Structure Of Elastomers Research Articles

Effect of Part Size, Displacement Rate, and Aging on Compressive Properties of Elastomeric Parts of Different Unit Cell Topologies Formed by Vat Photopolymerization Additive Manufacturing

Due to its ability to achieve geometric complexity at high resolution and low length scales, additive manufacturing (AM) has increasingly been used for fabricating cellular structures (e.g., foams and lattices) for a variety of applications. Specifically, elastomeric cellular structures offer tunability of compliance as well as energy absorption and dissipation characteristics. However, there are limited data available on compression properties for printed elastomeric cellular structures of different designs and testing parameters. In this work, the authors evaluate how unit cell topology, part size, the rate of compression, and aging affect the compressive response of polyurethane-based simple cubic, body-centered, and gyroid structures formed by vat photopolymerization AM. Finite element simulations incorporating hyperelastic and viscoelastic models were used to describe the data, and the simulated results compared well with the experimental data. Of the designs tested, only the parts with the body-centered unit cell exhibited differences in stress–strain responses at different part sizes. Of the compression rates tested, the highest displacement rate (1000 mm/min) often caused stiffer compressive behavior, indicating deviation from the quasi-static assumption and approaching the intermediate rate response. The cellular structures did not change in compression properties across five weeks of aging time, which is desirable for cushioning applications. This work advances knowledge on the structure–property relationships of printed elastomeric cellular materials, which will enable more predictable compressive properties that can be traced to specific unit cell designs.

Architected Design and Fabrication of Soft Mechanical Metamaterials

This study proposes a systematic design approach to 3D print soft mechanical metamaterials by tuning material flow behavior and using optimal toolpaths and print parameters. Planar printing tool paths, utilized in layer‐by‐layer printing such as fused deposition modeling (FDM) and prevalently used in most slicing algorithms, severely limit the realization of complex topologies required in metamaterials. Utilizing parametric design principles, the proposed approach employs discrete and continuous 3D freeform tool paths for supported and unsupported direct ink writing (DIW) of elastomeric structures. The resulting textured, soft topologies significantly enhance the performance of various mechanisms in soft robotics and impact energy‐absorbing wearable devices. Various bioinspired structures such as cilia, webs, leaf‐like structures, and lattices are explored using extrusion‐based silicone 3D printing, achieving features with high aspect ratios (L/D ≤ 12) without support. These complex structures are challenging to 3D print using conventional planar toolpaths. To demonstrate the enhanced functionalities enabled by these new topologies, cilia arrays added to suction cups increased the pull‐off forces by 18%. Additionally, 3D‐printed elastomeric lattice slabs used as energy‐absorbing structures reduced the maximum impact peak forces by 85%. Further functionalities, including magnetic, thermochromic, and signal transmission properties, are also showcased using functional soft mechanical metamaterials.

Direct Ink Writing 3D Printing Elastomeric Polyurethane Aided by Cellulose Nanofibrils.

3D printing of a flexible polyurethane elastomer is highly demandable for its potential to revolutionize industries ranging from footwear to soft robotics thanks to its exceptional design flexibility and elasticity performance. Nevertheless, conventional methods like fused deposition modeling (FDM) and vat photopolymerization (VPP) polyurethane 3D printing typically limit material options to thermoplastic or photocurable polyurethanes. In this research, a water-borne polyurethane ink was synthesized for direct ink writing (DIW) 3D printing through the incorporation of cellulose nanofibrils (CNFs), enabling direct printing of complex, monolithic elastomeric structures at room temperature that can maintain the designed structure. Additionally, a solvent-induced fast solidification (SIFS) method was introduced to facilitate room-temperature curing and enhance mechanical properties. The 3D-printed WPU structures demonstrated strong interfacial adhesion, exhibiting high ultimate tensile strength of up to 22 MPa and an elongation at break of 951%. The 3D-printed WPU structures also demonstrated outstanding resilience and durability, capable of enduring more than 100 cycles of compression and tension as well as withstanding vehicle crushing and heavy lifting. This method also shows suitability for 3D printing complex structures such as a vase and an octopus.

Microstructure phase analysis and process optimization of ZL205A metal mold casting

In this paper, we take an elastomeric transmission structure part made of ZL205A alloy as the research object, and use the metal type gravity casting technology for casting trial production, analyze the quality and mechanical properties of the molded parts of ZL205A alloy parts under different process parameters, optimize the casting process parameters, get the optimal combination of process parameters, and obtain large ZL205A castings with less internal quality defects and high mechanical properties.

