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

Javier M. Morales Ferrer, Chloe Kekedjian, Nicole Bacca and J. William Boley ()
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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

Nature Communications, 2025, vol. 16, issue 1, 1-12

Abstract: 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.

Date: 2025
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DOI: 10.1038/s41467-025-65279-w

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