Liquid Metal Droplet and Graphene Co-Fillers for Electrically Conductive Flexible Composites

Malleable, printable, bondable, and highly conductive MXene/liquid metal plasticine with improved wettability

Integration of functional fillers into liquid metals (LM) induces rheology modification, enabling the free-form shaping of LM at the micrometer scale. However, integrating non-chemically modified low-dimensional materials with LM to form stable and uniform dispersions remain a great challenge. Herein, we propose a solvent-assisted dispersion (SAD) method that utilizes the fragmentation and reintegration of LM in volatile solvents to engulf and disperse fillers. This method successfully integrates MXene uniformly into LM, achieving better internal connectivity than the conventional dry powder mixing (DPM) method. Consequently, the MXene/LM (MLM) coating exhibits high electromagnetic interference (EMI) shielding performance (105 dB at 20 μm, which is 1.6 times that of coatings prepared by DPM). Moreover, the rheological characteristic of MLM render it malleable and facilitates direct printing and adaptation to diverse structures. This study offers a convenient method for assembling LM with low-dimensional materials, paving the way for the development of multifunctional soft devices.

Mechanism behind the Controlled Generation of Liquid Metal Nanoparticles by Mechanical Agitation

The size-controlled synthesis of liquid metal nanoparticles is necessary in a variety of applications. Sonication is a common method for breaking down bulk liquid metals into small particles, yet the influence of critical factors such as liquid metal composition has remained elusive. Our study employs high-speed imaging to unravel the mechanism of liquid metal particle formation during mechanical agitation. Gallium-based liquid metals, with and without secondary metals of bismuth, indium, and tin, are analyzed to observe the effect of cavitation and surface eruption during sonication and particle release. The impact of the secondary metal inclusion is investigated on liquid metals' surface tension, solution turbidity, and size distribution of the generated particles. Our work evidences that there is an inverse relationship between the surface tension and the ability of liquid metals to be broken down by sonication. We show that even for 0.22 at. % of bismuth in gallium, the surface tension is significantly decreased from 558 to 417 mN/m (measured in Milli-Q water), resulting in an enhanced particle generation rate: 3.6 times increase in turbidity and ∼43% reduction in the size of particles for bismuth in gallium liquid alloy compared to liquid gallium for the same sonication duration. The effect of particles' size on the photocatalysis of the annealed particles is also presented to show the applicability of the process in a proof-of-concept demonstration. This work contributes to a broader understanding of the synthesis of nanoparticles, with controlled size and characteristics, via mechanical agitation of liquid metals for diverse applications.

Recent progress in multifunctional, reconfigurable, integrated liquid metal-based stretchable sensors and standalone systems

Possessing a unique combination of properties that are traditionally contradictory in other natural or synthetical materials, Ga-based liquid metals (LMs) exhibit low mechanical stiffness and flowability like a liquid, with good electrical and thermal conductivity like metal, as well as good biocompatibility and room-temperature phase transformation. These remarkable properties have paved the way for the development of novel reconfigurable or stretchable electronics and devices. Despite these outstanding properties, the easy oxidation, high surface tension, and low rheological viscosity of LMs have presented formidable challenges in high-resolution patterning. To address this challenge, various surface modifications or additives have been employed to tailor the oxidation state, viscosity, and patterning capability of LMs. One effective approach for LM patterning is breaking down LMs into microparticles known as liquid metal particles (LMPs). This facilitates LM patterning using conventional techniques such as stencil, screening, or inkjet printing. Judiciously formulated photo-curable LMP inks or the introduction of an adhesive seed layer combined with a modified lift-off process further provide the micrometer-level LM patterns. Incorporating porous and adhesive substrates in LM-based electronics allows direct interfacing with the skin for robust and long-term monitoring of physiological signals. Combined with self-healing polymers in the form of substrates or composites, LM-based electronics can provide mechanical-robust devices to heal after damage for working in harsh environments. This review provides the latest advances in LM-based composites, fabrication methods, and their novel and unique applications in stretchable or reconfigurable sensors and resulting integrated systems. It is believed that the advancements in LM-based material preparation and high-resolution techniques have opened up opportunities for customized designs of LM-based stretchable sensors, as well as multifunctional, reconfigurable, highly integrated, and even standalone systems.

Biphasic GaIn Alloy Constructed Stable Percolation Network in Polymer Composites over Ultrabroad Temperature Region

Flexible and adaptable polymer composites with high-performance reliability over wide temperature range are imperative for various applications. However, the distinct filler-matrix thermomechanical behaviors often cause severe structure damage and performance degradation upon large thermal shock. To address this issue, a general strategy is proposed to construct leakage-free, self-adaptive, stable percolation networks in polymer composites over wide temperature (77-473 K) with biphasic Ga35In65 alloy. The in situ micro-CT technology, for the first time, reveals the conformable phase transitions of Ga35In65 alloys in the polymer matrix that help repair the disruptive conductive networks over large temperature variations. The cryo-expanded Ga compensates the disruptive carbon networks at low temperatures, and flowable Ga and melted In at high temperatures conformably fill and repair the deboned interfaces and yielded crevices. As a proof-of-concept, this temperature-resistant composite demonstrates superb electrical conductivity and electromagnetic interference shielding properties and stability even after a large temperature shock (ΔT = 396 K). Furthermore, the superiority of the construction of temperature self-adaptive networks within the composite enables them for additive manufacturing of application-oriented components. This work offers helpful inspiration for developing high-performance polymer composites for extreme-temperature applications.