Advanced Flexible Physical Sensors with Independent Detection Mechanisms of Pressure and Strain Stimuli for Overcoming Signal Interference.

Flexible and wearable physical sensors have gained significant interest owing to their potential in attachable devices, electronic skin, and multipurpose sensors. The physical stimuli of these sensors typically consist of vertically and horizontally applied pressures and strains, respectively. However, owing to their similar response characteristics, interference occurs between the two types of signals detected, complicating the distinction between pressure and strain stimuli, leading to inaccurate data interpretation and reduced sensor specificity. Therefore, we developed a dual-sensing-mode physical sensor with separate response mechanisms for the two types of physical stimuli based on a unique structural design that can independently induce changes in the piezocapacitance and piezoresistance for pressure and strain stimuli, respectively. The asterisk-shaped piezoresistive pathway (electrode), designed for multifunctionality, effectively detected the intensity and direction of tensile deformation, and an elastomeric sponge structure positioned between the two electrodes detected the pressure signals via changes in capacitance. This dual-sensing-mode sensor offers clearer signal differentiation and enhanced multifunctionality compared to those of traditional single-mode sensors. Additionally, extensive experimentation demonstrated that our sensor has a good sensitivity, high linearity, and stability in detecting signals, proving its applicability for sophisticated monitoring and control tasks that require the differential detection between pressure and deformation signals.

A novel high-molecule inorganic composite material with excellent elasticity and toughness used in tunnel isolation – Material design and basic mechanical properties

Cross-sea engineering plays a crucial role in the advancement of human society. However, due to geological constraints, cross-sea tunnels, as the primary infrastructure of such projects, are prone to instability and compromised safety during severe seismic events. Existing tunnel isolation materials face challenges such as susceptibility to cracking and difficulty in withstanding cyclic loads. Therefore, the development of tunnel isolation materials with strong elasticity and toughness is of significant importance. This study addresses this need by developing a high-elasticity, super-tough polymer-inorganic composite tunnel isolation material. Drawing on the microphase separation structure of polyurethane elastomers and polymer-based composite material interfaces, the innovative material was synthesized and characterized. Uniaxial and cyclic loading tests were conducted to evaluate its mechanical behavior, while scanning electron microscopy (SEM) and atomic force microscopy (AFM) were employed to examine filler-polyurethane matrix bonding, microstructural changes, and interface modifications. These analyses revealed the synergistic mechanisms of the composite components. Results demonstrated significant enhancements in compressive performance and unit volume energy consumption, with the elastic modulus controllable at approximately 10 MPa, and the strain recovery rate stabilizing at 82 %. Moreover, a mix design model was developed for predicting compressive strength, elastic modulus, tensile strength, and elongation at break concerning PVA fiber content.

Tailoring molecular structure and electromechanical properties of polydimethylsiloxane elastomer for enhanced energy conversion efficiency

AbstractThe molecular structure of dielectric elastomers dictates their mechanical, electrical, and properties to react under external stimuli, influencing their suitability for applications such as actuators, sensors, and energy harvesting devices. The molecular structure of polymers can be tailored by incorporating plasticizers and particulate fillers to achieve multifunctional properties. However, achieving a balance between flexibility and maintaining mechanical strength due to incorporation of fillers induced phase separation and compromised intermolecular interactions remains challenging. In the present work, polydimethylsiloxane (PDMS) composites are synthesized using plasticizer and particulate fillers, polyethylene glycol (H‐(OCH2CH2)nOH) and titanium diboride (TiB2) respectively in various concentrations using shear mixing and doctor blade casting technique. Molecular structure of synthesized PDMS composite is confirmed by observing peaks of Raman spectra sift, which exhibits robust CO bonds dominating for both fillers. Chain entanglement due to filler incorporation significantly affects the crosslink density of PDMS composite, it increases with the concentration of plasticizer and possesses inverse relation for particulate. Furthermore, interdependence of the filler types and concentration are found on the mechanical as well as electrical properties. The specific deformation energy exhibits a significant increase of 118.9% when comparing particulate to the plasticizer at concentration of 8 wt.%. Although plasticizer increases the actuation strain and energy conversion efficiency but decreases the electrical breakdown voltage in comparison to particulate. By systematically varying fillers concentration, subtle changes in multifunctional properties are achieved. Overall, this investigation provides a framework for tailoring dielectric elastomer composites with desired electromechanical characteristics through the amalgamation of filler types and crosslinking densities, all intricately tied to the molecular architecture for electromechanical sensors.Highlights Filler incorporation changes DE molecular structure and materials properties. Formation of additional bonds and micro‐capacitors in DE enhances capacitance. Actuation strain in DE depends on filler type and concentration. Energy conversion efficiency varies with the concentration of filler.

