A new radially expanding conducting polymer microactuator is presented. The radially expanding micro-actuators are used as electroactive gates in an electrically controlled microparticle sieve. A novel configuration to dynamically filter particles of different sizes in a microfluidic chip is conceptualized. Micropillars of SU-8 combined with conducting polymers to provide the radial actuation are positioned in a microfluidic chip with a specifically designed 3D printed housing to allow for selective filtration of microparticles with varied sizes. These pillar-shaped microactuators of polypyrrole actuate radially to function as dynamic gates for the fluidic channel, controlling the porosity of the filter allowing for the filtration of specific size of microparticles. This sieve design provides user defined channel width modulation with external stimuli. Photolithography and electrochemical polymerizations are combined with additive manufacturing to fabricate the individual func-tional parts of the microfluidic filter. To demonstrate the new conceptual filter design, we have shown filtration of microparticles of the sizes 60, 80, 90 and 100 mu m by electrically actuating micropillars of the dynamic gate. The flow and aggregation of the microparticles were analysed at the dynamic gates to characterize the perfor-mance of the filter.

Current additive manufacturing, including three-dimensional (3D) and so-called four-dimensional printing, of soft robotic devices is limited to millimeter sizes. In this study, we present additive manufacturing of soft microactuators and microrobots to fabricate even smaller structures in the micrometer domain. Using a custom-built extrusion 3D printer, microactuators are scaled down to a size of 300 x 1000 mu m(2), with minimum thickness of 20 mu m. Microactuators combined with printed body and electroactive polymers to drive the actuators are fabricated from computer-aided design model of the device structure. To demonstrate the ease and versatility of 3D printing process, microactuators with varying lengths ranging from 1000 to 5000 mu m are fabricated and operated. Likewise, microrobotic devices consisting of a rigid body and individually controlled free-moving arms or legs are 3D printed to explore the microfabrication of soft grippers, manipulators, or microrobots through simple additive manufacturing technique.

The feasibility of additive manufacturing actuating microstructures and microdevices with small dimension is presented. Using a custom-built extrusion 3D printer and CAD model of the device structure, bilayer microactuators driven by hydrogels are fabricated down to a size of 300 x 1000 mu m(2,)with a minimum thickness of 30 mu m. To explore the limitations of the 3D printing process, microactuators with a width of 300 mu m and lengths ranging from 1000 to 5000 mu m are manufactured and thereafter operated to demonstrate the feasibility of the process. Similarly, microrobotic devices consisting of a passive rigid body and flexible moving parts are 3D printed to illustrate the ease and versatility of the additive manufacturing technique to fabricate soft microgrippers or micromanipulators.

Untethered actuation is important for robotic devices to achieve autonomous motion, which is typically enabled by using batteries. Using enzymes to provide the required electrical charge is particularly interesting as it will enable direct harvesting of fuel components from a surrounding fluid. Here, a soft artificial muscle is presented, which uses the biofuel glucose in the presence of oxygen. Glucose oxidase and laccase enzymes integrated in the actuator catalytically convert glucose and oxygen into electrical power that in turn is converted into movement by the electroactive polymer polypyrrole causing the actuator to bend. The integrated bioelectrode pair shows a maximum open-circuit voltage of 0.70 +/- 0.04 V at room temperature and a maximum power density of 0.27 mu W cm(-2) at 0.50 V, sufficient to drive an external polypyrrole-based trilayer artificial muscle. Next, the enzymes are fully integrated into the artificial muscle, resulting in an autonomously powered actuator that can bend reversibly in both directions driven by glucose and O-2 only. This autonomously powered artificial muscle can be of great interest for soft (micro-)robotics and implantable or ingestible medical devices manoeuvring throughout the body, for devices in regenerative medicine, wearables, and environmental monitoring devices operating autonomously in aqueous environments.

A simple and cost-effective method for the patterning and fabrication of soft polymer microactuators integrated with morphological computation is presented. The microactuators combine conducting polymers to provide the actuation, with spatially designed structures for a morphologically controlled, user-defined actuation. Soft lithography is employed to pattern and fabricate polydimethylsiloxane layers with geometrical pattern, for use as a construction element in the microactuators. These microactuators could obtain multiple bending motions from a single fabrication process depending on the morphological pattern defined in the final step. Instead of fabricating via conventional photolithography route, which involves multiple steps with different chromium photomasks, this new method uses only one single design template to produce geometrically patterned layers, which are then specifically cut to obtain multiple device designs. The desired design of the actuator is decided in the final step of fabrication. The resulting microactuators generate motions such as a spiral, screw, and tube, using a single design template.