In the evolving fields of soft robotics and wearable technology, sheet-based fluidic devices are reshaping how lightweight, flexible, and multifunctional systems are designed. However, with innovation comes new challenges—particularly in understanding and controlling failure in these devices. A new study by mechanical engineers at Rice University's George R. Brown School of Engineering and Computing explores how programmed failure in heat-sealable, sheet-based systems can protect devices, enable complex action sequencing, and simplify control mechanisms.“We are making soft, flexible machines smarter by designing their internal components to fail intentionally in a well-understood manner,” said Daniel J. Preston, corresponding author and assistant professor of mechanical engineering. “This allows systems to recover from pressure surges and even complete multiple tasks using a single control input.”Published in Cell Reports Physical Science, the research examines how thin, flexible sheets—patterned and selectively bonded to form internal fluidic networks—respond to pressure changes, particularly how they fail under excessive internal pressure. By studying adhesion between textile sheets, the team was able to predict maximum operating pressures and analyze how factors like bond geometry and material selection influence performance.“Our study provides a framework for predicting and leveraging failure in sheet-based fluidic systems,” said Sofia Urbina, co-first author and a second-year doctoral student in Preston’s lab. “Instead of viewing failure as a limitation, we explored how it can enhance functionality, making these devices more intelligent and efficient.”Engineering Failure for FunctionalityThe researchers conducted rigorous testing, including T-peel tests to evaluate adhesion strength and burst tests to assess material failure under high pressure. These experiments identified three distinct failure regimes shaped by the thermal bonding process: an initial phase where bond strength increases with bonding temperature, a plateau where material strength dictates cohesive failure, and a final phase where overheating degrades material integrity.These insights led to the development of a novel "fluidic fuse"—a protective component designed with multiple bonds of varying strengths that fails in a controlled manner to prevent system damage from pressure surges.“Think of it like an electrical fuse,” Preston explained. “When the pressure exceeds a certain threshold, the fuse ‘blows,’ preventing catastrophic damage to the entire system. It can even be replaced or rebonded for reuse.”Beyond protection, the research demonstrated that these fuses could be strategically placed to sequence multiple actions within a device. In one experiment, a system was designed to first unscrew a light bulb and then lift it from its socket—all using a single pressure input.“By programming when and where failure occurs, we can create devices that ‘fail’ their way into new operating modes, performing multiple tasks without requiring additional control inputs,” Preston said.
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Real-World ApplicationsThe implications of this research extend far beyond the lab. In wearable technology, fluidic networks embedded in clothing could provide adaptive support for rehabilitation patients, assist individuals with mobility impairments, and even enhance haptic communication. In robotics, the ability to sequence actions with a single input could streamline the design of multifunctional autonomous systems, reducing reliance on complex electronic controls.“This research enables smarter, more responsive sheet-based fluidic devices,” said co-first author Adam Broshkevitch, who recently earned his Master of Science in mechanical engineering from Rice and now serves in the Air Force. “By embracing failure as a design tool rather than a drawback, we can build systems that are not only more resilient but also more capable.”
