The use of liquid metals based on gallium for soft and stretchable electronics is discussed. This emerging class of electronics is motivated, in part, by the new opportunities that arise from devices that have mechanical properties similar to those encountered in the human experience, such as skin, tissue, textiles, and clothing. These types of electronics (e.g., wearable or implantable electronics, sensors for soft robotics, e-skin) must operate during deformation. Liquid metals are compelling materials for these applications because, in principle, they are infinitely deformable while retaining metallic conductivity. Liquid metals have been used for stretchable wires and interconnects, reconfigurable antennas, soft sensors, self-healing circuits, and conformal electrodes. In contrast to Hg, liquid metals based on gallium have low toxicity and essentially no vapor pressure and are therefore considered safe to handle. Whereas most liquids bead up to minimize surface energy, the presence of a surface oxide on these metals makes it possible to pattern them into useful shapes using a variety of techniques, including fluidic injection and 3D printing. In addition to forming excellent conductors, these metals can be used actively to form memory devices, sensors, and diodes that are completely built from soft materials. The properties of these materials, their applications within soft and stretchable electronics, and future opportunities and challenges are considered.

Stretchable and Soft Electronics using Liquid Metals.

This review comprises a detailed survey of ongoing methodologies for soft actuators, highlighting approaches suitable for nanometer- to centimeter-scale robotic applications. Soft robots present a special design challenge in that their actuation and sensing mechanisms are often highly integrated with the robot body and overall functionality. When less than a centimeter, they belong to an even more special subcategory of robots or devices, in that they often lack on-board power, sensing, computation, and control. Soft, active materials are particularly well suited for this task, with a wide range of stimulants and a number of impressive examples, demonstrating large deformations, high motion complexities, and varied multifunctionality. Recent research includes both the development of new materials and composites, as well as novel implementations leveraging the unique properties of soft materials.

Soft Actuators for Small-Scale Robotics.

Post-transition elements, together with zinc-group metals and their alloys belong to an emerging class of materials with fascinating characteristics originating from their simultaneous metallic and liquid natures. These metals and alloys are characterised by having low melting points (i.e. between room temperature and 300 °C), making their liquid state accessible to practical applications in various fields of physical chemistry and synthesis. These materials can offer extraordinary capabilities in the synthesis of new materials, catalysis and can also enable novel applications including microfluidics, flexible electronics and drug delivery. However, surprisingly liquid metals have been somewhat neglected by the wider research community. In this review, we provide a comprehensive overview of the fundamentals underlying liquid metal research, including liquid metal synthesis, surface functionalisation and liquid metal enabled chemistry. Furthermore, we discuss phenomena that warrant further investigations in relevant fields and outline how liquid metals can contribute to exciting future applications.

Liquid metals: fundamentals and applications in chemistry

Several gallium-based liquid metal alloys are liquid at room temperature. As 'liquid', such alloys have a low viscosity and a high surface tension while as 'metal', they have high thermal and electrical conductivities, similar to mercury. However, unlike mercury, these liquid metal alloys have low toxicity and a negligible vapor pressure, rendering them much safer. In comparison to mercury, the distinguishing feature of these alloys is the rapid formation of a self-limiting atomically thin layer of gallium oxide over their surface when exposed to oxygen. This oxide layer changes many physical and chemical properties of gallium alloys, including their interfacial and rheological properties, which can be employed and modulated for various applications in microfluidics. Injecting liquid metal into microfluidic structures has been extensively used to pattern and encapsulate highly deformable and reconfigurable electronic devices including electrodes, sensors, antennas, and interconnects. Likewise, the unique features of liquid metals have been employed for fabricating miniaturized microfluidic components including pumps, valves, heaters, and electrodes. In this review, we discuss liquid metal enabled microfluidic components, and highlight their desirable attributes including simple fabrication, facile integration, stretchability, reconfigurability, and low power consumption, with promising applications for highly integrated microfluidic systems.

Liquid metal enabled microfluidics

Binary mixtures of liquid metal (LM) or low-melting-point alloy (LMPA) in an elastomeric or fluidic carrier medium can exhibit unique combinations of electrical, thermal, and mechanical properties. This emerging class of soft multifunctional composites have potential applications in wearable computing, bio-inspired robotics, and shape-programmable architectures. The dispersion phase can range from dilute droplets to connected networks that support electrical conductivity. In contrast to deterministically patterned LM microfluidics, LMPA- and LM-embedded elastomer (LMEE) composites are statistically homogenous and exhibit effective bulk properties. Eutectic Ga-In (EGaIn) and Ga-In-Sn (Galinstan) alloys are typically used due to their high conductivity, low viscosity, negligible nontoxicity, and ability to wet to nonmetallic materials. Because they are liquid-phase, these alloys can alter the electrical and thermal properties of the composite while preserving the mechanics of the surrounding medium. For composites with LMPA inclusions (e.g., Field's metal, Pb-based solder), mechanical rigidity can be actively tuned with external heating or electrical activation. This progress report, reviews recent experimental and theoretical studies of this emerging class of soft material architectures and identifies current technical challenges and opportunities for further advancement.

