High-resolution patterning of graphene by screen printing with a silicon stencil for highly flexible printed electronics

Multiscale Transfer Printing via Shape Memory Polymer with High Adhesion and Modulus Switchability

Flexible electronics have gained significant attention as an innovative solution to meet the growing need for information collection from the human body and the environment. However, a critical challenge lies in the need for a transfer printing technique that can fabricate rigid and brittle devices on flexible organic substrates. Here, we develop a multiscale transfer printing technique using an ultraviolet-curable shape memory polymer (SMP) that serves as both the stamp and the receiver substrate. The SMP demonstrates exceptional mechanical performance with toughness at room temperature and remarkable flexibility near its glass transition temperature. The SMP material exhibits an impressive shape recovery ratio and remarkable adhesion switchability. We demonstrate robust transfer printing of diverse objects with different materials and morphologies and in situ transfer of multiscale metallic structures. In addition, the in situ fabricated transparent hyperthermia patches with embedded metal grids are demonstrated, offering potential application in the field of sensors, wearable devices, and electronic skin.

Solution-Processable and Printable Two-Dimensional Transition Metal Dichalcogenide Inks

Two-dimensional (2D) transition metal dichalcogenides (TMDs) with layered crystal structures have been attracting enormous research interest for their atomic thickness, mechanical flexibility, and excellent electronic/optoelectronic properties for applications in diverse technological areas. Solution-processable 2D TMD inks are promising for large-scale production of functional thin films at an affordable cost, using high-throughput solution-based processing techniques such as printing and roll-to-roll fabrications. This paper provides a comprehensive review of the chemical synthesis of solution-processable and printable 2D TMD ink materials and the subsequent assembly into thin films for diverse applications. We start with the chemical principles and protocols of various synthesis methods for 2D TMD nanosheet crystals in the solution phase. The solution-based techniques for depositing ink materials into solid-state thin films are discussed. Then, we review the applications of these solution-processable thin films in diverse technological areas including electronics, optoelectronics, and others. To conclude, a summary of the key scientific/technical challenges and future research opportunities of solution-processable TMD inks is provided.

Recent advances in implantable sensors and electronics using printable materials for advanced healthcare

This review article focuses on the recent printing technological progress in healthcare, underscoring the significant potential of implantable devices across diverse applications. Printing technologies have widespread use in developing health monitoring devices, diagnostic systems, and surgical devices. Recent years have witnessed remarkable progress in fabricating low-profile implantable devices, driven by advancements in printing technologies and nanomaterials. The importance of implantable biosensors and bioelectronics is highlighted, specifically exploring printing tools using bio-printable inks for practical applications, including a detailed examination of fabrication processes and essential parameters. This review also justifies the need for mechanical and electrical compatibility between bioelectronics and biological tissues. In addition to technological aspects, this article delves into the importance of appropriate packaging methods to enhance implantable devices' performance, compatibility, and longevity, which are made possible by integrating cutting-edge printing technology. Collectively, we aim to shed light on the holistic landscape of implantable biosensors and bioelectronics, showcasing their evolving role in advancing healthcare through innovative printing technologies.

Bayesian Optimization of Environmentally Sustainable Graphene Inks Produced by Wet Jet Milling

Liquid phase exfoliation (LPE) of graphene is a potentially scalable method to produce conductive graphene inks for printed electronic applications. Among LPE methods, wet jet milling (WJM) is an emerging approach that uses high-speed, turbulent flow to exfoliate graphene nanoplatelets from graphite in a continuous flow manner. Unlike prior WJM work based on toxic, high-boiling-point solvents such as n-methyl-2-pyrollidone (NMP), this study uses the environmentally friendly solvent ethanol and the polymer stabilizer ethyl cellulose (EC). Bayesian optimization and iterative batch sampling are employed to guide the exploration of the experimental phase space (namely, concentrations of graphite and EC in ethanol) in order to identify the Pareto frontier that simultaneously optimizes three performance criteria (graphene yield, conversion rate, and film conductivity). This data-driven strategy identifies vastly different optimal WJM conditions compared to literature precedent, including an optimal loading of 15 wt% graphite in ethanol compared to 1 wt% graphite in NMP. These WJM conditions provide superlative graphene production rates of 3.2 g hr-1 with the resulting graphene nanoplatelets being suitable for screen-printed micro-supercapacitors. Finally, life cycle assessment reveals that ethanol-based WJM graphene exfoliation presents distinct environmental sustainability advantages for greenhouse gas emissions, fossil fuel consumption, and toxicity.

A Guide to Printed Stretchable Conductors

Printing of stretchable conductors enables the fabrication and rapid prototyping of stretchable electronic devices. For such applications, there are often specific process and material requirements such as print resolution, maximum strain, and electrical/ionic conductivity. This review highlights common printing methods and compatible inks that produce stretchable conductors. The review compares the capabilities, benefits, and limitations of each approach to help guide the selection of a suitable process and ink for an intended application. We also discuss methods to design and fabricate ink composites with the desired material properties (e.g., electrical conductance, viscosity, printability). This guide should help inform ongoing and future efforts to create soft, stretchable electronic devices for wearables, soft robots, e-skins, and sensors.

Rapid Fabrication of High-Resolution Flexible Electronics via Nanoparticle Self-Assembly and Transfer Printing

Printed electronic technology serves as a key component in flexible electronics and wearable devices, yet achieving compatibility with both high resolution and high efficiency remains a significant challenge. Here, we propose a rapid fabrication method of high-resolution nanoparticle microelectronics via self-assembly and transfer printing. The tension gradient-electrostatic attraction composite-induced nanoparticle self-assembly strategy is constructed, which can significantly enhance the self-assembly efficiency, stability, and coverage by leveraging the meniscus Marangoni effect and the electric double-layer effect. The close-packed nanoparticle self-assembly layer can be rapidly formed on microstructure surfaces over a large area. Inspired by ink printing, a transfer printing strategy is further proposed to transform the self-assembly layer into conformal micropatterns. Large-area, high-resolution (2 μm), and ultrathin (1 μm) nanoparticle microelectronics can be stably fabricated, yielding a significant improvement over fluid printing methods. The unique deformability, recoverability, and scalability of nanoparticle microelectronics are revealed, providing promising opportunities for various academic and real applications.