Structure, morphology, and properties of aliphatic polyurethane elastomers from bio‐based 1,3‐propanediol

AbstractThe utilization of biomass resources in the production of bio‐based or bio‐recycled polyurethanes (PUs) enhances the sustainable development and eco‐friendliness of PU. Herein, a series of new bio‐based aliphatic poly(propylene dicarboxylate) diols were synthesized using bio‐based 1,3‐propanediol (bio‐PDO) and aliphatic dicarboxylic acids with different chain lengths. These bio‐based polyester diols and 1,4‐butanediol (BDO) reacted with 4,4′‐dicyclohexylmethane diisocyanate to produce aliphatic PU elastomers (PUEs). The study aimed to evaluate the impact of the structure of poly(propylene dicarboxylate) diols on the architecture, morphology, mechanical properties, and degradation of PUEs, thereby expanding the application of bio‐PDO. The results indicate a strong correlation between the degree of microphase separation, tensile properties, and degradation behavior of the synthesized PUEs and the number of methylene groups in the repeating unit of the poly(propylene dicarboxylate) diols. Notably, the PUE derived from poly(propylene pimelate) diol demonstrates the highest level of microphase separation and superior elasticity properties because of the high flexibility of the polyester. On the other hand, PUE prepared from poly(propylene succinate) diol exhibits the fastest degradation performance due to its high density of ester groups. Bio‐PDO based polyester diols show significant potential as raw materials for PUEs with biodegradable and adjustable mechanical properties.Highlights Poly(propylene dicarboxylate) diols were prepared from bio‐based 1,3‐propanediol. The poly(propylene dicarboxylate) diols based polyurethane elastomers (PUEs) have high tensile strength (>22 MPa) and elongation at break (>920%). The morphology, mechanical properties and degradation of PUEs are highly related to the structure of the poly(propylene dicarboxylate) diols. The increasing repeating unit length of the poly(propylene dicarboxylate) diols increases elastic recovery of PUEs.

Dynamic characteristics optimization of elastomer for resistance strain force sensor

PurposeThis paper aims to provide a new method to study and improve the dynamic characteristics of the four-column resistance strain force sensor through the elastomer structure design and optimization.Design/methodology/approachBased on the mechanism analysis method, the authors first present a dynamic characteristic model of the four-column resistance strain force sensors’ elastomer. Then, the authors verified and modified the model according to the Solidworks finite element simulation results. Finally, the authors designed and optimized two types of four-column elastomers based on the dynamic characteristic model and verified the improvement of sensor dynamic performance through a hammer knock dynamic experiment.FindingsThe Solidworks finite element simulation and hammer knock dynamic experiment results show that the relative error of the model is less than 10%, which confirms the accuracy of the model. The dynamic performance of the sensors based on the model can be improved by more than 30%, which is a great improvement in sensor dynamic performance.Originality/valueThe authors first present a dynamic characteristic model of the four-column elastomer and optimize the four-column sensors successfully based on the mechanism analysis method. And a new method to study and improve the dynamic characteristics of the resistance is provided.

Stretchable stiffness-tuning of liquid metal elastomer triggered by homocrystal seeds

The hybrid structure of liquid metal units and organic elastomer has huge potential in achieving stretchable and reversible stiffness regulation, while such tuning is often restrained by high energy consumption for liquid metal solidification. Here, we conceive to solve the above challenge through introducing the fully leveraging interaction between supercooled liquid metal and homocrystal seeds within silicone elastomer. It is disclosed that the supercooled liquid metal-elastomer can maintain an extremely stable soft state until the supercooling is eliminated by modulating the mechanical force and elastomer deformation. This circumvents the utilization of intricate refrigeration equipment and offers a highly efficient and concise strategy for stiffness regulation. Moreover, conceptual experiments were performed to demonstrate the practical values of this technology through designing and testing the new shape memory materials, temperature-sensitive switches, and controlled circuits. The solidification mechanisms of supercooled Ga triggered by homocrystal seeds were interpreted. Overall, the present finding has generalized purposes and holds promise to significantly extend the theoretical and technological categories of classical stiffness tunable materials.

