Homogeneity of liquid metal polymer composites: impact on mechanical, electrical, and sensing behavior

Liquid metal polymer composites (LMPCs) are formed by dispersing eutectic gallium-indium-tin (galinstan) droplets within a soft polymer matrix, such as polydimethylsiloxane (PDMS), resulting in an insulating composite that is suitable for dielectric applications, including wearable sensors and actuators. LMPCs offer a unique combination of robust mechanical performance and desirable electrical properties. While much research has focused on the effects of rigid fillers in polymer composites, the behavior of liquid metal fillers, particularly the impact of homogeneity, has received limited attention. The density disparity between galinstan and the polymer matrix (6.44 g cm^-3 compared to 0.97 g cm^-3) results in the settling of galinstan droplets before curing, especially in matrices with low viscosity, leading to an inhomogeneous composition that may affect material performance. To address this, an innovative approach was introduced that enabled a spatially uniform (homogeneous) dispersion of galinstan droplets in PDMS while preserving the non-conductive nature of the composites. Work described herein evaluates the influence of homogeneity on electrical and mechanical properties as well as performance of LMPCs as pressure sensors. It was found that homogeneity has minimal effect on permittivity and dielectric loss but exhibits a complex behavior with respect to other parameters, including dielectric strength, which is often exacerbated at higher concentrations (≥50 vol%). These findings provide valuable insight that contributes to improved control over the material properties of LMPCs and expands their potential applications in soft robotics and stretchable electronics.