Researchers at Rice University have developed a new approach to enhancing the reliability and functionality of sheet-based fluidic devices—key components in soft robotics and wearable sensors.
Image Credit: mentalmind/Shutterstock.com
These flexible, lightweight systems are widely used in applications ranging from medical wearables to autonomous robotics, but managing failure in these devices remains a challenge. The new study from Rice’s George R. Brown School of Engineering and Computing explores how programmed failure in heat-sealable, sheet-based systems can enhance device protection, enable complex action sequencing, and streamline control mechanisms.
Put simply, we are making soft, flexible machines smarter by designing their internal components to fail intentionally in a well-understood manner. In doing so, the resulting systems can recover from pressure surges and even complete multiple tasks using a single control input.
Daniel J. Preston, Study Corresponding Author and Assistant Professor, Mechanical Engineering, Rice University
The research, published in Cell Reports Physical Science, examines how thin, flexible sheets—patterned and selectively bonded to create internal fluidic networks—respond to pressure changes and, more specifically, how they fail when internal pressures become too high.
By studying adhesion between textile sheets, the team was able to predict maximum operating pressures and determine how factors like bond geometry and material selection influence performance.
Our study provides a framework for predicting and leveraging failure in sheet-based fluidic systems. Rather than seeing failure as a limitation, we explored how it can be used to enhance functionality, making these devices more intelligent and efficient.
Sofia Urbina, Study Co-First Author, GEM Associate Fellow and Second-year Doctoral Student, Rice University
Through rigorous testing—including T-peel tests to measure adhesion strength and burst tests to evaluate failure at elevated pressures—the researchers identified three distinct failure patterns influenced by the thermal bonding step during manufacturing. These phases include an initial stage where bond strength increases with bonding temperature, a plateau where material strength dictates cohesive failure and a final stage where overheating weakens material integrity.
These insights led to the development of a novel “fluidic fuse”—a protective component featuring multiple bonds with different strengths, designed to fail in a controlled manner to prevent system damage from pressure spikes.
“Think of it like an electrical fuse. When the pressure exceeds a set limit, the fuse ‘blows,’ preventing catastrophic damage to the entire system. This fluidic fuse can be easily replaced or even rebonded for reuse,” said Preston.
Beyond protection, these fuses can be strategically placed to trigger sequential actions within a device. In one experiment, a system was designed to first unscrew a light bulb and then lift it out of a socket—all using a single pressure input.
The potential applications extend far beyond the lab. In wearable technology, fluidic networks could be embedded into clothing to provide adaptive support for rehabilitation patients, assist individuals with mobility impairments, and even create new ways to interact through touch. In robotics, the ability to sequence actions with a single input could simplify the design of multifunctional autonomous systems, reducing the need for complex electronic controls.
This research allows for smarter, more responsive sheet-based fluidic devices. By embracing failure as a tool rather than a drawback, we can build systems that are not only more resilient but also more capable.
Adam Broshkevitch, Study Co-First Author, Rice University
Harnessing failure as an asset: How Rice researchers are innovating smarter wearable tech
Video Credit: Rice University
Journal Reference:
Broshkevitch, A., et al. (2025) Programmable failure in heat-sealable sheet-based fluidic devices. Cell Reports Physical Science. doi.org/10.1016/j.xcrp.2025.102437