Hydrogel-Templated Transfer-Printing of Conductive Nanonetworks for Wearable Sensors on Topographic Flexible Substrates

Wafer-Recyclable, Eco-Friendly, and Multiscale Dry Transfer Printing by Transferable Photoresist for Flexible Epidermal Electronics

Flexible electronics have been of great interest in the past few decades for their wide-ranging applications in health monitoring, human-machine interaction, artificial intelligence, and biomedical engineering. Currently, transfer printing is a popular technology for flexible electronics manufacturing. However, typical sacrificial intermediate layer-based transfer printing through chemical reactions results in a series of challenges, such as time consumption and interface incompatibility. In this paper, we have developed a time-saving, wafer-recyclable, eco-friendly, and multiscale transfer printing method by using a stable transferable photoresist. Demonstration of photoresist with various, high-resolution, and multiscale patterns from the donor substrate of silicon wafer to different flexible polymer substrates without any damage is conducted using the as-developed dry transfer printing process. Notably, by utilizing the photoresist patterns as conformal masks and combining them with physical vapor deposition and dry lift-off processes, we have achieved in situ fabrication of metal patterns on flexible substrates. Furthermore, a mechanical experiment has been conducted to demonstrate the mechanism of photoresist transfer printing and dry lift-off processes. Finally, we demonstrated the application of in situ fabricated electrode devices for collecting electromyography and electrocardiogram signals. Compared to commercially available hydrogel electrodes, our electrodes exhibited higher sensitivity, greater stability, and the ability to achieve long-term health monitoring.

Outstanding Synergy of Sensitivity and Linear Range Enabled by Multigradient Architectures

Flexible pressure sensors are devices that mimic the sensory capabilities of natural human skin and enable robots to perceive external stimuli. One of the main challenges is maintaining high sensitivity over a broad linear pressure range due to poor structural compressibility. Here, we report a flexible pressure sensor with an ultrahigh sensitivity of 153.3 kPa-1 and linear response over an unprecedentedly broad pressure range from 0.0005 to 1300 kPa based on interdigital-shaped, multigradient architectures, featuring modulus, conductivity, and microstructure gradients. Such multigradient architectures and interdigital-shaped configurations enable effective stress transfer and conductivity regulation, evading the pressure sensitivity-linear range trade-off dilemma. Together with high pressure resolution, high frequency response, and good reproducibility over the ultrabroad linear range, proof-of-concept applications such as acoustic wave detection, high-resolution pressure measurement, and healthcare monitoring in diverse scenarios are demonstrated.

Stretchable Semi-Interpenetrating Carboxymethyl Guar Gum-Based Composite Hydrogel for Moisture-Proof Wearable Strain Sensor

Wearable strain sensors of conductive hydrogels have very broad application prospects in electronic skins and human-machine interfaces. However, conductive hydrogels suffer from unstable signal transmission due to environmental humidity and inherent shortcomings of their materials. Herein, we introduce a novel moisture-proof conductive hydrogel with high toughness (2.89 MJ m-3), mechanical strength (1.00 MPa), and high moisture-proof sensing performance by using dopamine-functionalized gold nanoparticles as conductive fillers into carboxymethyl guar gum and acrylamide. Moreover, the hydrogel can realize real-time monitoring of major and subtle human movements with good sensitivity and repeatability. In addition, the hydrogel-assembled strain sensor exhibits stable sensing signals after being left for 1 h, and the relative resistance change rate under different strains (25-300%) shows no obvious noise signal up to 99% relative humidity. Notably, the wearable strain sensing is suitable for wearable sensor devices with high relative humidity.

An epifluidic electronic patch with spiking sweat clearance for event-driven perspiration monitoring

Sensory neurons generate spike patterns upon receiving external stimuli and encode key information to the spike patterns, enabling energy-efficient external information processing. Herein, we report an epifluidic electronic patch with spiking sweat clearance using a sensor containing a vertical sweat-collecting channel for event-driven, energy-efficient, long-term wireless monitoring of epidermal perspiration dynamics. Our sweat sensor contains nanomesh electrodes on its inner wall of the channel and unique sweat-clearing structures. During perspiration, repeated filling and abrupt emptying of the vertical sweat-collecting channel generate electrical spike patterns with the sweat rate and ionic conductivity proportional to the spike frequency and amplitude over a wide dynamic range and long time (> 8 h). With such 'spiking' sweat clearance and corresponding electronic spike patterns, the epifluidic wireless patch successfully decodes epidermal perspiration dynamics in an event-driven manner at different skin locations during exercise, consuming less than 0.6% of the energy required for continuous data transmission. Our patch could integrate various on-skin sensors and emerging edge computing technologies for energy-efficient, intelligent digital healthcare.

Topological Gradients for Metal Film-Based Strain Sensors

Metal film-based stretchable strain sensors hold great promise for applications in various domains, which require superior sensitivity-stretchability-cyclic stability synergy. However, the sensitivity-stretchability trade-off has been a long-standing dilemma and the metal film-based strain sensors usually suffer from weak cyclic durability, both of which significantly limit their practical applications. Here, we propose an extremely facile, low-cost and spontaneous strategy that incorporates topological gradients in metal film-based strain sensors, composed of intrinsic (grain size and interface) and extrinsic (film thickness and wrinkle) microstructures. The topological gradient strain sensor exhibits an ultrawide stretchability of 100% while simultaneously maintaining a high sensitivity at an optimal topological gradient of 4.5, due to the topological gradients-induced multistage film cracking. Additionally, it possesses a decent cyclic stability for >10 000 cycles between 0 and 40% strain enabled by the gradient-mixed metal/elastomer interfaces. It can monitor the full-range human activities from subtle pulse signals to vigorous joint movements.

