Aerosol Jet Printing (AJP) is an emerging contactless direct write approach aimed at the production of fine features on a wide range of substrates. Originally developed for the manufacture of electronic circuitry, the technology has been explored for a range of applications, including, active and passive electronic components, actuators, sensors, as well as a variety of selective chemical and biological responses. Freeform deposition, coupled with a relatively large stand-off distance, is enabling researchers to produce devices with increased geometric complexity compared to conventional manufacturing or more commonly used direct write approaches. Wide material compatibility, high resolution and independence of orientation have provided novelty in a number of applications when AJP is conducted as a digitally driven approach for integrated manufacture. This overview of the technology will summarise the underlying principles of AJP, review applications of the technology and discuss the hurdles to more widespread industry adoption. Finally, this paper will hypothesise where gains may be realised through this assistive manufacturing process.

With the maturity of surgical robotic systems based on traditional rigid-link principles, the rate of progress slowed as limits of size and controllable degrees of freedom were reached. Continuum robots came with the potential to deliver a step change in the next generation of medical devices, by providing better access, safer interactions and making new procedures possible. Over the last few years, several continuum robotic systems have been launched commercially and have been increasingly adopted in hospitals. Despite the clear progress achieved, continuum robots still suffer from design complexity hindering their dexterity and scalability. Recent advances in actuation methods have looked to address this issue, offering alternatives to commonly employed approaches. Additionally, continuum structures introduce significant complexity in modelling, sensing, control and fabrication; topics which are of particular focus in the robotics community. It is, therefore, the aim of the presented work to highlight the pertinent areas of active research and to discuss the challenges to be addressed before the potential of continuum robots as medical devices may be fully realised.

Soft robotics is a fast growing field of engineering where there are significant opportunities to realize new forms of actuation and sensing. However, there is also a challenge to translate some of the lab-based developments into a robust industrial manufacturing process. Linked to this is also the opportunity to create new forms of functionality in soft robotic devices by employing a flexible, digital manufacturing process for their creation. Overcoming these hurdles, and unlocking the possibilities for greater functionality, is likely to be a key enabler for wider applications and adoption of soft robotics in practical applications. We present a system of computer-controlled Aerosol Jet Printing that will enable complex soft robotic structures to be manufactured. The process is demonstrated through the deposition of a carbon-based conductive ink on to elastomeric substrates for high resolution, conformal and multilayer patterning. Functional demonstrators, in the form of a dielectric elastomer actuator and strain sensor, are produced to showcase the potential of the technique. *

The performance of soft sensing and actuation devices is dependent on their design, the electro‐mechanical response of materials, and the ability to copattern structural and functional features. For film based soft structures, such as wearable sensors and artificial muscles, manufacturing challenges exist that prevent the translation of technology from laboratory to practical application. In this work, a hybrid manufacturing technique is presented that integrates electro‐hydrodynamic and aerosol jet deposition to print multilayer, multimaterial structures. The combined approach overcomes the respective rheological constraints of the individual processes, while presenting a pathway to higher resolution computer‐controlled patterning. Electro‐hydrodynamic deposition of a polydimethylsiloxane elastomer is demonstrated and characterized, before being combined with aerosol jet deposition of a graphene platelet ink to produce functional devices. A proof‐of‐concept, multilayer capacitive sensor is presented as a first demonstration of the manufacturing technology.

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