the discovery of new fabrication approaches and design architectures. We also present applications of wearable LM technologies for physiological sensing, activity tracking, and energy harvesting. Finally, we discuss a perspective on future opportunities and challenges for wearable LM electronics as this field continues to grow.

Liquid Metal Based Flexible and Implantable Biosensors

Biosensors are the core elements for obtaining significant physiological information from living organisms. To better sense life information, flexible biosensors and implantable sensors that are highly compatible with organisms are favored by researchers. Moreover, materials for preparing a new generation of flexible sensors have also received attention. Liquid metal is a liquid-state metallic material with a low melting point at or around room temperature. Owing to its high electrical conductivity, low toxicity, and superior fluidity, liquid metal is emerging as a highly desirable candidate in biosensors. This paper is dedicated to reviewing state-of-the-art applications in biosensors that are expounded from seven aspects, including pressure sensor, strain sensor, gas sensor, temperature sensor, electrical sensor, optical sensor, and multifunctional sensor, respectively. The fundamental scientific and technological challenges lying behind these recommendations are outlined. Finally, the perspective of liquid metal-based biosensors is present, which stimulates the upcoming design of biosensors.

Bi-Sn Catalytic Foam Governed by Nanometallurgy of Liquid Metals

Metallic foams, with intrinsic catalytic properties, are critical for heterogeneous catalysis reactions and reactor designs. Market ready catalytic foams are costly and made of multimaterial coatings with large sub-millimeter open cells providing insufficient active surface area. Here we use the principle of nanometallurgy within liquid metals to prepare nanostructured catalytic metal foams using a low-cost alloy of bismuth and tin with sub-micrometer open cells. The eutectic bismuth and tin liquid metal alloy was processed into nanoparticles and blown into a tin and bismuth nanophase separated heterostructure in aqueous media at room temperature and using an indium brazing agent. The CO₂ electroconversion efficiency of the catalytic foam is presented with an impressive 82% conversion efficiency toward formates at high current density of -25 mA cm^-2 (-1.2 V vs RHE). Nanometallurgical process applied to liquid metals will lead to exciting possibilities for expanding industrial and research accessibility of catalytic foams.