Solvent-Assisted Graphene Exfoliation from Graphite Using Umbrella Sampling Simulations

We employed molecular dynamics (MD) simulations coupled with umbrella sampling to explore the thermodynamics governing the exfoliation of a single graphene layer from a graphitic substrate in five different solvents such as dimethylacetamide (DMA), N-methyl-2-pyrrolidone (NMP), dimethyl sulfoxide (DMSO), cyclohexane (CHX), and water. The substrate was modeled as a stack of three identical graphene layers with the graphene sheet undergoing exfoliation positioned on top of this stack. The initial configurations for each umbrella simulation were generated through steered MD simulations carried out along two distinct coordinates: one parallel and the other perpendicular to the graphene layers. Our analyses revealed a uniform wetting behavior for both the nanosheet and the graphitic substrate in all of the tested solvents. Consistent with experimental observations, the steered simulations confirmed that exfoliation is more favorable along the parallel direction than along the perpendicular one. All non-water solvents exhibit comparable effectiveness in the exfoliation of graphene. The calculated free energies of these solvents in parallel exfoliation consistently fell within the range of 90-100 kJ/mol/nm2. In perpendicular exfoliation, however, the corresponding energies converge to lower values. This difference is attributed to the nonequilibrium nature of the perpendicular exfoliation, primarily caused by the great steering velocity of the graphene sheet immediately after detachment from the substrate. This rapid motion of the nanosheet along the perpendicular coordinate results in an elevated system energy and heating.

Flexible and Scalable Dry Conductive Elastomeric Nanocomposites for Surface Stimulation Applications

OBJECTIVE

The study describes the development and testing of a dry surface stimulation flexible electrode (herein referred to as Flexatrode), a low-cost, flexible, and scalable elastomeric nanocomposite using carbon black (CB) and polydimethylsiloxane (PDMS).

METHODS

Flexatrodes composed of CB and PDMS were developed and tested for mechanical and functional stability up to 7 days. Uniform CB distribution was achieved by optimizing the dispersion process using toluene and methyl-terminated PDMS. Electromechanical testing in the through thickness directions over a long-term duration demonstrated stability of Flexatrode. Thermal stability of Flexatrode for up to a week was tested and validated, thus mitigating concerns of heat generation and deleterious skin reactions such as vasodilation or erythema.

RESULTS

25 wt.% CB was determined to be the optimal concentration. Electrical and thermal stability were demonstrated in the through thickness direction.

CONCLUSION

Flexatrode provides stable electrical properties combined with high flexibility and elasticity. Electrotherapy treated chronic wounds were 81.9% smaller than baseline at day 10. Wounds that received an inactive device (device without any electrical stimulation) were 58.1% smaller than baseline and wounds that received standard of care treatment were 62.2% smaller than baseline.

SIGNIFICANCE

The increasing need for wearable bioelectronics requiring long-term monitoring/treatment has highlighted the limitations of sustained use of gel-based electrodes. These can include skin irritation, bacterial overgrowth at the electrode site, gel dehydration over time, and signal degradation due to eccrine sweat formation. Flexatrode provides stable performance in a nanocomposite with scalable fabrication, thus providing a promising platform technology for wearable bioelectronics.

Screen-Printed Piezoelectric Sensors on Tattoo Paper Combined with All-Printed High-Performance Organic Electrochemical Transistors for Electrophysiological Signal Monitoring

This work demonstrates sensitive and low-cost piezoelectric sensors on skin-friendly, ultrathin, and conformable substrates combined with organic electrochemical transistors (OECTs) for the detection and amplification of alternating low-voltage input signals. The fully screen-printed (SP) piezoelectric sensors were manufactured on commercially available tattoo paper substrates, while the all-printed OECTs, relying on an extended gate electrode architecture, were manufactured either by solely using SP or by combining SP and aerosol jet printing (AJP) on PET substrates. Applying a low-voltage signal (±25 mV) to the gate electrode of the SP+AJP OECT results in approximately five times higher current modulation as compared to the fully SP reference OECT. The tattoo paper-based substrate enables transfer of the SP piezoelectric sensor to the skin, which in turn allows for radial pulse monitoring when combined with the SP+AJP OECT; this is possible due to the ability of the conformable sensor to convert mechanical vibrations into voltage signals along with the highly sensitive current modulation ability of the transistor device to further amplify the output signal. The results reported herein pave the way toward all-printed fully conformable wearable devices with high sensitivity to be further utilized for the real-time monitoring of electrophysiological signals.

Correlation of Transmission Properties with Glucose Concentration in a Graphene-Based Microwave Resonator

Carbon-based materials, such as graphene, exhibit interesting physical properties and have been recently investigated in sensing applications. In this paper, a novel technique for glucose concentration correlation with the resonant frequency of a microwave resonator is performed. The resonator exploits the variation of the electrical properties of graphene at radio frequency (RF). The described approach is based on the variation in transmission coefficient resonating frequency of a microstrip ring resonator modified with a graphene film. The graphene film is doctor-bladed on the ring resonator and functionalised in order to detect glucose. When a drop with a given concentration is deposited on the graphene film, the resonance peak is shifted. The graphene film is modelled with a lumped element analysis. Several prototypes are realised on Rogers Kappa substrate and their transmission coefficient measured for different concentrations of glucose. Results show a good correlation between the frequency shift and the concentration applied on the film.

Assembled one-dimensional nanowires for flexible electronic devices via printing and coating: Techniques, applications, and perspectives

The rapid progress in flexible electronic devices has necessitated continual research into nanomaterials, structural design, and fabrication processes. One-dimensional nanowires, characterized by their distinct structures and exceptional properties, are considered essential components for various flexible electronic devices. Considerable attention has been directed toward the assembly of nanowires, which presents significant advantages. Printing and coating techniques can be used to assemble nanowires in a relatively simple, efficient, and cost-competitive manner and exhibit potential for scale-up production in the foreseeable future. This review aims to provide an overview of nanowire assembly using printing and coating techniques, such as bar coating, spray coating, dip coating, blade coating, 3D printing, and so forth. The application of assembled nanowires in flexible electronic devices is subsequently discussed. Finally, further discussion is presented on the potential and challenges of flexible electronic devices based on assembled nanowires via printing and coating.

