Liquid Crystal Elastomers Filaments for Adaptive Textiles and Soft Robotics: A Processing-Centric Review

Liquid crystal elastomers (LCEs) combine mesogenic orientational order with rubber elasticity, enabling large, reversible actuation for applications in soft robotics, smart textiles, artificial muscles, and adaptive structures. However, translating LCEs from lab-scale films to continuous, industrially relevant filaments remains constrained by fragmented and non-standardized processing strategies. This review presents an integrated synthesis-to-filament framework linking molecular formulation, rheological conditioning, flow-induced alignment, and network fixation. Benchmark systems based on diacrylate mesogens (RM82/257) and triazine crosslinkers (TATATO) are highlighted, where staged Michael-addition produces shear-thinning oligomers (30-200 Pa s) suitable for extrusion, wet spinning, and melt drawing. Distinct viscosity regimes (low, intermediate, and high) are systematically compared, clarifying their effects on filament stability, alignment retention, and actuation performance. We further examine how mesogen architecture, crosslinker geometry, and photopolymerization kinetics define processable viscosity windows and defect-free filament formation. The coupled interplay between viscosity, extrusion pressure, and flow rate is emphasized to establish realistic and scalable processing windows. Processing strategies, including nozzle design, draw ratios, in-line UV curing, and thermal annealing, are outlined for encoding anisotropy and improving durability. The review concludes with a roadmap for standardized processing metrics, sustainable chemistries, and emerging machine learning-assisted formulation strategies to enable scalable LCE filament manufacturing.