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Fracture-induced patterns are ubiquitous in nature and diverse patterns1,2 are found in many inanimate objects such as dried mud and rocks. Cellular or hierarchical crack patterns are also observed on the surfaces of living creatures, occasionally determining appearances3,4. In order to increase our understanding of these problems, the formation of crack arrays in multilayers has been extensively studied as a fundamental problem in fracture mechanics5,6,7,8,9,10,11. Using this knowledge of the theoretical background, artificial crack patterning on layered materials has been achieved for practical applications in micro/nano-fabrication12,13,14,15,16. Nevertheless, cracks are typically difficult to control precisely as a means of manufacturing, because they tend to initiate from random defects created during processing. Carefully-controlled conditions, such as those that can be obtained in a clean-room, are required to create systems in which any natural defects are small and few enough for fracture to be controlled by the subsequent deliberate introduction of artificial flaws17,18. While it has been shown that such an initiation-controlled approach can be used to control fracture patterns18, this technique has only been applied specifically to materials in which intrinsic flaws are kept below a minimum threshold and is not robust against accidental introduction of damage or use with soft materials. Here, we report an alternative and more general propagation-controlled approach for precision cracking of multi-layered materials; one that is relatively robust and not sensitive to the nature of the flaws in the system. While our experiments focus on thin films supported by silicone elastomers, the general principles elucidated by the observations are applicable to a broad range of multilayered systems. To our knowledge, this is the first approach to control crack patterns by propagation control, rather than initiation control and it is a technique that can also be used on multi-layered soft materials, not prepared under clean-room conditions.
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Although uniform crack spacing was achieved in Regime II, individual cracks in paired notches occasionally generated multiple branches. Presumably, cracks simultaneously propagated from opposing sides and met to form misaligned cracks (Fig. 3a). To reduce the incidence of such imperfections, we tested un-paired notch configurations that initiate cracks from one side only. However, cracks starting from the notched side occasionally did not propagate to the other side; and intrinsic defects along the un-patterned side were occasionally activated and extended to the notched side (Fig. 3b). To address these imperfections, alternating notch structures were tested. This configuration significantly improved crack quality and cracks propagated only from the notches (Fig. 3c). The problem with paired notches is that each notch in a pair will be the same distance from a fully channeled crack. Cracks will be equally likely to propagate from either notch. A similar problem exists with notches on only one side. Since the notches only serve to control crack propagation and shield flaws at neighboring sites, channel cracks can equally likely grow from the un-notched side as from the notched side. The advantage of the alternating notches is that each notch on each side provides a single site from which it is thermo-dynamically possible for a crack to channel at a given level of strain and current crack pattern. 2ff7e9595c
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