Surface Embedded Metal Nanowire-Liquid Metal-Elastomer Hybrid Composites for Stretchable Electronics

Both liquid metal (LM) and metallic filler-based conductive composites are promising stretchable conductors. LM alloys exhibit intrinsically high deformability but present challenges for patterning on polymeric substrates due to high surface tension. On the other hand, conductive composites comprising metallic fillers undergo considerable decrease in electrical conductivity under mechanical deformation. To address the challenges, we present silver nanowire (AgNW)-LM-elastomer hybrid composite films, where AgNWs and LM are embedded below the surface of an elastomeric matrix, using two fabrication approaches, sequential and mixed. We investigate and understand the process-structure-property relationship of the AgNW-LM-elastomer hybrid composites fabricated using two approaches. Different weight ratios of AgNWs and LM particles provide tunable electrical conductivity. The hybrid composites show more stable electromechanical performance than the composites with AgNWs alone. In particular, 1:2.4 (AgNW:LMP w/w) sequential hybrid composite shows electromechanical stability similar to that of the LM-elastomer composite, with a resistance increase of 2.04% at 90% strain. The sequential approach is found to form AgIn2 intermetallic compounds which along with Ga-In bonds, imparts large deformability to the sequential hybrid composite as well as mechanical robustness against scratching, cutting, peeling, and wiping. To demonstrate the application of the hybrid composite for stretchable electronics, a laser patterned stretchable heater on textile and a stretchable circuit including a light-emitting diode are fabricated.

Programmable and Weldable Superelastic EGaIn/TPU Composite Fiber by Wet Spinning for Flexible Electronics

As an essential component of flexible electronics, superelastic conductive fibers with good mechanical and electrical properties have drawn significant attention, especially in their preparation. In this study, we prepared a superelastic conductive fiber composed of eutectic gallium-indium (EGaIn) and thermoplastic polyurethane (TPU) by simple wet spinning. The composite conductive fiber with a liquid metal (LM) content of 85 wt % achieved a maximum strain at a break of 659.2%, and after the conductive pathway in the porous structure of the composite fibers was fully activated, high conductivity (1.2 × 105 S/m) was achieved with 95 wt % LM by mechanical sintering and training processes. The prepared conductive fibers exhibited a stable resistive response as the fibers were strained and could be sewn into fabrics and used as wearable strain sensors to monitor various human motions. These conductive fibers can be molded into helical by heating, and they have excellent electrical properties at a maximum mechanical strain of 3400% (resistance change <0.27%) with a helical index of 11. Moreover, the conductive fibers can be welded to various two or three-dimensional conductors. In summary, with a scalable manufacturing process, weldability, superelasticity, and high electrical conductivity, EGaIn/TPU composite fibers fabricated by wet spinning have considerable potential for flexible electronics.

Recyclable Thin-Film Soft Electronics for Smart Packaging and E-Skins

Despite advances in soft, sticker-like electronics, few efforts have dealt with the challenge of electronic waste. Here, this is addressed by introducing an eco-friendly conductive ink for thin-film circuitry composed of silver flakes and a water-based polyurethane dispersion. This ink uniquely combines high electrical conductivity (1.6 × 105 S m-1 ), high resolution digital printability, robust adhesion for microchip integration, mechanical resilience, and recyclability.  Recycling is achieved with an ecologically-friendly processing method to decompose the circuits into constituent elements and recover the conductive ink with a decrease of only 2.4% in conductivity. Moreover, adding liquid metal enables stretchability of up to 200% strain, although this introduces the need for more complex recycling steps. Finally, on-skin electrophysiological monitoring biostickers along with a recyclable smart package with integrated sensors for monitoring safe storage of perishable foods are demonstrated.

Ultrasensitive and ultrastretchable electrically self-healing conductors

Self-healing is a bioinspired strategy to repair damaged conductors under repetitive wear and tear, thereby largely extending the life span of electronic devices. The self-healing process often demands external triggering conditions as the practical challenges for the widespread applications. Here, a compliant conductor with electrically self-healing capability is introduced by combining ultrahigh sensitivity to minor damages and reliable recovery from ultrahigh tensile deformations. Conductive features are created in a scalable and low-cost fabrication process comprising a copper layer on top of liquid metal microcapsules. The efficient rupture of microcapsules is triggered by structural damages in the copper layer under stress conditions as a result of the strong interfacial interactions. The liquid metal is selectively filled into the damaged site for the instantaneous restoration of the metallic conductivity. The unique healing mechanism is responsive to various structural degradations including microcracks under bending conditions and severe fractures upon large stretching. The compliant conductor demonstrates high conductivity of ∼12,000 S/cm, ultrahigh stretchability of up to 1,200% strain, an ultralow threshold to activate the healing actions, instantaneous electrical recovery in microseconds, and exceptional electromechanical durability. Successful implementations in a light emitting diode (LED) matrix display and a multifunctional electronic patch demonstrate the practical suitability of the electrically self-healing conductor in flexible and stretchable electronics. The developments provide a promising approach to improving the self-healing capability of compliant conductors.