4D Fabrication of Two-Way Shape Memory Polymeric Composites by Electrospinning and Melt Electrowriting.

This work presents a new method for 4D fabrication of two-way shape memory materials that are capable of reversible shapeshifting right after manufacturing, upon application of proper heating and cooling cycles. The innovative solution presented here consists in the combination of highly stretched electrospun shape memory polymer (SMP) nanofibers with a melt electrowritten elastomer. More specifically, the stretched nanofibers are made of a biocompatible thermoplastic polyurethane (TPU) with crystallizable soft segments, undergoing melt-induced contraction and crystallization-induced elongation upon heating and cooling, respectively. Reversible actuation during crystallization becomes possible due to the elastic recovery of the elastomer component, obtained by melt electrowriting of a commercial TPU filament. Thanks to the design freedom offered by additive manufacturing, the elastomer structure also has the role of guiding the shape transformation. Electrospinning and melt electrowriting process parameters are set up so to obtain smart 4D objects capable of two-way shape memory effect (SME), and the possibility of reversible and repeatable actuation is demonstrated. The two components are then combined in different proportions with the aim of tailoring the two-way SME, taking into account the effect of design parameters such as the SMP content, the elastomer pattern, and the composite thickness.

Research on the Thermal Aging Performance of a GAP-Based Polyurethane Elastomer.

Glycidyl azide polymer (GAP)-based polyurethane is an ideal elastomeric matrix for high-energy, low-smoke, and insensitive solid propellants. As the skeleton structure of GAP propellants, changes in the structure and properties of GAP elastomers during aging lead to the deterioration of propellant performance (especially in relation to mechanical properties), which causes safety risks. A high-temperature-accelerated aging experiment (70 °C) on a GAP elastomer was conducted. The evolution of the microstructure of the GAP elastomer system was analyzed by Fourier-transform infrared spectroscopy (FTIR) and nuclear magnetic resonance spectroscopy (NMR), and variations in the macroscopic properties were analyzed by the hardness test and the uniaxial tensile test. The experimental results showed that thermal aging of the GAP elastomer is a coupled process of multiple chemical reactions. The azide groups, urethane groups, and ether bonds were the weak links in the network structure, breaking during the aging process, and the crosslinking density rose and then decreased. Macroscopic properties also showed segmented changes. The aging process was divided into three stages: post-curing (stage one); when the crosslinked network began to break (stage two), and when the crosslinked network was destroyed (stage three). Changes in the microstructure and macroscopic properties were consistent. This work is of great significance for exploring the aging mechanism of GAP propellants and extending their storage life.

Melt electrowriting enabled 3D liquid crystal elastomer structures for cross-scale actuators and temperature field sensors.

Liquid crystal elastomers (LCEs) have garnered attention for their remarkable reversible strains under various stimuli. Early studies on LCEs mainly focused on basic dimensional changes in macrostructures or quasi-three-dimensional (3D) microstructures. However, fabricating complex 3D microstructures and cross-scale LCE-based structures has remained challenging. In this study, we report a compatible method named melt electrowriting (MEW) to fabricate LCE-based microfiber actuators and various 3D actuators on the micrometer to centimeter scales. By controlling printing parameters, these actuators were fabricated with high resolutions (4.5 to 60 μm), actuation strains (10 to 55%), and a maximum work density of 160 J/kg. In addition, through the integration of a deep learning-based model, we demonstrated the application of LCE materials in temperature field sensing. Large-scale, real-time, LCE grid-based spatial temperature field sensors have been designed, exhibiting a low response time of less than 42 ms and a high precision of 94.79%.

Additive manufacturing of thermoplastic elastomer structures using dual material core-shell filaments

