A 3D‐Printed Blister Test Platform for Quantifying Biointerface Adhesion Mechanisms

ABSTRACT Engineering robust soft–rigid interfaces remains a central challenge in functional materials, limiting the durability of hydrogel‐based implants, biointegrated systems, and hybrid composites. Although adhesion is often treated as an intrinsic material constant, failure in hydrated soft matter is governed by nonlinear deformation, geometry‐coupled energy dissipation, and dynamic mechanical feedback, which are poorly captured by indentation‐based and lap‐shear techniques. Here, we introduce a programmable blister‐based mechanointerrogation platform that converts a classical adhesion assay into a predictive, energy‐resolved framework for large‐deformation fracture at soft–rigid junctions. By integrating precision pressure control, in‐situ optical morphometry, and hyperelastic modeling, the system directly extracts adhesion energy ( G ) and R‐curve toughening rate ( m ) under fully hydrated conditions. Using collagen hydrogels as a model fibrillar network, we reveal a tunable transition between intrinsic cohesive strengthening and extrinsic interfacial toughening driven by fibril bridging and mechanical interlocking. Modulating network density and substrate microtopography increases m and uncovers a bimodal failure regime governed by competition between cohesion and adhesion. Overall, these findings pave the way to establish a predictive, energy‐guided platform for the design and utilization of robust soft–rigid interfaces in biointegrated material systems.