Formation of inorganic liquid gallium particle-manganese oxide composites

Gallium (Ga) is a low melting point post-transition metal that, under mild mechanical agitation, can form micron and submicron-sized particles with combined fluid-like and metallic properties. In this work, an inorganic network of Ga liquid metal particles was synthesised via spontaneous formation of manganese (Mn) oxide species on their liquid metallic surfaces forming an all-inorganic composite. The micron-sized Ga particles formed by sonication were connected together by Mn oxide nanostructures spontaneously established from the reduction of a Mn salt in aqueous solution slightly above the melting point of Ga. The formed Mn oxide nanostructures were found to coalesce from the surface of the Ga particles into a continuous inorganic network. The morphology of the composites could be altered by varying the Mn salt concentration and by performing post-treatment annealing. The composites presented a shell of various Mn oxide nanostructures including wrinkled sheets, rods and nanoneedles, around spherical liquid Ga particles, and a liquid metal core. The photoelectric and optical properties of the composites were thoroughly characterised, which revealed decreasing bandgaps and valence band edge characteristics as a function of increased Mn oxide coverage. The photoluminescence properties of the composites could be also engineered by increasing the Mn oxide coverage. The all-inorganic liquid Ga composite could be formed via a straightforward reduction reaction of a Mn-rich salt at the surface of liquid Ga particles with tunable surface properties for future optoelectronic applications.

Flexible and Stretchable Elastomer Composites Based on Lightweight Liquid Metal Foam Spheres with Pod-like Contacts

Liquid metal (LM) is increasingly employed as a conductive filler in soft and flexible elastomer composites owing to its favorable conductivity and liquid fluidity. However, the high density of LM inevitably increases the weight of composites, which brings limitations in large-area and weight-sensitive applications. This work reports a flexible and stretchable elastomer composite composed of pod-like contacting lightweight LM foam spheres and polydimethylsiloxane matrix (LMS/PDMS). The lightweight LMS reduces the amount of LM used in the preparation process while imparting good electrical conductivity and deformability to the composite. The different contact modes of LMS endow the final composites with diverse strain sensitivity. The mechanism of interfacial contact conduction between the LMS with different melting points has been systematically studied, and the result shows that the liquid-solid contact mode of LMS further improves the strain sensitivity of the composite. Moreover, the composite also has satisfactory electrothermal properties and the temperature can quickly reach 70 °C within 30 s, showing good applicability in electric heating. Finally, the composites containing LMS with different contact modes can be developed as multifunctional sensors to detect human activities, temperature variation, and even underwater vibration, demonstrating the great potential in next-generation sensors and electronics.

Recent Advances in Thermal Interface Materials for Thermal Management of High-Power Electronics

With the increased level of integration and miniaturization of modern electronics, high-power density electronics require efficient heat dissipation per unit area. To improve the heat dissipation capability of high-power electronic systems, advanced thermal interface materials (TIMs) with high thermal conductivity and low interfacial thermal resistance are urgently needed in the structural design of advanced electronics. Metal-, carbon- and polymer-based TIMs can reach high thermal conductivity and are promising for heat dissipation in high-power electronics. This review article introduces the heat dissipation models, classification, performances and fabrication methods of advanced TIMs, and provides a summary of the recent research status and developing trends of micro- and nanoscale TIMs used for heat dissipation in high-power electronics.

Silicone Rubber Based-Conductive Composites for Stretchable "All-in-One" Microsystems

Wearable electronics with development trends such as miniaturization, multifunction, and smart integration have become an important part of the Internet of Things (IoT) and have penetrated various sectors of modern society. To meet the increasing demands of wearable electronics in terms of deformability and conformability, many efforts have been devoted to overcoming the nonstretchable and poor conformal properties of traditional functional materials and endowing devices with outstanding mechanical properties. One of the promising approaches is composite engineering in which traditional functional materials are incorporated into the various polymer matrices to develop different kinds of functional composites and construct different functions of stretchable electronics. Herein, we focus on the approach of composite engineering and the polymer matrix of silicone rubber (SR), and we summarize the state-of-the-art details of silicone rubber-based conductive composites (SRCCs), including a summary of their conductivity mechanisms and synthesis methods and SRCC applications for stretchable electronics. For conductivity mechanisms, two conductivity mechanisms of SRCC are emphasized: percolation theory and the quantum tunneling mechanism. For synthesis methods of SRCCs, four typical approaches to synthesize different kinds of SRCCs are investigated: mixing/blending, infiltration, ion implantation, and in situ formation. For SRCC applications, different functions of stretchable electronics based on SRCCs for interconnecting, sensing, powering, actuating, and transmitting are summarized, including stretchable interconnects, sensors, nanogenerators, antennas, and transistors. These functions reveal the feasibility of constructing a stretchable all-in-one self-powered microsystem based on SRCC-based stretchable electronics. As a prospect, this microsystem is expected to integrate the functional sensing modulus, the energy harvesting modulus, and the process and response modulus together to sense and respond to environmental stimulations and human physiological signals.