Soft Multifunctional Composites and Emulsions with Liquid Metals

Continuous electrowetting (CEW) is demonstrated to be an effective actuation mechanism for reconfigurable radio frequency (RF) devices that use non-toxic liquid-metal tuning elements. Previous research has shown CEW is an efficient means of electrically inducing motion in a liquid-metal slug, but precise control of the slug's position within fluidic channels has not been demonstrated. Here, the precise positioning of liquid-metal slugs is achieved using CEW actuation in conjunction with channels designed to minimize the liquid-metal surface energy at discrete locations. This approach leverages the high surface tension of liquid metal to control its resting position with submillimeter accuracy. The CEW actuation and fluidic channel design were optimized to create reconfigurable RF devices. In addition, solutions for the reliable actuation of a gallium-based, non-toxic liquid-metal alloy (Galinstan) are presented that mitigate the tendency of the alloy to form a surface oxide layer capable of wetting to the channel walls, inhibiting motion. A reconfigurable slot antenna utilizing these techniques to achieve a 15.2% tunable frequency bandwidth is demonstrated.

Continuous Electrowetting of Non-toxic Liquid Metal for RF Applications

Presented here is a method for actuating a gallium-based liquid-metal alloy without the need for an external power supply. Liquid metal is used as an anode to drive a complementary oxygen reduction reaction, resulting in the spontaneous growth of hydrophilic gallium oxide on the liquid-metal surface, which induces flow of the liquid metal into a channel. The extent and duration of the actuation are controllable throughout the process, and the induced flow is both reversible and repeatable. This self-actuation technique can also be used to trigger other electrokinetic or fluidic mechanisms.

Self-Actuation of Liquid Metal via Redox Reaction.

A low-voltage, low-power method of electrically deforming a liquid-metal droplet via the direct manipulation of its surface tension is presented. By imposing a quasi-planar geometry on the liquid metal, its sensitivity to electrocapillary actuation is increased by more than a factor of 40. This heightened responsiveness allows the liquid metal to be deformed at rates exceeding 120 mm/s, greater than an order of magnitude faster than existing techniques for electrical deformation. Significantly, it is demonstrated how this process can be combined with voltage-controlled oxide growth on the surface of non-toxic, gallium-based liquid metals to reversibly form and maintain arbitrary, high-energy shapes.

https://link.springer.com/content/pdf/10.1186%2Fs40486-015-0017-z.pdf

Rapid electrocapillary deformation of liquid metal with reversible shape retention

This paper presents a frequency-tunable slot antenna which uses liquid metal to vary the electrical length of the radiating aperture. The liquid metal is driven by continuous electrowetting (CEW), a process by which motion is induced in a liquid-metal droplet through the application of a potential gradient across an electrolytic carrier fluid. The process is both fully reversible and repeatable, and the low-voltage electrical driving mechanism allows for simpler integration into electronic architectures than more common hydraulic methods. We believe this is the first instance of CEW being used to create a tunable RF device.

Frequency-tunable slot antenna using continuous electrowetting of liquid metal

A tunable bandpass filter based on reconfigurable liquid-metal perturbing posts in a substrate integrated waveguide (SIW) cavity is demonstrated. The design consists of four reconfigurable posts in a single cavity which provide five center frequencies from 10.13 GHz to 11.31 GHz. To enable frequency tuning, nontoxic liquid-metal Galinstan is hydraulically actuated to activate and deactivate posts. The five states have an average peak insertion loss of 1.35 dB with fractional bandwidths of 0.6% to 1% and unloaded quality factors of 96 to 154.

Jonathan H. Dang

Papers

Continuous Electrowetting of Non-toxic Liquid Metal for RF Applications

Self-Actuation of Liquid Metal via Redox Reaction.

Rapid electrocapillary deformation of liquid metal with reversible shape retention

Frequency-tunable slot antenna using continuous electrowetting of liquid metal

A tunable x-band substrate integrated waveguide cavity filter using reconfigurable liquid-metal perturbing posts