Filament-based flexible material extrusion additive manufacturing is highly desirable yet faces critical challenges such as limited print resolution and repeatability. To enhance printability of a thermoplastic elastomer (TPE), a series of core-shell filaments comprising a TPE shell (Shore hardness 75 A) and a rigid ABS core are fabricated, with the ABS volume fraction varying from 11% to 78%. The presence of an ABS core imparts rigidity to the filament to inhibit buckling and allow for successful high-fidelity 3D printing. Rheological characterizations of TPE and ABS using capillary and parallel-plate viscometry point to the optimized extrusion parameters suitable for filament coextrusion, printability, and wettability between the print interfaces. Complex benchmark geometries are printed to verify the print resolution. Printed specimens with less than 20% ABS preserve the shore hardness of 75 A, providing flexibility and a soft touch to the printed structures. Izod impact, 3-point bending, and tensile tests reveal tunable mechanical properties of parts printed in z-direction with ABS+TPE filaments. Lower ABS content exhibits higher flexibility and impact resistance, while higher ABS imparts higher stiffness and tensile strength. Notably, the parts printed with 30–40% ABS exhibit higher toughness and impact strength than specimens composed of ABS or TPE alone. Lastly, a coil spring printed with a ABS+TPE filament exhibits reversible extension up to 120 mm, at least twice the reversible extension of an ABS-printed coil spring.

Sidewinder-Inspired Self-Adjusting, Lateral-Rolling Soft Robots for Autonomous Terrain Exploration.

Helical structures of liquid crystal elastomers (LCEs) hold promise in soft robotics for self-regulated rolling motions. The understanding of their motion paths and potentials for terrain exploration remains limited. This study introduces a self-adjusting, lateral-rolling soft robot inspired by sidewinder snakes. The spring-like LCE helical filaments (HFs) autonomously respond to thermal cues, demonstrating dynamic and sustainable locomotion with adaptive rolling along non-linear paths. By fine-tuning the diameter, pitch, and modulus of the LCE HFs, and the environmental temperature, the movements of the LCE HFs, allowing for exploration of diverse terrains over a 600cm2 area within a few minutes, can be programmed. LCE HFs are showcased to navigate through over nine obstacles, including maze escaping, terrain exploration, target hunting, and successfully surmounting staircases through adaptable rolling.

Reversible Elastomer–Fluid Transitions for Metamorphosic Robots

AbstractEndowing robots with reversible phase transition ability, especially between elastomer and fluid states, can significantly broaden their functionality and applicability. Limited attempts have been made to realize the reversible elastomer–fluid transition. Existing phase transition materials in robotics have over‐hard (≈4 GPa) or over‐soft (≈4 kPa) stiffness in the solid states, which should be further investigated to perform more compliant motions. To address these challenges, a reversible elastomer–fluid transition mechanism enabled by magnetically induced hot melt materials (MIMMs) is presented. The transition principle is explained and material characterizations are conducted. MIMMs‐based metamorphosic robots endow self‐metamorphosing abilities, such as self‐healing, spatial reshaping, self‐division/assembly, and additive manufacturability. When interacting with external environments, MIMMs‐based robots can perform further multifunctional abilities, such as collaborations for structure repairs, swimming by symbiosis with external objects, flowing through a narrow terrain by transiting to fluid, and working with elastomeric structures for stiffness‐variable fluid soft actuators. The proposed elastomer–fluid transitions open a new path for robots to generate more flexible and metamorphosic motions, thereby addressing the cross‐phase transformation challenges that soft robots face.

Simultaneous Visualization of Microscopic Conductivity and Deformation in Conductive Elastomers.

Conductive elastomers are promising for a wide range of applications in many fields due to their unique mechanical and electrical properties, and an understanding of the conductive mechanisms of such materials under deformation is crucial. However, revealing the microscopic conduction mechanism of conductive elastomers is a challenge. In this study, we developed a method that combines in situ deformation nanomechanical atomic force microscopy (AFM) and conductive AFM to successfully and simultaneously characterize the microscopic deformation and microscopic electrical conductivity of nanofiller composite conductive elastomers. With this approach, we visualized the conductive network structure of carbon black and carbon nanotube composite conductive elastomers at the nanoscale, tracked their microscopic response under different compressive strains, and revealed the correlation between microscopic and macroscopic electrical properties. This technique is important for understanding the conductive mechanism of conductive elastomers and improving the design of conductive elastomers.

Effect of silver particles on the crystal structure and the mechanical, optical and antibacterial properties of various polypropylene based plastomers and elastomers

