Asymmetric toughening in the lap shear of metamaterial structural adhesives

Metamaterial structural adhesives (MSAs), whose properties primarily rely on structural design, offer promising advantages over traditional adhesives, including asymmetric, switchable, and programmable adhesion. However, the effects of thick backing structures on the adhesion properties remain largely underexplored. Herein, we investigate a series of MSAs featuring a thin adhesive layer and an asymmetric thick beam structure terminated with a film. We conduct lap shear tests on the MSAs with varying terminated film thickness (t) and beam tilting angle (θ) while maintaining an identical adhesive layer. For MSAs with a thick terminated film (t = 2 mm), the effective adhesion energy is double that of solid samples without compromising shear strength, consistent with the theoretical predictions based on the crack trapping mechanism. Conversely, for MSAs with a thin terminated film (t = 0.5 mm), the maximum shear strength and effective adhesion energy are ∼2.8 times and ∼18.6 times those of solid samples, respectively, deviating significantly from the theoretical predictions due to new crack initiations. We further explore adhesion asymmetry by tuning the beam tilting angle (θ). For MSAs with highly tilted beams (θ = 70.3°), we achieve a maximum adhesion strength asymmetry factor of τ₂/τ₁ ∼ 2.2 for a thick terminated film (t = 2 mm), and a maximum adhesion energy asymmetry factor of Γ₁/Γ₂ ∼ 5.3 for a thin terminated film (t = 0.5 mm). Our work provides useful insights for designing metamaterial structural adhesives suitable for robotic grippers, wall-climbing robots, and wearable devices, particularly those requiring asymmetric, switchable, and stimuli-responsive adhesion, and adhesives on rough surfaces or in underwater conditions.