Nanomaterial based PVA nanocomposite hydrogels for biomedical sensing: Advances toward designing the ideal flexible/wearable nanoprobes

In today's world, the progress of wearable tools has gained increasing momentum. Notably, the demand for stretchable strain sensors has considerably increased owing to various potential and emerging applications like human motion monitoring, soft robotics, prosthetics, and electronic skin. Hydrogels possess excellent biocompatibility, flexibility, and stretchability that render them ideal candidates for flexible/wearable substrates. Among them, enormous efforts were focused on the progress of polyvinyl alcohol (PVA) hydrogels to realize multifunctional wearable sensing through using additives/nanofillers/functional groups to modify the hydrogel network. Herein, this review offers an up-to-date and comprehensive summary of the research progress of PVA hydrogel-based wearable sensors in view of their properties, strain sensory efficiency, and potential applications, followed by specifically highlighting their probes using metallic/non-metallic, liquid metal (LM), 2D materials, bio-nanomaterials, and polymer nanofillers. Indeed, flexible electrodes and strain/pressure sensing performance of designed PVA hydrogels for their effective sensing are described. The representative cases are carefully selected and discussed regarding the construction, merits and demerits, respectively. Finally, the necessity and requirements for future advances of conductive and stretchable hydrogels engaged in the wearable strain sensors are also presented, followed by opportunities and challenges.

Conductive Polymer Enabled Biostable Liquid Metal Electrodes for Bioelectronic Applications

Gallium (Ga)-based liquid metal materials have emerged as a promising material platform for soft bioelectronics. Unfortunately, Ga has limited biostability and electrochemical performance under physiological conditions, which can hinder the implementation of its use in bioelectronic devices. Here, an effective conductive polymer deposition strategy on the liquid metal surface to improve the biostability and electrochemical performance of Ga-based liquid metals for use under physiological conditions is demonstrated. The conductive polymer [poly(3,4-ethylene dioxythiophene):tetrafluoroborate]-modified liquid metal surface significantly outperforms the liquid metal.based electrode in mechanical, biological, and electrochemical studies. In vivo action potential recordings in behaving nonhuman primate and invertebrate models demonstrate the feasibility of using liquid metal electrodes for high-performance neural recording applications. This is the first demonstration of single-unit neural recording using Ga-based liquid metal bioelectronic devices to date. The results determine that the electrochemical deposition of conductive polymer over liquid metal can improve the material properties of liquid metal electrodes for use under physiological conditions and open numerous design opportunities for next-generation liquid metal-based bioelectronics.

Emerging Role of Liquid Metals in Sensing

Low melting point metals and alloys are the group of materials that combine metallic and liquid properties, simultaneously. The fascinating characteristics of liquid metals (LMs) including softness and high electrical and thermal conductivity, as well as their unique interfacial chemistry, have started to dominate various research disciplines. Utilization of LMs as responsive interfaces, enabling sensing in a flexible and versatile manner, is one of the most promising traits demonstrated for LMs. In the context of LMs-enabled sensors, gallium (Ga) and its alloys have emerged as multipurpose functional materials with many compelling physical and chemical properties. Responsiveness to different stimuli and easy-to-functionalize interfaces of Ga-based LMs make them ideal candidates for a variety of sensing applications. However, despite the vast capabilities of Ga-based LMs in sensing, applications of these materials for developing different sensors have not been fully explored. In the present review, we provide a comprehensive overview regarding the applications of Ga-based LMs in a wide range of sensing approaches that cover different physical and chemical sensors. The unique features of Ga-based LMs, which make them promising materials for sensing, are discussed in subsections followed by relevant case studies. Finally, challenges as well as the prospected future and developing motifs are highlighted for each type of LM-based sensors.

Applications of liquid metals in nanotechnology

Post-transition liquid metals (LMs) offer new opportunities for accessing exciting dynamics for nanomaterials. As entities with free electrons and ions as well as fluidity, LM-based nanomaterials are fundamentally different from their solid counterparts. The low melting points of most post-transition metals (less than 330 °C) allow for the formation of nanodroplets from bulk metal melts under mild mechanical and chemical conditions. At the nanoscale, these liquid state nanodroplets simultaneously offer high electrical and thermal conductivities, tunable reactivities and useful physicochemical properties. They also offer specific alloying and dealloying conditions for the formation of multi-elemental liquid based nanoalloys or the synthesis of engineered solid nanomaterials. To date, while only a few nanosized LM materials have been investigated, extraordinary properties have been observed for such systems. Multi-elemental nanoalloys have shown controllable homogeneous or heterogeneous core and surface compositions with interfacial ordering at the nanoscale. The interactions and synergies of nanosized LMs with polymeric, inorganic and bio-materials have also resulted in new compounds. This review highlights recent progress and future directions for the synthesis and applications of post-transition LMs and their alloys. The review presents the unique properties of these LM nanodroplets for developing functional materials for electronics, sensors, catalysts, energy systems, and nanomedicine and biomedical applications, as well as other functional systems engineered at the nanoscale.

Exploring Interfacial Graphene Oxide Reduction by Liquid Metals: Application in Selective Biosensing

Liquid metals (LMs) are electronic liquid with enigmatic interfacial chemistry and physics. These features make them promising materials for driving chemical reactions on their surfaces for designing nanoarchitectonic systems. Herein, we showed the interfacial interaction between eutectic gallium-indium (EGaIn) liquid metal and graphene oxide (GO) for the reduction of both substrate-based and free-standing GO. NanoIR surface mapping indicated the successful removal of carbonyl groups. Based on the gained knowledge, a composite consisting of assembled reduced GO sheets on LM microdroplets (LM-rGO) was developed. The LM enforced Ga³⁺ coordination within the rGO assembly found to modify the electrochemical interface for selective dopamine sensing by separating the peaks of interfering biologicals. Subsequently, paper-based electrodes were developed and modified with the LM-rGO that presented the compatibility of the assembly with low-cost commercial technologies. The observed interfacial interaction, imparted by LM's interfaces, and electrochemical performance observed for LM-rGO will lead to effective functional materials and electrode modifiers.