Progress in wearable acoustical sensors for diagnostic applications

With extensive and widespread uses of miniaturized and intelligent wearable devices, continuously monitoring subtle spatial and temporal changes in human physiological states becomes crucial for daily healthcare and professional medical diagnosis. Wearable acoustical sensors and related monitoring systems can be comfortably applied onto human body with a distinctive function of non-invasive detection. This paper reviews recent advances in wearable acoustical sensors for medical applications. Structural designs and characteristics of the structural components of wearable electronics, including piezoelectric and capacitive micromachined ultrasonic transducer (i.e., pMUT and cMUT), surface acoustic wave sensors (SAW) and triboelectric nanogenerators (TENGs) are discussed, along with their fabrication techniques and manufacturing processes. Diagnostic applications of these wearable sensors for detection of biomarkers or bioreceptors and diagnostic imaging have further been discussed. Finally, main challenges and future research directions in these fields are highlighted.

PANI-Coated VOx Nanobelts with Core-Shell Architecture for Flexible All-Solid-State Supercapacitor

As a typical pseudocapacitor material, VOx possesses mixed valence states, making it an ideal electrode material for symmetric screen-printed supercapacitors. However, its high internal resistance and low energy density are the main hurdles to its widespread application. In this study, a two-dimensional PANI@VOx nanobelt with a core-shell architecture was constructed via a two-step route. This strategy involves the preparation of VOx using a solvothermal method, and a subsequent in situ polymerization process of the PANI. By virtue of the synergistic effect between the VOx core and the PANI shell, the optimal VOx@PANI has an enhanced conductivity of 0.7 ± 0.04 S/Ω, which can deliver a high specific capacitance of 347.5 F/g at 0.5 A/g, a decent cycling life of ~72.0%, and an outstanding Coulomb efficiency of ~100% after 5000 cycles at 5 A/g. Moreover, a flexible all-solid-state symmetric supercapacitor (VOx@PANI SSC) with an in-planar interdigitated structure was screen-printed and assembled on a nickel current collector; it yielded a remarkable areal energy density of 115.17 μWh/cm2 at an areal power density of 0.39 mW/cm2, and possessed outstanding flexibility and mechanical performance. Notably, a "Xiaomi" hygrothermograph (3.0 V) was powered easily by tandem SSCs with an operating voltage of 3.1 V. Therefore, this advanced pseudocapacitor material with core-shell architecture opens novel ideas for flexible symmetric supercapacitors in powering portable/wearable products.

Development of Nafion/single-walled carbon nanotube integrated arrays for the rapid detection of salbutamol doping

Salbutamol (SAL), a drug originally intended for the treatment of bronchial and pulmonary diseases, has repeatedly been used for doping in competitive sports. Herein, an integrated array (NFCNT array) that prepared by template-assisted scalable filtration using Nafion-coated single-walled carbon nanotube (SWCNT) is presented for the rapid field detection of SAL. Spectroscopic and microscopic measurements were used to confirm the introduction of Nafion onto the surface of the array and to analyze the resulting morphological changes. The effects of Nafion addition on the resistance and electrochemical properties of the arrays (e.g., the electrochemically active area, charge-transfer resistance, and adsorption charge) are also discussed in depth. With an electrolyte/Nafion/SWCNT interface and moderate resistance, the NFCNT-4 array prepared containing 0.04 wt% Nafion suspension exhibits the greatest voltammetric response to SAL. Subsequently, a possible mechanism for the oxidation of SAL was proposed, and a calibration curve in the range of 0.1-15 μM was established. Finally, the NFCNT-4 arrays were applied to the detection of SAL in human urine samples with satisfactory recoveries.

Flexible organic field-effect transistors-based biosensors: progress and perspectives

Organic field-effect transistors (OFETs) have been proposed beyond three decades while becoming a research hotspot again in recent years because of the fast development of flexible electronics. Many novel flexible OFETs-based devices have been reported in these years. Among these devices, flexible OFETs-based sensors made great strides because of the extraordinary sensing capability of FET. Most of these flexible OFETs-based sensors were designed for biological applications due to the advantages of flexibility, reduced complexity, and lightweight. This paper reviews the materials, fabrications, and applications of flexible OFETs-based biosensors. Besides, the challenges and opportunities of the flexible OFETs-based biosensors are also discussed.

Screen-Printed Corrosion-Resistant and Long-Term Stable Stretchable Electronics Based on AgAu Microflake Conductors

High-throughput production methods such as screen printing can bring stretchable electronics out of the lab into the market. Most stretchable conductor inks for screen printing are based on silver nanoparticles or flakes due to their favorable performance-to-cost ratio, but silver is prone to tarnishing and corrosion, thereby limiting the stability of such conductors. Here, we report on a cost-efficient and scalable approach to resolve this issue by developing screen printable inks based on silver flakes chemically coated by a thin layer of gold. The printed stretchable AgAu conductors reach a conductivity of 8500 S cm^-1, remain conductive up to 250% strain, show excellent corrosion and tarnishing stability, and are used to demonstrate wearable LED and NFC circuits. The reported approach is attractive for smart clothing, as the long-term functionality of such devices is expected in a variety of environments.

Capillary instability in screen-printed micropatterns

Screen printing (SP) has been extensively studied owing to its widespread industrial applications; however, only a few studies have focused on the substrate effect. Herein, we demonstrate that a screen-printed line can undergo a broadening effect or lateral undulation, which is determined by the substrate and printed dimensions. The degree of spreading was systematically investigated by employing 1D and 2D geometrical parameters. Based on the liquidity of the ink, we developed a simple inviscid theory with imposed perturbation to analyze the instability of screen-printed lines. The dispersion relation was derived to estimate the geometry of the laterally undulated lines and compared with the experimental results. The proposed argument is particularly applicable to a regime in which SP inks have greater liquidity. The screen-printed patterns exhibited unique undulated shapes and were utilized as photomasks for the facile fabrication of raccoon-type microchannels.

