Princeton engineers have developed an easily scalable 3D printing technique to manufacture soft plastics with programmed stretchiness and flexibility that are also recyclable and inexpensive—qualities not typically combined in commercially manufactured materials.

In an article in the journal Advanced Functional Materials, a team led by Emily Davidson reported that they used a class of widely available polymers called thermoplastic elastomers to create soft 3D printed structures with tunable stiffness. Engineers can design the print path used by the 3D printer to program the plastic’s physical properties so that a device can stretch and flex repeatedly in one direction while remaining rigid in another. Davidson, an assistant professor of chemical and biological engineering, said this approach to engineering soft architected materials could have many uses, such as soft robots, medical devices and prosthetics, strong lightweight helmets, and custom high-performance shoe soles.

“The elastomer we are using forms nanostructures that we are able to control,” Davidson said. This allows designers a great degree of control over finished products.  “We can create materials that have tailored properties in different directions.”