In composite materials consisting of silver particles and a polypropylene matrix, the silver must migrate to the surface of the materials in order to exert on antibacterial effect. Substrates with various crystal structures may have different interactions with the silver particles, which can significantly impact the antibacterial performance. The research described in this paper investigates the influence of silver particles on the crystallization behavior of materials with varying crystallinity capabilities by selecting various polypropylene-based plastics and elastomers (Homopolymer polypropylene (PPH-T03), random poly(propylene/ethylene) copolymers (PPR-YPR503 and PPR-P340R), polyolefin elastomers (VERSIFY3000 (POE-1) and VERSIFY3401 (POE-2)), and ethylene propylene diene monomer for polymers (EPDM4725 and EPDM4770)). The research results indicated that the silver only entered the amorphous regions of the PP rather than entering the crystal regions, where they can more easily migrate to the material surface, resulting in a higher antibacterial effect. Therefore, the antibacterial degree of PP-Ag was as high as 99.9%. Silver can enter the micro-crystals of both the random copolymer polypropylene, (PPR-YPR503, PPR-1) and the random copolymer polypropylene, (PPR-P340R, PPR-2,) with a stronger effect on PPR-2. More silver entered the micro-crystals of PPR-2, and it was difficult for the silver ions to migrate out of the crystalline regions to exhibit antibacterial properties. The antibacterial degree of PPR-1-Ag was higher than that of PPR-2-Ag (77.8% vs. 66.7%). Similarly, silver had a greater impact on the lamellar structure of the polyolefin elastomer (VERSIFY3401, POE-2) compared to the polyolefin elastomer (VERSIFY3000, POE-1). In comparison with POE-2-Ag, POE-1-Ag exhibited a higher antibacterial degree (79.6% vs. 57.4%). Research on the two types of ethylene propylene diene monomer (EPDM) composite materials indicated that EPDM-1 exhibited a lower Mooney viscosity and poorer flowability. The EPDM-1 tended to encapsulate the silver within its molecular chains, thereby impeding the migration of silver to the surface. The optical performance analysis indicated that silver antibacterial agents had little impact on the optical properties of PP-Ag, PPR-1, PPR-2, POE-1, POE-2 and the EPDMs. We suggest that this research provides theoretical guidance for selecting highly antibacterial polypropylene materials.

Degradable biomedical elastomers: paving the future of tissue repair and regenerative medicine.

Degradable biomedical elastomers (DBE), characterized by controlled biodegradability, excellent biocompatibility, tailored elasticity, and favorable network design and processability, have become indispensable in tissue repair. This review critically examines the recent advances of biodegradable elastomers for tissue repair, focusing mainly on degradation mechanisms and evaluation, synthesis and crosslinking methods, microstructure design, processing techniques, and tissue repair applications. The review explores the material composition and cross-linking methods of elastomers used in tissue repair, addressing chemistry-related challenges and structural design considerations. In addition, this review focuses on the processing methods of two- and three-dimensional structures of elastomers, and systematically discusses the contribution of processing methods such as solvent casting, electrostatic spinning, and three-/four-dimensional printing of DBE. Furthermore, we describe recent advances in tissue repair using DBE, and include advances achieved in regenerating different tissues, including nerves, tendons, muscle, cardiac, and bone, highlighting their efficacy and versatility. The review concludes by discussing the current challenges in material selection, biodegradation, bioactivation, and manufacturing in tissue repair, and suggests future research directions. This concise yet comprehensive analysis aims to provide valuable insights and technical guidance for advances in DBE for tissue engineering.

Morphology of poly-3-hexyl-thiophene blends with styrene-isoprene-styrene block-copolymer elastomers from X-ray and neutron scattering.

The nano- and micron scale morphology of poly(3-hexylthiophene) (P3HT) and polystyrene-block-polyisoprene-block-polystyrene (PS-PI-PS) elastomeric blends is investigated through the use of ultra-small and small angle X-ray and neutron scattering (USAXS, SAXS, SANS). It is demonstrated that loading P3HT into elastomer matrices is possible with little distortion of the elastomeric structure up to a loading of ∼5 wt%. Increased loadings of conjugated polymer is found to significantly distort the matrix structure. Changes in processing conditions are also found to affect the blend morphology with especially strong dependence on processing temperature. Processing temperatures above the glass transition temperature (Tg) of polystyrene and the melting temperature (Tm) of the conjugated polymer additive (P3HT) creates significantly more organized mesophase domains. P3HT blends with PS-PI-PS can also be flow-aligned through processing, which results in an anisotropic structure that could be useful for the generation of anisotropic properties (e.g. conductivity). Moreover, the extent of flow alignment is significantly affected by the P3HT loading in the PS-PI-PS matrix. The work adds insight to the morphological understanding of a complex P3HT and PS-PI-PS polymer blend as conjugated polymer is added to the system. We also provide studies isolating the effect of processing changes aiding in the understanding of the structural changes in this elastomeric conjugated polymer blend.