Eco-friendly screen printing of silver nanowires for flexible and stretchable electronics

Screen printing is a promising route towards high throughput printed electronics. Currently, the preparation of nanomaterial based conductive inks involves complex formulations with often toxic surfactants in the ink's composition, making them unsuitable as an eco-friendly printing technology. This work reports the development of a silver nanowire (AgNW) ink with a relatively low conductive particle loading of 7 wt%. The AgNW ink involves simple formulation and comprises a biodegradable binder and a green solvent with no toxic surfactants in the ink formulation, making it an eco-friendly printing process. The formulated ink is suitable for printing on a diverse range of substrates such as polydimethylsiloxane (PDMS), polyethylene terephthalate (PET), polyimide (PI) tape, glass, and textiles. By tailoring the rheological behaviour of the ink and developing a one-step post-printing process, a minimum feature size of 50 μm and conductivity as high as 6.70 × 106 S m-1 was achieved. Use of a lower annealing temperature of 150 °C makes the process suitable for plastic substrates. A flexible textile heater and a wearable hydration sensor were fabricated using the reported AgNW ink to demonstrate its potential for wearable electronic applications.

Printed Electronics Based on 2D Material Inks: Preparation, Properties, and Applications toward Memristors

Printed electronics, which fabricate electrical components and circuits on various substrates by leveraging functional inks and advanced printing technologies, have recently attracted tremendous attention due to their capability of large-scale, high-speed, and cost-effective manufacturing and also their great potential in flexible and wearable devices. To further achieve multifunctional, practical, and commercial applications, various printing technologies toward smarter pattern-design, higher resolution, greater production flexibility, and novel ink formulations toward multi-functionalities and high quality have been insensitively investigated. 2D materials, possessing atomically thin thickness, unique properties and excellent solution-processable ability, hold great potential for high-quality inks. Besides, the great variety of 2D materials ranging from metals, semiconductors to insulators offers great freedom to formulate versatile inks to construct various printed electronics. Here, a detailed review of the progress on 2D material inks formulation and its printed applications has been provided, specifically with an emphasis on emerging printed memristors. Finally, the challenges facing the field and prospects of 2D material inks and printed electronics are discussed.

Fully desktop fabricated flexible graphene electrocorticography (ECoG) arrays

Objective:Flexible Electrocorticography (ECoG) electrode arrays that conform to the cortical surface and record surface field potentials from multiple brain regions provide unique insights into how computations occurring in distributed brain regions mediate behavior. Specialized microfabrication methods are required to produce flexible ECoG devices with high-density electrode arrays. However, these fabrication methods are challenging for scientists without access to cleanroom fabrication equipment.Results:Here we present a fully desktop fabricated flexible graphene ECoG array. First, we synthesized a stable, conductive ink via liquid exfoliation of Graphene in Cyrene. Next, we established a stencil-printing process for patterning the graphene ink via laser-cut stencils on flexible polyimide substrates. Benchtop tests indicate that the graphene electrodes have good conductivity of ∼1.1 × 10³S cm^-1, flexibility to maintain their electrical connection under static bending, and electrochemical stability in a 15 d accelerated corrosion test. Chronically implanted graphene ECoG devices remain fully functional for up to 180 d, with averagein vivoimpedances of 24.72 ± 95.23 kΩ at 1 kHz. The ECoG device can measure spontaneous surface field potentials from mice under awake and anesthetized states and sensory stimulus-evoked responses.Significance:The stencil-printing fabrication process can be used to create Graphene ECoG devices with customized electrode layouts within 24 h using commonly available laboratory equipment.

Perovskite solar cells based on screen-printed thin films

One potential advantage of perovskite solar cells (PSCs) is the ability to solution process the precursors and deposit films from solution^1,2. At present, spin coating, blade coating, spray coating, inkjet printing and slot-die printing have been investigated to deposit hybrid perovskite thin films^3-6. Here we expand the range of deposition methods to include screen-printing, enabled by a stable and viscosity-adjustable (40-44,000 cP) perovskite ink made from a methylammonium acetate ionic liquid solvent. We demonstrate control over perovskite thin-film thickness (from about 120 nm to about 1,200 nm), area (from 0.5 × 0.5 cm² to 5 × 5 cm²) and patterning on different substrates. Printing rates in excess of 20 cm s^-1 and close to 100% ink use were achieved. Using this deposition method in ambient air and regardless of humidity, we obtained the best efficiencies of 20.52% (0.05 cm²) and 18.12% (1 cm²) compared with 20.13% and 12.52%, respectively, for the spin-coated thin films in normal devices with thermally evaporated metal electrodes. Most notably, fully screen-printing devices with a single machine in ambient air have been successfully explored. The corresponding photovoltaic cells exhibit high efficiencies of 14.98%, 13.53% and 11.80% on 0.05-cm², 1.00-cm² and 16.37-cm² (small-module) areas, respectively, along with 96.75% of the initial efficiency retained over 300 h of operation at maximum power point.

Advances in Materials, Sensors, and Integrated Systems for Monitoring Eye Movements

Eye movements show primary responses that reflect humans' voluntary intention and conscious selection. Because visual perception is one of the fundamental sensory interactions in the brain, eye movements contain critical information regarding physical/psychological health, perception, intention, and preference. With the advancement of wearable device technologies, the performance of monitoring eye tracking has been significantly improved. It also has led to myriad applications for assisting and augmenting human activities. Among them, electrooculograms, measured by skin-mounted electrodes, have been widely used to track eye motions accurately. In addition, eye trackers that detect reflected optical signals offer alternative ways without using wearable sensors. This paper outlines a systematic summary of the latest research on various materials, sensors, and integrated systems for monitoring eye movements and enabling human-machine interfaces. Specifically, we summarize recent developments in soft materials, biocompatible materials, manufacturing methods, sensor functions, systems' performances, and their applications in eye tracking. Finally, we discuss the remaining challenges and suggest research directions for future studies.

Graphene-Based Composites with Silver Nanowires for Electronic Applications

Graphene/metal nanocomposites have shown a strong potential for use in electronic applications. In particular, the combination of silver nanowires (AgNWs) with graphene derivatives leads to the formation of an efficient conductive network, thus improving the electrical properties of a composite. This work focused on developing highly conductive hydrophilic hybrids of simultaneously functionalized and reduced graphene oxide (f-rGO) and AgNWs in different weight ratios by following two different synthetic routes: (a) the physical mixture of f-rGO and AgNWs, and (b) the in situ reduction of GO in the presence of AgNWs. In addition, the role of AgNWs in improving the electrical properties of graphene derivatives was further examined by mixing AgNWs with a hybrid of few-layered graphene with functionalized multiwalled carbon nanotubes (FLG/MWNT-f-OH). The studied materials showed a remarkable improvement in the overall electrical conductivity due to the synergistic effect of their components, which was proportional to the percentage of Ag and dependent on the procedure of the hybrid formation. One of the f-rGO/AgNWs composites was also selected for the preparation of gravure printing inks that were tested to determine their rheological and printing properties. All of the f-rGO/AgNWs composites were shown to be very promising materials for use as conductive inks for flexible electronics.

