Direct Assembly of Multilayered Core–Shell Structured Composites for Self‐Sensing and Soft Robotic Fingers

Abstract The growing demand for intelligent, adaptive gripping in soft robotics has driven interest in advanced manufacturing techniques for self‐sensing, stiffness‐programmable composites. Traditional fabrication methods often involve complex multi‐step processes, limiting efficiency and functionality. In this work, a novel core‐programmable coaxial direct ink writing (CPC‐DIW) technique is presented for the rapid, one‐step fabrication of soft robotic fingers with programmable stiffness and integrated self‐sensing capabilities. The basic structure consists of a lower‐modulus silicone core encapsulated in a higher‐modulus silicone shell, forming coaxial fibers that provide tunable stiffness. Conductive silicone alternatively embedded within the fiber's core enables real‐time strain sensing without the need for external sensors. This seamless integration of actuation and sensing components eliminates mechanical mismatches, enhancing durability and functionality. Finite element analysis and experimental results confirm the soft fingers’ precise, adaptive control, demonstrating the potential of CPC‐DIW for direct manufacturing of multifunctional soft robotic systems. This approach provides an effective strategy for manufacturing intelligent soft grippers with precise control and unprecedented versatility.