Liquid metal polymer composite: Flexible, conductive, biocompatible, and antimicrobial scaffold

Gallium and its alloys, such as eutectic gallium indium alloy (EGaIn), a form of liquid metal, have recently attracted the attention of researchers due to their low toxicity and electrical and thermal conductivity for biomedical application. However, further research is required to harness EGaIn-composites advantages and address their application as a biomedical scaffold. In this research, EGaIn-polylactic acid/polycaprolactone composites with and without a second conductive filler, MXene, were prepared and characterized. The addition of MXene, into the EGaIn-composite, can improve the composite's electrochemical properties by connecting the liquid metal droplets resulting in electrically conductive continuous pathways within the polymeric matrix. The results showed that the composite with 50% EGaIn and 4% MXene, displayed optimal electrochemical properties and enhanced mechanical and radiopacity properties. Furthermore, the composite showed good biocompatibility, examined through interactions with fibroblast cells, and antibacterial properties against methicillin-resistant Staphylococcus aureus. Therefore, the liquid metal (EGaIn) polymer composite with MXene provides a first proof-of-concept engineering scaffold strategy with low toxicity, functional electrochemical properties, and promising antimicrobial properties.

3D Printable concentrated liquid metal composite with high thermal conductivity

Heat dissipation materials in which fillers are dispersed in a polymer matrix typically do not exhibit both high thermal conductivity (k) and processability due to a trade-off. In this paper, we fabricate heat dissipation composites which overcome the trade-off using liquid metal (LM). By exceeding the conventional filler limit, ten times higher k is achieved for a 90 vol% LM composite compared with k of 50 vol% LM composite. Further, an even higher k is achieved by introducing h-BN between the LM droplets, and the highest k in this study was 17.1 W m^-1 K^-1. The LM composite is processable at room temperature and used as inks for 3D printing. This combination of high k and processability not only allows heat dissipation materials to be processed on demand under ambient conditions but it also increases the surface area of the LM composite, which enables rapid heat dissipation.

Conductive Polymer Nanocomposites for Stretchable Electronics: Material Selection, Design, and Applications

Stretchable electronics that can elongate elastically as well as flex are crucial to a wide range of emerging technologies, such as wearable medical devices, electronic skin, and soft robotics. Critical to stretchable electronics is their ability to withstand large mechanical strain without failure while retaining their electrical conduction properties, a feat significantly beyond traditional metals and silicon-based semiconductors. Herein, we present a review of the recent advances in stretchable conductive polymer nanocomposites with exceptional stretchability and electrical properties, which have the potential to transform a wide range of applications, including wearable sensors for biophysical signals, stretchable conductors and electrodes, and deformable energy-harvesting and -storage devices. Critical to achieving these stretching properties are the judicious selection and hybridization of nanomaterials, novel microstructure designs, and facile fabrication processes, which are the focus of this Review. To highlight the potentials of conductive nanocomposites, a summary of some recent important applications is presented, including COVID-19 remote monitoring, connected health, electronic skin for augmented intelligence, and soft robotics. Finally, perspectives on future challenges and new research opportunities are also presented and discussed.

Enhancing Thermal Transport in Silicone Composites via Bridging Liquid Metal Fillers with Reactive Metal Co-Fillers and Matrix Viscosity Tuning

Polymer matrix composites containing room temperature liquid metal (LM) microdroplets offer a unique set of thermo-mechanical characteristics that makes them attractive candidates for high performance thermal interface materials. However, to achieve the desired level of the composite thermal conductivity, effective bridging of such fillers into interconnected percolation networks needs to be induced. Thermal percolation of the LM microdroplets requires two physical barriers to be overcome. First, the LM microdroplets must directly contact each other through the polymer matrix. Second, the native oxide shell on the LM microdroplet must also be ruptured. In this work, we demonstrate that both physical barriers can be penetrated to induce ample bridging of the LM microdroplets and thereby achieve higher thermal conductivity composites. We accomplish this through a synergistic combination of solid silver and LM fillers, tuning of the silicone oil "matrix" viscosity, and sample compression. We selected silver as the solid additive because it rapidly alloys with gallium to form microscale needles that could act as additional paths that aid in connecting the LM droplets. We systematically explore the impact of the composition (filler type, volume fraction, and matrix oil viscosity) and applied pressure on the thermal conductivity and multiscale structure of these composites. We reveal the microscopic mechanism underlying the macroscopic experimental trends and also identify an optimal composition of the multiphase Ag-LM-Silicone oil composite for thermal applications. The identified design knobs offer path for developing tunable LM-based polymer composites for microelectronics cooling, biomedical applications, and flexible electronics.