Low-Temperature Soldering of Surface Mount Devices on Screen-Printed Silver Tracks on Fabrics for Flexible Textile Hybrid Electronics

The combination of flexible-printed substrates and conventional electronics leads to flexible hybrid electronics. When fabrics are used as flexible substrates, two kinds of problems arise. The first type is related to the printing of the tracks of the corresponding circuit. The second one concerns the incorporation of conventional electronic devices, such as integrated circuits, on the textile substrate. Regarding the printing of tracks, this work studies the optimal design parameters of screen-printed silver tracks on textiles focused on printing an electronic circuit on a textile substrate. Several patterns of different widths and gaps between tracks were tested in order to find the best design parameters for some footprint configurations. With respect to the incorporation of devices on textile substrates, the paper analyzes the soldering of surface mount devices on fabric substrates. Due to the substrate's nature, low soldering temperatures must be used to avoid deformations or damage to the substrate caused by the higher temperatures used in conventional soldering. Several solder pastes used for low-temperature soldering are analyzed in terms of joint resistance and shear force application. The results obtained are satisfactory, demonstrating the viability of using flexible hybrid electronics with fabrics. As a practical result, a simple single-layer circuit was implemented to check the results of the research.

Ultrawide meta-film replication process for the mass production of a flexible microwave absorbing meta-surface

The manufacturing process for an ultrawide flexible microwave absorbing meta-surface was developed and optimized experimentally. The developed replication process consists of four main steps to demonstrate double-square loop array meta-structures: (1) mechanical machining of a master mold, (2) soft mold replication and patterned film imprinting, (3) conductive ink blade filling, (4) lamination of a base flexible film to meta sheet. Based on experimental optimization of the individual steps, the manufacturing process for a large-area flexible meta-film was established successfully. The feasibility of a developed process has been demonstrated with a 200 mm × 500 mm fabricated meta-film with a focus on microwave absorbing uniformity in the X-band region.

Screen-Printable Hexagonal Boron Nitride Ionogel Electrolytes for Mechanically Deformable Solid-State Lithium-Ion Batteries

Ionogel electrolytes present several benefits for solid-state lithium-ion batteries including nonflammability, favorable electrochemical properties, and high thermal stability. However, limited processing methods are currently available for ionogel electrolytes, restricting their practical applications. Here, we present a screen-printable ionogel electrolyte formulation based on hexagonal boron nitride (hBN) nanoplatelets. To achieve screen-printable rheological properties, hBN nanoplatelets are mixed with an imidazolium ionic liquid in ethyl lactate. Following screen printing, the resulting spatially uniform and mechanically flexible hBN ionogel electrolytes achieve high room-temperature ionic conductivities >1 mS cm^-1 and stiff mechanical moduli >1 MPa. These hBN ionogel electrolytes enable the fabrication of fully screen-printed lithium-ion batteries with high cycling stability, rate performance, and mechanical resilience against flexion and external forces, thus providing a robust energy storage solution that is compatible with scalable additive manufacturing.

Aerosol-jet-printed graphene electrochemical immunosensors for rapid and label-free detection of SARS-CoV-2 in saliva

Rapid, inexpensive, and easy-to-use coronavirus disease 2019 (COVID-19) home tests are key tools in addition to vaccines in the world-wide fight to eliminate national and local shutdowns. However, currently available tests for SARS-CoV-2, the virus that causes COVID-19, are too expensive, painful, and irritating, or not sufficiently sensitive for routine, accurate home testing. Herein, we employ custom-formulated graphene inks and aerosol jet printing (AJP) to create a rapid electrochemical immunosensor for direct detection of SARS-CoV-2 Spike Receptor-Binding Domain (RBD) in saliva samples acquired non-invasively. This sensor demonstrated limits of detection that are considerably lower than most commercial SARS-CoV-2 antigen tests (22.91 ± 4.72 pg/mL for Spike RBD and 110.38 ± 9.00 pg/mL for Spike S1) as well as fast response time (~30 mins), which was facilitated by the functionalization of printed graphene electrodes in a single-step with SARS-CoV-2 polyclonal antibody through the carbodiimide reaction without the need for nanoparticle functionalization or secondary antibody or metallic nanoparticle labels. This immunosensor presents a wide linear sensing range from 1 to 1000 ng/mL and does not react with other coexisting influenza viruses such as H1N1 hemagglutinin. By combining high-yield graphene ink synthesis, automated printing, high antigen selectivity, and rapid testing capability, this work offers a promising alternative to current SARS-CoV-2 antigen tests.

Printable inks and deformable electronic array devices

Deformable printed electronic array devices are expected to revolutionize next-generation electronics. However, although remarkable technological advances in printable inks and deformable electronic array devices have recently been achieved, technical challenges remain to commercialize these technologies. In this review article a brief introduction to printing methods highlighting significant research studies on ink formation for conductors, semiconductors, and insulators is provided, and the structural design and successful printing strategies of deformable electronic array devices are described. Successful device demonstrations are presented in the applications of passive- and active-matrix array devices. Finally, perspectives and technological challenges to be achieved are pointed out to print practically available deformable devices.

Neuro-inspired electronic skin for robots

Touch is a complex sensing modality owing to large number of receptors (mechano, thermal, pain) nonuniformly embedded in the soft skin all over the body. These receptors can gather and encode the large tactile data, allowing us to feel and perceive the real world. This efficient somatosensation far outperforms the touch-sensing capability of most of the state-of-the-art robots today and suggests the need for neural-like hardware for electronic skin (e-skin). This could be attained through either innovative schemes for developing distributed electronics or repurposing the neuromorphic circuits developed for other sensory modalities such as vision and audio. This Review highlights the hardware implementations of various computational building blocks for e-skin and the ways they can be integrated to potentially realize human skin-like or peripheral nervous system-like functionalities. The neural-like sensing and data processing are discussed along with various algorithms and hardware architectures. The integration of ultrathin neuromorphic chips for local computation and the printed electronics on soft substrate used for the development of e-skin over large areas are expected to advance robotic interaction as well as open new avenues for research in medical instrumentation, wearables, electronics, and neuroprosthetics.

