Conductive polymer composites in soft robotics, flexible sensors and energy storage: Fabrication, applications and challenges

Conductive Polymer Composites (CPCs) have emerged as promising materials with applications in soft robotics, flexible sensors, and energy storage. This review paper begins with a brief introduction to the available polymers and additives in context of CPCs, followed by a classification of the resulting composites, setting the stage for further discussions. Then we sequentially analyze the fabrication techniques and practical applications of CPC in the aforementioned sectors highlighting their performance. Furthermore, the review delves into critical aspects such as failure modes, including interfacial debonding and fatigue, the environmental impact and sustainability of CPCs, considering the source and biodegradability of polymers and the environmental implications of additives. Limitations such as particle leakage in metal-based flexible devices, nanoparticle agglomeration and high cost of modern fabrication techniques have been discussed. Future research directions, including development of cost-effective manufacturing methods and proper encapsulation techniques for flexible devices have been highlighted. • CPCs are used in soft robotics, flexible sensors, and energy storage for their electrical conductivity, mechanical flexibility, and processability. • CPCs are made from polymers with conductive fillers like carbon nanotubes (CNTs), graphene, and metal particles. • Various methods, such as SLS, SLA and electrospinning are used to produce CPCs with good precision and desired properties. • Low-cost fabrication, improved fatigue strength, and encapsulation methods for flexible devices are key for future research.