Magnetic Field-Assisted Manufacturing of Groove-Structured Flexible Actuators with Enhanced Performance

Magnetic flexible actuators have attracted widespread attention due to their small size, adaptability, and wireless control capability. The manufacturing method of these actuators plays a crucial role in their functionality. Vat photopolymerization (VPP) offers the ability to manufacture precise structures and the capability of selective area curing. Based on these characterizations, we propose a magnetic field-assisted manufacturing method based on VPP to produce magnetic flexible actuators with 3D architecture in both geometry structure and magnetization arrangements, with accuracy of 200 μm. In addition, we construct groove structure to enhance the actuators' deformation, which is confirmed by both theoretical and experimental analyses, and successfully reduce the content requirement of magnetic particles. Flexible actuators with a low magnetic particle content (10 wt%) can be fabricated and fulfill intended functionality. We demonstrate the effectiveness of our method by manufacturing multi-arm grippers, showcasing their transportation capabilities. Moreover, we construct a 2-DOF joint for a crawling robot, significantly improving its motion performance and increasing the average step length to 6.8 times. Finally, we design and manufacture a magnetic diaphragm with complex structure and 3D magnetization arrangements, which is applied to a micro pump, demonstrating its pumping process with a rate of about 3.6 mL/min. These results highlight the potential of the magnetic field-assisted manufacturing method in designing complex structures and magnetization arrangements of flexible actuators, expanding their functional boundaries.