Morphotaxy of Layered van der Waals Materials

Layered van der Waals (vdW) materials have attracted significant attention due to their materials properties that can enhance diverse applications including next-generation computing, biomedical devices, and energy conversion and storage technologies. This class of materials is typically studied in the two-dimensional (2D) limit by growing them directly on bulk substrates or exfoliating them from parent layered crystals to obtain single or few layers that preserve the original bonding. However, these vdW materials can also function as a platform for obtaining additional phases of matter at the nanoscale. Here, we introduce and review a synthesis paradigm, morphotaxy, where low-dimensional materials are realized by using the shape of an initial nanoscale precursor to template growth or chemical conversion. Using morphotaxy, diverse non-vdW materials such as HfO₂ or InF₃ can be synthesized in ultrathin form by changing the composition but preserving the shape of the original 2D layered material. Morphotaxy can also enable diverse atomically precise heterojunctions and other exotic structures such as Janus materials. Using this morphotaxial approach, the family of low-dimensional materials can be substantially expanded, thus creating vast possibilities for future fundamental studies and applied technologies.

A Fabrication of Multichannel Graphite Electrode Using Low-Cost Stencil-Printing Technique

Multichannel graphite electrodes (MGrEs) have been designed and fabricated in this study. A template was cut from an adhesive plastic sheet using a desktop cutting device. The template was placed on a polypropylene substrate, and carbon graphite ink was applied with a squeegee to the template. The size of the auxiliary electrode (AE) as well as the location of the reference electrode (RE) of MGrEs design were investigated. Scanning electron microscopy was used to determine the thickness of the ink on the four working electrodes (WEs), which was 21.9 ± 1.8 µm. Cyclic voltammetry with a redox probe solution was used to assess the precision of the four WEs. The intra-electrode repeatability and inter-electrode reproducibility of the MGrEs production were satisfied by low RSD (<6%). Therefore, the MGrEs is reliable and capable of detecting four replicates of the target analyte in a single analysis. The electrochemical performance of four WEs was investigated and compared to one WE. The sensitivity of the MGrEs was comparable to the sensitivity of a single WE. The MGrEs’ potential applications were investigated by analyzing the nitrite in milk and tap water samples (recoveries values of 97.6 ± 0.4 to 110 ± 2%).

Screen-Overprinted Perovskite RGB Microdisk Arrays Based on Wet-Solute-Chemical Dynamics for Full-Color Laser Displays

Owing to outstanding optoelectronic properties, halide perovskites are great candidates for novel laser display applications. However, the realization of their practical flat-panel display applications is challenging because of the incapacity to controllably assemble different halide perovskite microlaser arrays onto an identical substrate as pixelated full-color panels due to intrinsic fragile crystal lattices. Here, perovskite red-green-blue (RGB) microdisk arrays are reported, acting as flat-panels for full-color laser displays. A universal screen-overprinting technology is developed to integrate full-color perovskite microdisk arrays on a prepatterned template, which is on the basis of wet-solute-chemical dynamics involving a combination of surface tailoring and solvent selection. Via such an overprinting method, perovskite RGB microlaser matrices with precise localizations and well-defined dimensions were fabricated on an identical substrate, and each set of RGB microlaser served as a pixel for full-color display panels. On this basis, static and dynamic laser displays have been demonstrated with as-prepared full-color panels. These results will provide novel design concepts and device structures for future full-color laser display applications.

A Universal Approach for Room-Temperature Printing and Coating of 2D Materials

Processing 2D materials into printable or coatable inks for the fabrication of functional devices has proven to be quite difficult. Additives are often used in large concentrations to address the processing challenges, but they drastically degrade the electronic properties of the materials. To remove the additives a high-temperature post-deposition treatment can be used, but this complicates the fabrication process and limits the choice of materials (i.e., no heat-sensitive materials). In this work, by exploiting the unique properties of 2D materials, a universal strategy for the formulation of additive-free inks is developed, in which the roles of the additives are taken over by van der Waals (vdW) interactions. In this new class of inks, which is termed "vdW inks", solvents are dispersed within the interconnected network of 2D materials, minimizing the dispersibility-related limitations on solvent selection. Furthermore, flow behavior of the inks and mechanical properties of the resultant films are mainly controlled by the interflake vdW attractions. The structure of the vdW inks, their rheological properties, and film-formation behavior are discussed in detail. Large-scale production and formulation of the vdW inks for major high-throughput printing and coating methods, as well as their application for room-temperature fabrication of functional films/devices are demonstrated.

Additively Manufactured Flexible Electronics with Ultrabroad Range and High Sensitivity for Multiple Physiological Signals' Detection

Flexible electronics can be seamlessly attached to human skin and used for various purposes, such as pulse monitoring, pressure measurement, tensile sensing, and motion detection. Despite their broad applications, most flexible electronics do not possess both high sensitivity and wide detection range simultaneously; their sensitivity drops rapidly when they are subjected to even just medium pressure. In this study, ultrabroad-range, high-sensitivity flexible electronics are fabricated through additive manufacturing to address this issue. The key to possess high sensitivity and a wide detection range simultaneously is to fabricate flexible electronics with large depth-width ratio circuit channels using the additive manufacturing inner-rinsing template method. These electronics exhibit an unprecedented high sensitivity of 320 kPa^-1 over the whole detection range, which ranges from 0.3 to 30,000 Pa (five orders of magnitude). Their minimum detectable weight is 0.02 g (the weight of a fly), which is comparable with human skin. They can stretch to over 500% strain without breaking and show no tensile fatigue after 1000 repetitions of stretching to 100% strain. A highly sensitive and flexible electronic epidermal pulse monitor is fabricated to detect multiple physiological signals, such as pulse signal, breathing rhythm, and real-time beat-to-beat cuffless blood pressure. All of these signals can be obtained simultaneously for detailed health detection and monitoring. The fabrication method does not involve complex expensive equipment or complicated operational processes, so it is especially suitable for the fabrication of large-area, complex flexible electronics. We believe this approach will pave the way for the application of flexible electronics in biomedical detection and health monitoring.

