Hard magnetics and soft materials—a synergy

Hard-magnetic soft materials (hMSMs) are smart composites that consist of a mechanically soft polymer matrix impregnated with mechanically hard magnetic filler particles. This dual-phase composition renders them with exceptional magneto-mechanical properties that allow them to undergo large reversible deformations under the influence of external magnetic fields. Over the last decade, hMSMs have found extensive applications in soft robotics, adaptive structures, and biomedical devices. However, despite their widespread utility, they pose considerable challenges in fabrication and magneto-mechanical characterization owing to their multi-phase nature, miniature length scales, and nonlinear material behavior. Although noteworthy attempts have been made to understand their coupled nature, the rudimentary concepts of inter-phase interactions that give rise to their mechanical nonlinearity remain insufficiently understood, and this impedes their further advancements. This holistic review addresses these standalone concepts and bridges the gaps by providing a thorough examination of their myriad fabrication techniques, applications, and experimental, and modeling approaches. Specifically, the review presents a wide spectrum of fabrication techniques, ranging from traditional molding to cutting-edge four-dimensional printing, and their unbounded prospects in diverse fields of research. The review covers various modeling approaches, including continuum mechanical frameworks encompassing phenomenological and homogenization models, as well as microstructural models. Additionally, it addresses emerging techniques like machine learning-based modeling in the context of hMSMs. Finally, the expansive landscape of these promising material systems is provided for a better understanding and prospective research.

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