This paper describes a method to direct-write 3D liquid metal microcomponents at room temperature. The thin oxide layer on the surface of the metal allows the formation of mechanically stable structures strong enough to stand against gravity and the large surface tension of the liquid. The method is capable of printing wires, arrays of spheres, arches, and interconnects.

The fabrication and characterization of fibers that are ultrastretchable and have metallic electrical conductivity are described. The fibers consist of a liquid metal alloy, eutectic gallium indium (EGaIn), injected into the core of stretchable hollow fibers composed of a triblock copolymer, poly[styrene‐b‐(ethylene‐co‐butylene)‐b‐styrene] (SEBS) resin. The hollow fibers are easy to mass‐produce with controlled size using commercially available melt processing methods. The fibers are similar to conventional metallic wires, but can be stretched orders of magnitude further while retaining electrical conductivity. Mechanical measurements with and without the liquid metal inside the fibers show the liquid core has a negligible impact on the mechanical properties of the fibers, which is in contrast to most conductive composite fibers. The fibers also maintain the same tactile properties with and without the metal. Electrical measurements show that the fibers increase resistance as the fiber elongates and the cross sectional area narrows. Fibers with larger diameters change from a triangular to a more circular cross‐section during stretching, which has the appeal of lowering the resistance below that predicted by theory. To demonstrate their utility, the ultrastretchable fibers are used as stretchable wires for earphones and for a battery charger and perform as well as their conventional parts.

This paper describes the fabrication and characterization of fluidic dipole antennas that are reconfigurable, reversibly deformable, and mechanically tunable. The antennas consist of a fluid metal alloy injected into microfluidic channels comprising a silicone elastomer. By employing soft lithographic, rapid prototyping methods, the fluidic antennas are easier to fabricate than conventional copper antennas. The fluidic dipole radiates with ≈90% efficiency over a broad frequency range (1910–1990 MHz), which is equivalent to the expected efficiency for a similar dipole with solid metallic elements such as copper. The metal, eutectic gallium indium (EGaIn), is a low‐viscosity liquid at room temperature and possesses a thin oxide skin that provides mechanical stability to the fluid within the elastomeric channels. Because the conductive element of the antenna is a fluid, the mechanical properties and shape of the antenna are defined by the elastomeric channels, which are composed of polydimethylsiloxane (PDMS). The antennas can withstand mechanical deformation (stretching, bending, rolling, and twisting) and return to their original state after removal of an applied stress. The ability of the fluid metal to flow during deformation of the PDMS ensures electrical continuity. The shape and thus, the function of the antenna, is reconfigurable. The resonant frequency can be tuned mechanically by elongating the antenna via stretching without any hysteresis during strain relaxation, and the measured resonant frequency as a function of strain shows excellent agreement (±0.1–0.3% error) with that predicted by theoretical finite element modeling. The antennas are therefore sensors of strain. The fluid metal also facilitates self‐healing in response to sharp cuts through the antenna.

The mechanical features of biological muscles are difficult to reproduce completely in synthetic systems. A new class of soft pneumatic structures (vacuum‐actuated muscle‐inspired pneumatic structures) is described that combines actuation by negative pressure (vacuum), with cooperative buckling of beams fabricated in a slab of elastomer, to achieve motion and demonstrate many features that are similar to that of mammalian muscle.

This paper describes the fabrication and characterization of microelectrodes that are inherently aligned with microfluidic channels and in direct contact with the fluid in the channels. Injecting low melting point alloys, such as eutectic gallium indium (EGaIn), into microchannels at room temperature (or just above room temperature) offers a simple way to fabricate microelectrodes. The channels that define the shape and position of the microelectrodes are fabricated simultaneously with other microfluidic channels (i.e., those used to manipulate fluids) in a single step; consequently, all of the components are inherently aligned. In contrast, conventional techniques require multiple fabrication steps and registration (i.e., alignment of the electrodes with the microfluidic channels), which are technically challenging. The distinguishing characteristic of this work is that the electrodes are in direct contact with the fluid in the microfluidic channel, which is useful for a number of applications such as electrophoresis. Periodic posts between the microelectrodes and the microfluidic channel prevent the liquid metal from entering the microfluidic channel during injection. A thin oxide skin that forms rapidly and spontaneously on the surface of the metal stabilizes mechanically the otherwise low viscosity, high surface tension fluid within the channel. Moreover, the injected electrodes vertically span the sidewalls of the channel, which allows for the application of uniform electric field lines throughout the height of the channel and perpendicular to the direction of flow. The electrodes are mechanically stable over operating conditions commonly used in microfluidic applications; the mechanical stability depends on the magnitude of the applied bias, the nature of the bias (DC vs. AC), and the conductivity of the solutions in the microfluidic channel. Electrodes formed using alloys with melting points above room temperature ensure mechanical stability over all of the conditions explored. As a demonstration of their utility, the fluidic electrodes are used for electrohydrodynamic mixing, which requires extremely high electric fields (~10(5) V m(-1)).