Physical and Chemical Sensors on the Basis of Laser-Induced Graphene: Mechanisms, Applications, and Perspectives

Laser-induced graphene (LIG) is produced rapidly by directly irradiating carbonaceous precursors, and it naturally exhibits as a three-dimensional porous structure. Due to advantages such as simple preparation, time-saving, environmental friendliness, low cost, and expanding categories of raw materials, LIG and its derivatives have achieved broad applications in sensors. This has been witnessed in various fields such as wearable devices, disease diagnosis, intelligent robots, and pollution detection. However, despite LIG sensors having demonstrated an excellent capability to monitor physical and chemical parameters, the systematic review of synthesis, sensing mechanisms, and applications of them combined with comparison against other preparation approaches of graphene is still lacking. Here, graphene-based sensors for physical, biological, and chemical detection are reviewed first, followed by the introduction of general preparation methods for the laser-induced method to yield graphene. The preparation and advantages of LIG, sensing mechanisms, and the properties of different types of emerging LIG-based sensors are comprehensively reviewed. Finally, possible solutions to the problems and challenges of preparing LIG and LIG-based sensors are proposed. This review may serve as a detailed reference to guide the development of LIG-based sensors that possess properties for future smart sensors in health care, environmental protection, and industrial production.

Planar Graphene-Based Microsupercapacitors

With the development of wearable, portable, and implantable electronic devices, flexible and on-chip microsupercapacitors (MSCs) are urgently needed for miniaturized energy storage. Planar MSCs have high power density, fast charge/discharge rate, and long operating lifetime, and can adapt to future flexible, integrated, and miniaturized electronic systems for wide application foreground. Due to the high specific surface area, outstanding electrical conductivity, and excellent electron mobility, graphene shows promising advantages in planar MSCs devices, thus stimulates wide-ranging research in the last few years. Herein, the recent progress of planar graphene-based MSCs, including the intrinsic structure regulation of graphene-based electrode materials, the specific fabrication techniques, the multifunctional integration, and various applications of MSCs as flexible and on-chip energy storage is systematically summarized. The key challenges and prospects of future planar graphene-based MSCs are also discussed targeting to realize their practical applications.

Reviews on Machine Learning Approaches for Process Optimization in Noncontact Direct Ink Writing

Recently, machine learning has gained considerable attention in noncontact direct ink writing because of its novel process modeling and optimization techniques. Unlike conventional fabrication approaches, noncontact direct ink writing is an emerging 3D printing technology for directly fabricating low-cost and customized device applications. Despite possessing many advantages, the achieved electrical performance of produced microelectronics is still limited by the printing quality of the noncontact ink writing process. Therefore, there has been increasing interest in the machine learning for process optimization in the noncontact direct ink writing. Compared with traditional approaches, despite machine learning-based strategies having great potential for efficient process optimization, they are still limited to optimize a specific aspect of the printing process in the noncontact direct ink writing. Therefore, a systematic process optimization approach that integrates the advantages of state-of-the-art machine learning techniques is in demand to fully optimize the overall printing quality. In this paper, we systematically discuss the printing principles, key influencing factors, and main limitations of the noncontact direct ink writing technologies based on inkjet printing (IJP) and aerosol jet printing (AJP). The requirements for process optimization of the noncontact direct ink writing are classified into four main aspects. Then, traditional methods and the state-of-the-art machine learning-based strategies adopted in IJP and AJP for process optimization are reviewed and compared with pros and cons. Finally, to further develop a systematic machine learning approach for the process optimization, we highlight the major limitations, challenges, and future directions of the current machine learning applications.

Recent Advances on 2D Materials towards 3D Printing

In recent years, 2D materials have been implemented in several applications due to their unique and unprecedented properties. Several examples can be named, from the very first, graphene, to transition-metal dichalcogenides (TMDs, e.g., MoS2), two-dimensional inorganic compounds (MXenes), hexagonal boron nitride (h-BN), or black phosphorus (BP). On the other hand, the accessible and low-cost 3D printers and design software converted the 3D printing methods into affordable fabrication tools worldwide. The implementation of this technique for the preparation of new composites based on 2D materials provides an excellent platform for next-generation technologies. This review focuses on the recent advances of 3D printing of the 2D materials family and its applications; the newly created printed materials demonstrated significant advances in sensors, biomedical, and electrical applications.

Functional 2D MXene Inks for Wearable Electronics

Inks printing is an innovative and practicable technology capable of fabricating the next generation of flexible functional systems with various designs and desired architectures. As a result, inks printing is extremely attractive in the development of printed wearables, including wearable sensors, micro supercapacitor (MSC) electrodes, electromagnetic shielding, and thin-film batteries. The discovery of Ti₃C₂T_x in 2011, a 2D material known as a MXene, which is a compound composed of layered nitrides, carbides, or carbonitrides of transition metals, has attracted significant interest within the research community because of its exceptional physical and chemical properties. MXene has high metallic conductivity of transition metal carbides combined with hydrophilic behavior due to its surface terminated functional groups, all of which make it an excellent candidate for promising inks printing applications. This paper reviews recent progress in the development of 2D MXene inks, including synthesis procedures, inks formulation and performance, and printing methods. Further, the review briefly provides an overview of future guidelines for the study of this new generation of 2D materials.

