Development of 3D Printable Highly Flexible Siloxane Elastomers for Direct Ink Writing (DIW) of Soft Robotic Actuators for Space Applications
Authors: Demirkal Emrah , Sierros Kostas , Banerjee Derrick , Burke John , Sabolsky Katarzyna , Sabolsky Edward 
Published: September 2023

There is an interest in soft robotics for various space applications within low gravity and tight space environments to navigate, observe and even service various components within space assets, spacecraft and planetary stations. As an example, in an emergency, such as a pipe system failure occurring in a spacecraft, a soft robot may be able to assist in navigating the structure to detect the location and means of failure. The manufacturing of soft robotic actuators in space can be crucial. In addition, the fabrication of soft robotic tooling in a single step plays a critical role in space. 3D printing systems allow the manufacturing of soft robotic actuator parts in a single step. Stereolithography (SLA) and digital light processing (DLP) systems are not convenient because of the space environment. However, direct ink writing (DIW) which is the most commonly available and affordable system compared to SLA or DLP can be utilized to produce 3D objects, in addition, the DIW process permits the ability to in situ produce composite structures during the printing process. Various inorganic particles can be inserted within the elastomer print to control the mechanical, electrical and magnetic properties on-demand to produce smart or multi-functional soft robotic actuators and structures.

The current work focuses on the development of a highly flexible and low (or nearly no) cytotoxicity silicone-based elastomer via thiol-ene click reaction that allows rapid polymerization of an elastomer to prevent the collapse of the structure during the printing. The work also demonstrates the use of this novel UV-durable elastomer to produce structures with embedded electrical interconnects and sensors for in-situ measurement of temperature and strain. In this study Poly(mercaptopropylmethylsiloxane-co-dimethylsiloxane) (M-MPS) was first prepared through the cohydrolysis-condensation reaction of 3-Mercaptopropylmethyltrimethoxysilane (MPS) and dimethyldimethoxylsilane (DMDES) with water and hydrochloric acid. Then M-MPS was compounded with various molecular weight vinyl-terminated polydimethylsiloxane (VPS) (MW~800-25000) and different dosage (0.1- 4.0 wt%) of a photoinitiator (1:1 weight ratio of 2-Hydroxy-2-methyl-phenyl-propane-1-one (PI 1173) and phenyl bis (2,4,6-trimethylbenzoyl) phosphine oxide (PI819)). For example, Figure 1 depicts the change in the viscosity of (M-MPS)-VPS 6000 2 wt% when it exposes to UV light irradiation. When (M-MPS)-VPS 6000 2 wt% was exposed to UV light irradiation, it polymerized at ~2 sec which is enough time to retain the structure during printing. To elucidate the properties of synthesized elastomer, FTIR, NMR, SEM, and tensile test measurements were performed. Furthermore, the synthesized elastomer was loaded with conductive inorganic particles so as to utilize the printed material as a temperature and tactile sensor (and sensor array). In addition, other printing variables were evaluated to produce 2D/3D structures of the pure and composite elastomers, such as the effect of the power and wavelength of UV light source, loading different types of conductive powders, and thiol-ene ratio.

Acknowledgments:

Work supported by a subcontract under the NASA-EPSCOR program (project number is 80NSSC20M0218). The authors would like to thank our NASA technical monitor Mr. Curtis Hill and project manager Dr. Melanie Page due to their contributions. Material characterization and imaging work were made possible with the support of the West Virginia University Shared Research Facilities (SRF).

Figure 1