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Synthetic fascia for stiff and tough 4D printed multifunctional structures that detect and tolerate damage

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  • Javier M. Morales Ferrer

    (Boston University Department of Mechanical Engineering)

  • Chloe Kekedjian

    (Boston University Division of Materials Science and Engineering)

  • Nicole Bacca

    (Boston University Department of Mechanical Engineering)

  • J. William Boley

    (Boston University Department of Mechanical Engineering
    Boston University Division of Materials Science and Engineering)

Abstract

Creating shape-morphing structures with time-responsive materials is a key goal of 4D printing, but combining high stiffness (E) and toughness (K) in a single material remains difficult. Soft materials stretch but lack strength, while stiff materials resist deformation but are brittle. Nature overcomes this trade-off in skeletal muscle by surrounding strong fibers with soft, tough tissue for protection and support. Inspired by this strategy, we develop a multi-material printing method that combines stiff synthetic muscle with a soft, stretchable adhesive to form a composite structure. Here, we show that this design greatly improves toughness without sacrificing stiffness, enables controlled actuation, and maintains function after multiple fractures. We demonstrate these properties in a damage-tolerant actuator, a lifting robot with record performance, and a lattice that detects and withstands extreme loads while remaining operational.

Suggested Citation

  • Javier M. Morales Ferrer & Chloe Kekedjian & Nicole Bacca & J. William Boley, 2025. "Synthetic fascia for stiff and tough 4D printed multifunctional structures that detect and tolerate damage," Nature Communications, Nature, vol. 16(1), pages 1-12, December.
    • Handle: RePEc:nat:natcom:v:16:y:2025:i:1:d:10.1038_s41467-025-65279-w
    DOI: 10.1038/s41467-025-65279-w
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