Laser 'writes' and 'bends': A dual-laser method creates adaptive, shape-locking devices in situ

Imagine using one laser beam to 'write' instructions into a material and another to 'bend' it into a complex, functional shape—all on the spot, without moving a thing. Researchers at the University of Science and Technology of China (USTC) have turned this concept into reality, developing a novel dual-laser method that creates adaptive, shape-locking devices in situ.

This innovative approach, reported in the International Journal of Extreme Manufacturing, solves a critical challenge for soft robotics and smart devices: creating materials that are both highly reconfigurable and able to hold their complex forms to perform tasks without continuous power. This opens the door to creating truly adaptive robots for complex environments, or medical devices that can be adjusted remotely after implantation.

For years, scientists have worked with magneto-responsive composites (MRCs), but these materials have major limitations that have hindered their real-world application.

"We faced a two-fold problem," said Jiawen Li, a professor at USTC's Department of Precision Machinery and Precision Instrumentation and the corresponding author on the paper. "First, most smart materials are either permanently programmed or too soft to hold a functional shape without power. Second, the 'writing' of magnetic instructions and the 'bending' into shape required completely separate, bulky equipment. Our goal was to integrate both actions into one elegant, in situ process."

The challenge was to create a material that could transition between a pliable, moldable state and a rigid, load-bearing state, while also allowing its internal magnetic programming to be rewritten on demand.

Existing methods required either complex fabrication that permanently fixed the magnetic properties, or reprogramming that relied on bulky external heaters or high-strength magnetic systems, making on-site adjustments impossible.

The USTC team solved this by creating a novel reprogrammable magnetic shape-memory composite (RM-SMC). The material cleverly integrates a shape-memory polymer (SMP) skeleton with specially designed phase-transition magnetic microcapsules. The magic happens with their dual-laser method:

The team first 'writes' new instructions into the material using a high-intensity laser. This beam precisely heats a tiny spot above 85°C, melting internal magnetic microcapsules. An external magnetic field then orients the freed magnetic particles, encoding a specific instruction before the spot rapidly cools and locks the new programming in place.

To 'bend' the material, a second, low-intensity laser gently warms a larger area above 60°C. This softens the material's shape-memory polymer skeleton, making it pliable. A different magnetic field then acts on the 'written' instructions, guiding the material to fold, twist, or bend into its intended 3D form. Once the laser is off, the material cools and rigidly locks its new shape, no power required.

"By being able to both 'write' new magnetic programs and 'bend' the structure on demand, we've created a platform for truly dynamic devices," said Li. "An impeller pump that can reshape its blades in situ to handle different liquids is just one example. This opens a new chapter for smart manufacturing and robotics where devices can adapt their hardware, not just their software."

The team is now working to further refine the control system, potentially integrating automated feedback to create even more intelligent and autonomous devices. They believe this technology establishes a new paradigm for multifunctional soft robotics, with potential impacts in fields ranging from smart manufacturing and sustainable energy to advanced biomedical devices.

International Journal of Extreme Manufacturing (IJEM, IF: 21.3) is dedicated to publishing the best advanced manufacturing research with extreme dimensions to address both the fundamental scientific challenges and significant engineering needs.

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