Materials, Electrical Performance, Mechanisms, Applications, and Manufacturing Approaches for Flexible Strain Sensors

With the recent great progress made in flexible and wearable electronic materials, the upcoming next generation of skin-mountable and implantable smart devices holds extensive potential applications for the lifestyle modifying, including personalized health monitoring, human-machine interfaces, soft robots, and implantable biomedical devices. As a core member within the wearable electronics family, flexible strain sensors play an essential role in the structure design and functional optimization. To further enhance the stretchability, flexibility, sensitivity, and electricity performances of the flexible strain sensors, enormous efforts have been done covering the materials design, manufacturing approaches and various applications. Thus, this review summarizes the latest advances in flexible strain sensors over recent years from the material, application, and manufacturing strategies. Firstly, the critical parameters measuring the performances of flexible strain sensors and materials development contains different flexible substrates, new nano- and hybrid- materials are introduced. Then, the developed working mechanisms, theoretical analysis, and computational simulation are presented. Next, based on different material design, diverse applications including human motion detection and health monitoring, soft robotics and human-machine interface, implantable devices, and biomedical applications are highlighted. Finally, synthesis consideration of the massive production industry of flexible strain sensors in the future; different fabrication approaches that are fully expected are classified and discussed.

Vapor-Mediated Stretchable and Reversible Conductors from Microporous Liquid Metal Polymers

Flexible electronic devices have penetrated into a variety of industry sectors (i.e., consumer electronics, automotive, and medical) in human life, and this calls for better properties of stretchable conductive composites as the crucial elements. Traditionally, conductive inorganic fillers are incorporated in flexible polymers to prepare conductive composites, which falls short of the required properties in more demanding devices nowadays due to limited deformation, low conductivity, and poor processability. Herein, liquid metals were successfully incorporated in microporous polymer matrixes using a simple codissolving and film casting/solvent evaporation approach. The microporous liquid metal-embedded polymer (LMEP) was insulative as fabricated due to discontinuous liquid metals (LMs), while it became conductive upon stretching. Interestingly, the LMEP films showed a reversible insulator-conductor transition due to the regenerated pores in polymer matrix under organic vapor. Negligible changes in the resistance value were seen even after 50 solvent exposure-tensile strain cycles, demonstrating the excellent stability of the electrical properties of these films. Furthermore, most of the commercially available soluble polymers including rigid plastics and soft elastomers are suitable for the fabrication of LMEP. With the ideal characteristics, they have been successfully exploited in model alarm systems to prevent temperature overloads and solvent leakage, showcasing the great potential in next generation sensors used in industry settings.

Bi-Phasic Ag-In-Ga-Embedded Elastomer Inks for Digitally Printed, Ultra-Stretchable, Multi-layer Electronics

A bi-phasic ternary Ag-In-Ga ink that demonstrates high electrical conductivity, extreme stretchability, and low electromechanical gauge factor (GF) is introduced. Unlike popular liquid metal alloys such as eutectic gallium-indium (EGaIn), this ink is easily printable and nonsmearing and bonds strongly to a variety of substrates. Using this ink and a simple extrusion printer, the ability to perform direct writing of ultrathin, multi-layer circuits that are highly stretchable (max. strain >600%), have excellent conductivity (7.02 × 10⁵ S m^-1), and exhibit only a modest GF (0.9) related to the ratio of percent increase in trace resistance with mechanical strain is demonstrated. The ink is synthesized by mixing optimized quantities of EGaIn, Ag microflakes, and styrene-isoprene block copolymers, which functions as a hyperelastic binder. When compared to the same composite without EGaIn, the Ag-In-Ga ink shows over 1 order of magnitude larger conductivity, up to ∼27× lower GF, and ∼5× greater maximum stretchability. No significant change over the resistance of the ink was observed after 1000 strain cycles. Microscopic analysis shows that mixing EGaIn and Ag microflakes promotes the formation of AgIn₂ microparticles, resulting in a cohesive bi-phasic ink. The ink can be sintered at room temperature, making it compatible with many heat-sensitive substrates. Additionally, utilizing a simple commercial extrusion based printer, the ability to perform stencil-free, digital printing of multi-layer stretchable circuits over various substrates, including medical wound-dressing adhesives, is demonstrated for the first time.

Recent Development in Liquid Metal Materials

Liquid metals (LM) have shown a very broad development prospect over the past decades. This review article focuses on the latest research dedicated to liquid metal materials and their applications in five significant areas: stretchable conductive composite, intelligent sensing electronic skin, catalysis, 3D printing material, and driving machines. The fabrication, specific properties and application of stretchable liquid metal-polymer composites that can be used as self-healing materials have been summarized. Liquid metal deposition printing technology, liquid phase 3D printing, suspension 3D printing technology, micro-contact printing technology, and in vivo 3D printing molding technology have also been reviewed. Furthermore, the application of liquid metal catalyst in aldehyde reaction, photocatalysis, and electrocatalysis have been discussed. We have shown that electricity, magnetism, sound, light and heat could stimulate the movement of liquid metal. Through this comprehensive overview of the latest research, the main practical application, development, and mechanism of liquid metal were summarized and described. The future development of liquid metal technology was prospected, thus providing a strong basic research support for the further development of LM materials and their applications.

Liquid metal-based nanocomposite materials: fabrication technology and applications

Research on liquid metals has been steadily garnering more interest in recent times, especially in flexible electronics applications because of their properties like possessing high conductivity and being liquid state at room temperature. The unique properties afforded by such materials at low temperatures can compensate for the limitations of stretchable electronic devices, particularly robustness and their fluidic property, which can enhance the flexibility and deformation of these devices. Therefore, interest in liquid-metal nanoparticles and liquid metals with nanocomposites has enabled research into their fabrication technologies as well as utilisation in fields such as chemistry, polymer engineering, computational modelling, and nanotechnology. In particular, in flexible and stretchable electronic device applications, the research attention is focused on the fabrication methodologies of liquid-metal nanoparticles and liquid metals containing nanocomposites. This review attempts to summarise the available stretchable and flexible electronics applications that use liquid-metal nanoparticles as well as liquid metals with nanomaterial additives.