Solution-processed two-dimensional materials for next-generation photovoltaics

In the ever-increasing energy demand scenario, the development of novel photovoltaic (PV) technologies is considered to be one of the key solutions to fulfil the energy request. In this context, graphene and related two-dimensional (2D) materials (GRMs), including nonlayered 2D materials and 2D perovskites, as well as their hybrid systems, are emerging as promising candidates to drive innovation in PV technologies. The mechanical, thermal, and optoelectronic properties of GRMs can be exploited in different active components of solar cells to design next-generation devices. These components include front (transparent) and back conductive electrodes, charge transporting layers, and interconnecting/recombination layers, as well as photoactive layers. The production and processing of GRMs in the liquid phase, coupled with the ability to "on-demand" tune their optoelectronic properties exploiting wet-chemical functionalization, enable their effective integration in advanced PV devices through scalable, reliable, and inexpensive printing/coating processes. Herein, we review the progresses in the use of solution-processed 2D materials in organic solar cells, dye-sensitized solar cells, perovskite solar cells, quantum dot solar cells, and organic-inorganic hybrid solar cells, as well as in tandem systems. We first provide a brief introduction on the properties of 2D materials and their production methods by solution-processing routes. Then, we discuss the functionality of 2D materials for electrodes, photoactive layer components/additives, charge transporting layers, and interconnecting layers through figures of merit, which allow the performance of solar cells to be determined and compared with the state-of-the-art values. We finally outline the roadmap for the further exploitation of solution-processed 2D materials to boost the performance of PV devices.

Recent Advances in Printing Technologies of Nanomaterials for Implantable Wireless Systems in Health Monitoring and Diagnosis

The development of wireless implantable sensors and integrated systems, enabled by advances in flexible and stretchable electronics technologies, is emerging to advance human health monitoring, diagnosis, and treatment. Progress in material and fabrication strategies allows for implantable electronics for unobtrusive monitoring via seamlessly interfacing with tissues and wirelessly communicating. Combining new nanomaterials and customizable printing processes offers unique possibilities for high-performance implantable electronics. Here, this report summarizes the recent progress and advances in nanomaterials and printing technologies to develop wireless implantable sensors and electronics. Advances in materials and printing processes are reviewed with a focus on challenges in implantable applications. Demonstrations of wireless implantable electronics and advantages based on these technologies are discussed. Lastly, existing challenges and future directions of nanomaterials and printing are described.

Fibre electronics: towards scaled-up manufacturing of integrated e-textile systems

The quest for a close human interaction with electronic devices for healthcare, safety, energy and security has driven giant leaps in portable and wearable technologies in recent years. Electronic textiles (e-textiles) are emerging as key enablers of wearable devices. Unlike conventional heavy, rigid, and hard-to-wear gadgets, e-textiles can lead to lightweight, flexible, soft, and breathable devices, which can be worn like everyday clothes. A new generation of fibre-based electronics is emerging which can be made into wearable e-textiles. A suite of start-of-the-art functional materials have been used to develop novel fibre-based devices (FBDs), which have shown excellent potential in creating wearable e-textiles. Recent research in this area has led to the development of fibre-based electronic, optoelectronic, energy harvesting, energy storage, and sensing devices, which have also been integrated into multifunctional e-textile systems. Here we review the key technological advancements in FBDs and provide an updated critical evaluation of the status of the research in this field. Focusing on various aspects of materials development, device fabrication, fibre processing, textile integration, and scaled-up manufacturing we discuss current limitations and present an outlook on how to address the future development of this field. The critical analysis of key challenges and existing opportunities in fibre electronics aims to define a roadmap for future applications in this area.

Dual Surface Architectonics for Directed Self-Assembly of Ultrahigh-Resolution Electronics

The directed self-assembly of electronic circuits using functional metallic inks has attracted intensive attention because of its high compatibility with extensive applications ranging from soft printed circuits to wearable devices. However, the typical resolution of conventional self-assembly technologies is not sufficient for practical applications in the rapidly evolving additively manufactured electronics (AMEs) market. Herein, an ultrahigh-resolution self-assembly strategy is reported based on a dual-surface-architectonics (DSA) process. Inspired by the Tokay gecko, the approach is to endow submicrometer-scale surface regions with strong adhesion force toward metallic inks via a series of photoirradiation and chemical polarization treatments. The prepared DSA surface enables the directed self-assembly of electronic circuits with unprecedented 600 nm resolution, suppresses the coffee-ring effect, and results in a reliable conductivity of 14.1 ± 0.6 µΩ cm. Furthermore, the DSA process enables the layer-by-layer fabrication of fully printed organic thin-film transistors with a short channel length of 1 µm, which results in a large on-off ratio of 10⁶ and a high field-effect mobility of 0.5 cm²  V^-1  s^-1 .

Fabrication and characterization of resistive double square loop arrays for ultra-wide bandwidth microwave absorption

Microwave absorbers using conductive ink are generally fabricated by printing an array pattern on a substrate to generate electromagnetic fields. However, screen printing processes are difficult to vary the sheet resistance values for different regions of the pattern on the same layer, because the printing process deposits materials at the same height over the entire surface of substrate. In this study, a promising manufacturing process was suggested for engraved resistive double square loop arrays with ultra-wide bandwidth microwave. The developed manufacturing process consists of a micro-end-milling, inking, and planing processes. A 144-number of double square loop array was precisely machined on a polymethyl methacrylate workpiece with the micro-end-milling process. After engraving array structures, the machined surface was completely covered with the developed conductive carbon ink with a sheet resistance of 15 Ω/sq. It was cured at room temperature. Excluding the ink that filled the machined double square loop array, overflowed ink was removed with the planing process to achieve full filled and isolated resistive array patterns. The fabricated microwave absorber showed a small radar cross-section with reflectance less than − 10 dB in the frequency band range of 8.0–14.6 GHz.

Recent Advances in High-Throughput Nanomaterial Manufacturing for Hybrid Flexible Bioelectronics

Hybrid flexible bioelectronic systems refer to integrated soft biosensing platforms with tremendous clinical impact. In this new paradigm, electrical systems can stretch and deform with the skin while previously hidden physiological signals can be continuously recorded. However, hybrid flexible bioelectronics will not receive wide clinical adoption until these systems can be manufactured at industrial scales cost-effectively. Therefore, new manufacturing approaches must be discovered and studied under the same innovative spirit that led to the adoption of novel materials and soft structures. Recent works have taken mature manufacturing approaches from the graphics industry, such as gravure, flexography, screen, and inkjet printing, and applied them to fully printed bioelectronics. These applications require the cohesive study of many disparate parts. For instance, nanomaterials with optimal properties for each specific application must be dispersed in printable inks with rheology suited to each printing method. This review summarizes recent advances in printing technologies, key nanomaterials, and applications of the manufactured hybrid bioelectronics. We also discuss the existing challenges of the available nanomanufacturing methods and the areas that need immediate technological improvements.