Conventional deformable wheel systems in robots and other mechatronic systems face significant challenges in achieving miniaturization, intelligence, and integration. To address these issues, we propose a novel integrated structural design method and four-dimensional printing strategy for deformable wheels capable of shaping among multiple programmable direct-driven deformation configurations. The load-bearing capacity of the printed wheel is strengthened by employing deformed components in various locations and actuated states. Additionally, a novel analytical design method is presented to determine the structure, actuation, and deformation parameters of each component under complex coupled deformation. Our findings reveal that the designed wheel can transform into three different configurations, exhibiting desired deformations of 12.5% in the radial direction and 19.6% in the axial direction. It also demonstrates robust deformation behavior and structural stability under multi-directional loads. By integrating a terrain sensing system, the designed wheel exhibits highly adaptive deformation capabilities on various terrains, showing great potential for exploring complex environments.

The development of projection-based stereolithography additive manufacturing techniques and magnetic photosensitive resins has provided a powerful approach to fabricate miniaturized magnetic functional devices with complex three-dimensional spatial structures. However, the present magnetic photosensitive resins face great challenges in the trade-off between high ferromagnetism and excellent printing quality. To address these challenges, we develop a novel NdFeB-Fe₃O₄ magnetic photosensitive resin comprising 20 wt.% solid loading of magnetic particles, which can be used to fabricate high-precision and ferromagnetic functional devices via micro-continuous liquid interface production process. This resin combining ferromagnetic NdFeB microparticles and strongly absorbing Fe₃O₄ nanoparticles is able to provide ferromagnetic capabilities and excellent printing quality simultaneously compared to both existing soft and hard magnetic photosensitive resins. The established penetration depth model reveals the effect of particle size, solid loading, and absorbance on the curing characteristics of magnetic photosensitive resin. A high-precision forming and ferromagnetic capability of the NdFeB-Fe₃O₄ magnetic photosensitive resin are comprehensively demonstrated. It is found that the photosensitive resin (NdFeB:Fe₃O₄ = 1:1) can print samples with sub-40 μm fine features, reduced by 87% compared to existing hard magnetic photosensitive resin, and exhibits significantly enhanced coercivity and remanence in comparison with existing soft magnetic photosensitive resins, showing by an increase of 24 times and 6 times, respectively. The reported NdFeB-Fe₃O₄ magnetic photosensitive resin is anticipated to provide a new functional material for the design and manufacture of next-generation micro-robotics, electromagnetic sensor, and magneto-thermal devices.