Highly Sensitive and Stretchable Strain Sensor Based on a Synergistic Hybrid Conductive Network

Highly sensitive and stretchable strain sensors have attracted considerable attention due to their promising applications in human motion detection, soft robot, wearable electronics, etc. However, there is still a trade-off between high sensitivity and high stretchability. Here, we reported a stretchable strain sensor by sandwiching reduced graphene oxide (RGO)-coated polystyrene microspheres (PS@RGO) and silver nanowires (AgNWs) conductive hybrids in an elastic polydimethylsiloxane (PDMS) matrix. Due to the synergistic effect of PS@RGO and AgNWs, the PDMS/PS@RGO/AgNWs/PDMS sensor exhibits a high initial electrical conductivity of 8791 S m^-1, wide working range of 0-230%, large gauge factor of 11 at 0-60% of strain and 47 at 100%-230% of strain with a high linear coefficient of 0.9594 and 0.9947, respectively, low limit of detection (LOD) of 1% of strain, and excellent long-term stability over 1000 stretching/releasing cycles under 50% strain. Furthermore, the strain sensor has been demonstrated in detecting human body motion and fan rotation with high stretchability and stability, showing potential application in intelligent robot and Internet of things.

Corrosion-Resistant Functional Diamond Coatings for Reliable Interfacing of Liquid Metals with Solid Metals

Gallium-based liquid metals (GLMs) exist as atypical liquid-phase metals at and near room temperature while being electrically and thermally conductive, enabling copious applications in soft electronics and thermal management systems. Yet, solid metals are affected by interfacing with GLMs, resulting in liquid metal embrittlement and device failure. To avert this issue, mechanically durable and electrically tunable diffusion barriers for long-term reliable liquid metal-solid metal interfacing based on the deposition of various diamond coatings are designed and synthesized, as they feature high chemical inertness and extraordinary mechanical resistance. The diamond coatings show superlyophobicity (GLM contact angle ≥ 155°) and are nonstick toward GLMs, thereby achieving high mobility of GLM droplets (sliding angle 8-12°). The excellent barrier and anti-adhesion performance of the diamond coatings are proven in long-term experiments (3 weeks) of coated titanium alloy (Ti) samples in contact with GLMs. The electrical performance of the conductive diamond coating deposited on Ti is reliable and stable over a period of 50 h. As proof-of-concept applications a switch and a thermal management device based on liquid metals are demonstrated, signifying that coating diamond films on metals is a potent means to achieve stable integration of solid metals with GLMs.

Surface Engineering of Liquid Metal Nanodroplets by Attachable Diblock Copolymers

Liquid metal (LM) micro/nano droplets have promising applications in various fields such as flexible electronics, catalysis, and soft composites as well as biomedicines. However, the preparation of highly stable LM nanodroplets suspension based on eutectic gallium/indium (EGaIn) alloys is still challenging. Herein, we report a general and robust strategy to fabricate EGaIn nanodroplets stabilized by polymer brushes (polymer brushes/EGaIn nanodroplets) via in situ attachment of well-defined diblock copolymers with short poly(acrylic acid) (PAA) anchoring segments. Under ultrasonication, the anchoring PAA block is in situ attached onto the gallium oxide "skin" layer of EGaIn nanodroplets to form polymer brushes. The attachable diblock copolymer surfactants allow for highly efficient formation of EGaIn nanodroplets in high yield and with narrow size distribution. The polymer brushes/EGaIn nanodroplets contain very low fractions of attached polymer (<1 wt %) and exhibit high colloidal stability (>30 days) and good redispersibility. Precise control of polymer architecture by atom-transfer radical polymerization was employed to prepare various block copolymers for suspensions in a variety of solvents.

Highly conductive graphene/carbon black screen printing inks for flexible electronics

The industrial scale production and application of liquid conductive nanomaterials with well-defined conductive properties, printing adaptability and mechanical properties are crucial for the flexible electronic devices. Although graphene can be used as an attractive liquid nanoink platform for electronic devices, it is still a major challenge to prepare graphene conductive inks with high concentration, conductivity and stability with graphene powders as raw materials and improve the post-treatment process for printed patterns. Here, a novel graphene-based screen printing conductive ink employing liquid-exfoliated graphene powders produced by jet cavitation and carbon black jointly as conductive filler is presented. The inks with graphene powders containing thicker smaller-area flakes and carbon black fraction of 15% in the total conductive fillers exhibit printability down to lines of 90 μm in width and printed pattern electrical conductivity of 2.15 × 10⁴ S/m at 7 μm thickness along with outstanding mechanical properties. Also, special post-treatment, i.e. heating-compression rolling-heating, makes the conductive ink formulation compatible with a wide range of substrates and suitable for Roll-to-Roll applications. Overall, this paper provides a new solution to high-efficiency, low-cost, large-scale production of printed flexible electronics.

