Open Access

This paper concerns recent research into the autonomous formation of micro-structures in low carbonyl iron powder (CIP) concentration magneto active polymers (MAP). Higher concentrations of CIP show an isotropic distribution of magnetic filler throughout the entire sample, while autonomous structure formation is possible at mass concentrations lower than 3%. The formation of micro-toroids commences as CIP concentration approaches 1% wt. Further development of coherent rings with a defined order follow as CIP concentrations increase toward 2% wt, whilst exceeding 3% wt leads to the same isotropic distribution found in higher concentration MAP. Structured samples containing between 1% wt and 3% wt CIP were investigated using X-Ray tomography where solitary structures could clearly be observed. The ring structures represent microinductivities whose geometries can be manipulated during fabrication. In addition, these structures are magnetic field sensitive. This is not only relevant to applications in the GHz and THz areas but recent research has revealed implications for optical, thermal, acoustic and even chemical MAP sensors. (C) 2019 Author(s).

This work describes the development of a new miniature extruder, essential to cavity-free 3D printing of silicone-based smart materials. This makes the 3D printing of magnetoactive and electroactive polymer soft robotic components and devices directly from CAD data possible. The special feature of such an extruder is that it is designed for use with addition-crosslinking RTV-2 silicones, including solid particulate additives. The extruder merges the respective components automatically during extrusion which obviates the need for premixing and vacuum evacuation. Problems associated with inhomogeneities and unwanted cavity production are consequently eliminated. Rheological details necessary to the design, together with some preliminary performance results, are presented.

Compared to conventional end effectors, electro-adhesive grippers enable the handling of sensitive, soft or air-permeable materials [1]. The prehension force is based on a strong electric field generated by electrodes resulting in a polarisation of the dielectric and the generation of mirror charges in the workpiece. When the electrode supply voltage is deactivated, the electric field drops,but an electrostatic field remains due to remanent polarisation of the dielectric. The residual charge on the gripper surface reduces only slowly and in combination with other influencing factors can prevent the workpieces from being ejected temporarily or completely. In this work a solution to this problem is presented by means of gripper surface deforming caused by the applicat ion of a magnetic field to a magneto- active polymer (MAP) actuator. The in-creased distance between the workpiece and the dielectric enables precise and controlled ejection. In addition to compliance and deformability, the employment of soft smart materials enables the integration of self-sens-ing mechanisms for the measurement of surface deformation. The embedding of electrically conductive flexible electrodes within the soft silicone dielectric sup port such movements and serves as the n ecessary electrodes for electroadhesion. Since the implementation of the end effectoris based entirely on soft materials, the self-sensing magnetically controllable electroadhesive gripper (SMEG) can be produced in a shape deposition manufacturing (SDM) process [2], [3] and is highly applicable to the field of soft robotics.

The objectives of this work include the analysis of electrical and magnetic properties of magneto-elastic hybrid materials with the intention of developing new techniques for sensor and actuator applications. This includes the investigation of dielectric properties at both low and high frequencies. The behaviour of capacitors whose dielectrics comprise magnetic hybrid materials is well known. Such interfacial magnetocapacitance can be varied according to magnetic content, magnetic flux density and the relative permittivity of the polymer matrix together with other dielectric content. The basic function of trapping electrical charges in polymers (electrets) is also established technology. However, the combination of magnetoactive polymers and electrets has led to the first electromagnetic device capable of adhering to almost any material, whether magnetically susceptible or not. During the course of this research, in addition to dielectrics, electrically conductive polymers based on (PDMS) matrices were developed in order to vary the electrical properties of the material in a targeted manner. In order to ensure repeatable results, this demanded new fabrication techniques hitherto unavailable. The 3D printing of silicones is far from being a mature technology and much pioneering work was necessary before extending the usual 3 d.o.f. to include orientation about and diffusion of particles in these three axes, thus leading to the concept of 6D printing. In 6D printing, the application of a magnetic field can be used during the curing process to control the particulate distribution and thus the spatial filler particle density as desired. Most of the devices (sensors and actuators) produced by such methods contain levels of carbonyl iron powder (CIP) embedded magnetic filler of up to 70 wt%. Contrary to this, a hitherto neglected research area, namely magnetoactive polymers (MAPs) having significantly lower magnetic particle concentrations (1 to 3 wt% CIP) were also investigated. With filler concentrations lower than 3 wt%, structures are formed which are completely absent at higher filler levels. CIP concentrations in the range of 1wt% demonstrate the formation of toroidal structures. Further development of coherent rings with a compact order results as filler concentrations increase towards 2 wt%. Above 3 wt% the structure eventually disintegrates to the usual random order found in traditional MAP with higher CIP content. Structured samples containing 1%–3 wt% CIP were investigated with the aid of X-ray tomography where solitary ring structures can be observed and eventually the formation of capillary doubles. Over wavelengths ranging from 1 to 25 µm, spectroscopic analysis of thin film MAP samples containing 2 wt% CIP revealed measurable magnetic-field-dependent changes in IR absorption at a wavenumber 2350 (λ = 4.255 µm). This was found to be due to the diamagnetic susceptibility of atmospheric carbon dioxide (CO2). Consequently, the first potential application for sparse matrix MAPs was found.