Multimaterial 3D Printing for Microrobotic Mechanisms

Multimaterial mechanisms are seen throughout natural organisms across all length scales. The different materials in their bodies, from rigid, structural materials to soft, elastic materials, enable mobility in complex environments. As robots leave the lab and begin to move in real environments, including a range of materials in 3D robotics mechanisms can help robots handle uncertainty and lessen control requirements. For the smallest robots, soft materials combined with rigid materials can facilitate large motions in compact spaces due to the increased compliance. However, integrating various material components in 3D at the microscale is a challenge. We present an approach for 3D microscale multimaterial fabrication using two-photon polymerization. Two materials with three orders of magnitude difference in Young's moduli are printed in consecutive cycles. Integrating a soft elastic material that is capable of more than 200% strain along with a rigid material has enabled the formation of hybrid elements, strongly adhered together, with layer accuracy below 3-μm resolution. We demonstrate a multilink multimaterial mechanism showing large deformation, and a 3D-printed 2-mm wingspan flapping wing mechanism, showing rapid prototyping of complex designs. This fabrication strategy can be extended to other materials, thus enhancing the functionality and complexity of small-scale robots.