Direct write printing of a self-encapsulating liquid metal-silicone composite

Silicone composites featuring inclusions of liquid metal particles are soft and stretchable materials with useful electric, dielectric, mechanical, and thermal properties. Until recently, these materials have primarily been cast as films. This work examines the possibility of using uncured liquid metal-elastomer (LME) composites as inks for direct writing. The liquid metal inclusions act as rheological modifiers for the silicone, forming a gel-structure that can be extruded from a nozzle and hold its shape after printing. Additionally, by tuning the particle size, larger particles in the printed structures can settle to form metal-rich regions at the bottom of the structures, encased by metal-depleted (insulating) regions. Using mechanical force, the liquid metal-rich interior can be rendered conductive by sintering without affecting the insulating exterior. Thus, it is possible to print this soft and stretchable material while creating conductors with self-insulating shells.

Exploring Electrochemical Extrusion of Wires from Liquid Metals

Metal melt extrusion in gaseous or vacuum environments is a classical approach for forming wires. However, such extrusions have not been investigated in ionic solutions. Here, we use liquid metal (LM) gallium (Ga) and its eutectic alloy with indium (EGaIn) to explore the possibility of electrochemical extrusion of wires and study the tuning of the self-liming oxide layers as the coating for these wires formed during the process. By controlling the surface tension of the LM immersed in an electrolyte, and through the electrocapillary effect, we enable the extrusion of LM wires. The surface morphologies of LM wires and the thickness of the oxide layers are investigated when Ga and EGaIn are processed in neutral and basic electrolytes using various voltages. Taking advantage of the LM oxides, we show that LM wires offer tunable surface oxide thickness and composition using the electrochemical system and investigate the related working mechanisms. The wires are formed into patterns using an automated stage and show a self-healing capability. This work presents an unconventional method for electrochemical fabrication of LM wires, offering prospects for further research and industrial scale-up.

All-Soft Supercapacitors Based on Liquid Metal Electrodes with Integrated Functionalized Carbon Nanotubes

Soft energy storage devices, such as supercapacitors, are an essential component for powering integrated soft microsystems. However, conventional supercapacitors are mainly manufactured using hard/brittle materials that easily crack and eventually delaminate from the current collector by mechanical deformation. Therefore, to realize all-soft supercapacitors, the electrodes should be soft, stretchable, and highly conductive without compromising the electrochemical performance. This paper presents all-soft supercapacitors for integrated soft microsystems based on gallium-indium liquid metal (eutectic gallium-indium alloy, EGaIn) electrodes with integrated functionalized carbon nanotubes (CNTs). Oxygen functional groups on the surface of the CNTs ensure strong adhesion between the functionalized CNTs and the thin native oxide layer on the surface of EGaIn, which enables delamination-free soft and stretchable electrodes even under mechanical deformation. The electrochemical performances of fabricated all-soft supercapacitors in a parallel-plate arrangement were investigated without and with applied mechanical deformation. The fabricated supercapacitors exhibit areal capacitances as high as 12.4 mF cm^-2 and show nearly unchanged performance under 30% applied strain. They maintain >95% of their original capacitance after >4200 charging and discharging cycles with a periodic applied strain of 30%. Finally, fabricated supercapacitors have been successfully integrated with a commercial light-emitting diode to demonstrate an integrated soft microsystem.

Magnetic and Conductive Liquid Metal Gels

Liquid metals are fast becoming a new class of universal and frictionless additives for the development of multifunctional soft and flexible materials. Herein, nanodroplets of eutectic gallium-indium alloy, which is liquid at room temperature, were used as a platform for the formulation of electrically conductive and magnetically responsive gels with the incorporation of Fe₃O₄ nanoparticles. The nanoadditives were prepared in situ within a water-based solution of polyvinyl alcohol. A borax cross-linking reaction was then performed to yield multifunctional flexible and self-healing gels. The physicochemical properties and changes in the nanoadditives at each step of the gel preparation method were characterized. Oxidation and complexation reactions between the liquid metal and iron oxide nanoadditives were observed. A mixture of nanosized functional magnetic Fe₃O₄/Fe₂O₃ and In-Fe oxide complexes was found to enable the magnetic susceptibility of the gels. The mechanical and self-healing properties of the gels were assessed, and finally, this flexible and multifunctional material was used as an electronic switch via remote magnetic actuation. The developed conductive and magnetic gels demonstrate great potential for the design of soft electronic systems.

Liquid Metal-Based Route for Synthesizing and Tuning Gas-Sensing Elements

There is a strong demand for developing tunable and facile routes for synthesizing gas-sensitive semiconducting compounds. The concept of synthesizing micro- and nanoparticles of metallic compounds in a tunable process, which relies on liquid metals, is presented here. This is a liquid-based ultrasonication procedure within which additional metallic elements (In, Sn, and Zn) are incorporated into liquid Ga that is sonicated in a secondary solvent. We investigate liquid metal sonication in dimethyl sulfoxide (DMSO) and water to show their impact on the size, morphology, and crystal structure of the particulated products. The synthesized materials are annealed to investigate their responses to model reducing (H₂) and oxidizing (NO₂) gas species. The preparation process in DMSO gives rise to predominantly monoclinic Ga₂O₃ crystals which are favorable for gas sensing, while the emergence of rhombohedral Ga₂O₃ phases from the water sonication process led to inactive samples. The ease of tunability without hazardous precursors during the synthesis procedure is demonstrated. The route presented here can be uniquely employed for designing and engineering on-demand functional materials for sensing applications.