Smart Antifreeze Hydrogels with Abundant Hydrogen Bonding for Conductive Flexible Sensors

Recently, flexible sensors based on conductive hydrogels have been widely used in human health monitoring, human movement detection and soft robotics due to their excellent flexibility, high water content, good biocompatibility. However, traditional conductive hydrogels tend to freeze and lose their flexibility at low temperature, which greatly limits their application in a low temperature environment. Herein, according to the mechanism that multi−hydrogen bonds can inhibit ice crystal formation by forming hydrogen bonds with water molecules, we used butanediol (BD) and N−hydroxyethyl acrylamide (HEAA) monomer with a multi−hydrogen bond structure to construct LiCl/p(HEAA−co−BD) conductive hydrogel with antifreeze property. The results indicated that the prepared LiCl/p(HEAA−co−BD) conductive hydrogel showed excellent antifreeze property with a low freeze point of −85.6 °C. Therefore, even at −40 °C, the hydrogel can still stretch up to 400% with a tensile stress of ~450 KPa. Moreover, the hydrogel exhibited repeatable adhesion property (~30 KPa), which was attributed to the existence of multiple hydrogen bonds. Furthermore, a simple flexible sensor was fabricated by using LiCl/p(HEAA−co−BD) conductive hydrogel to detect compression and stretching responses. The sensor had excellent sensitivity and could monitor human body movement.

An Artificial Tactile Neuron Enabling Spiking Representation of Stiffness and Disease Diagnosis

Mechanical properties of biological systems provide useful information about the biochemical status of cells and tissues. Here, an artificial tactile neuron enabling spiking representation of stiffness and spiking neural network (SNN)-based learning for disease diagnosis is reported. An artificial spiking tactile neuron based on an ovonic threshold switch serving as an artificial soma and a piezoresistive sensor as an artificial mechanoreceptor is developed and shown to encode the elastic stiffness of pressed materials into spike frequency evolution patterns. SNN-based learning of ultrasound elastography images abstracted by spike frequency evolution rate enables the classification of malignancy status of breast tumors with a recognition accuracy up to 95.8%. The stiffness-encoding artificial tactile neuron and learning of spiking-represented stiffness patterns hold a great promise for the identification and classification of tumors for disease diagnosis and robot-assisted surgery with low power consumption, low latency, and yet high accuracy.

Soft Bioelectronics Based on Nanomaterials

Recent advances in nanostructured materials and unconventional device designs have transformed the bioelectronics from a rigid and bulky form into a soft and ultrathin form and brought enormous advantages to the bioelectronics. For example, mechanical deformability of the soft bioelectronics and thus its conformal contact onto soft curved organs such as brain, heart, and skin have allowed researchers to measure high-quality biosignals, deliver real-time feedback treatments, and lower long-term side-effects in vivo. Here, we review various materials, fabrication methods, and device strategies for flexible and stretchable electronics, especially focusing on soft biointegrated electronics using nanomaterials and their composites. First, we summarize top-down material processing and bottom-up synthesis methods of various nanomaterials. Next, we discuss state-of-the-art technologies for intrinsically stretchable nanocomposites composed of nanostructured materials incorporated in elastomers or hydrogels. We also briefly discuss unconventional device design strategies for soft bioelectronics. Then individual device components for soft bioelectronics, such as biosensing, data storage, display, therapeutic stimulation, and power supply devices, are introduced. Afterward, representative application examples of the soft bioelectronics are described. A brief summary with a discussion on remaining challenges concludes the review.

Integrating Highly Porous and Flexible Au Hydrogels with Soft-MEMS Technologies for High-Performance Wearable Biosensing

Wearable biosensors for real-time and non-invasive detection of biomarkers are of importance in early diagnosis and treatment of diseases. Herein, a high-performance wearable biosensing platform was proposed by combining a three-dimensional hierarchical porous Au hydrogel-enzyme electrode with high biocompatibility, activity, and flexibility and soft-MEMS technologies with high precision and capability of mass production. Using glucose oxidase as the model enzyme, the glucose sensor exhibits a sensitivity of 10.51 μA mM^-1 cm^-2, a long durability over 15 days, and a good selectivity. Under the mechanical deformation (0 to 90°), it is able to maintain an almost constant performance with a low deviation of <1.84%. With the assistance of a wireless or a Bluetooth module, this wearable sensing platform achieves real-time and non-invasive glucose monitoring on human skins. Similarly, continuous lactic acid monitoring was also realized with lactate oxidase immobilized on the same sensing platform, further verifying the universality of this sensing platform. Therefore, our work holds promise to provide a universal, high-performance wearable biosensing platform for various biomarkers in sweat and reliable diagnostic information for health management.

Stretchable and Sensitive Silver Nanowire-Hydrogel Strain Sensors for Proprioceptive Actuation

Safer human-robot interactions mandate the adoption of proprioceptive actuation. Strain sensors can detect the deformation of tools and devices in unstructured and capricious environments. However, such sensor integration in surgical/clinical settings is challenging due to confined spaces, structural complexity, and performance losses of tools and devices. Herein, we report a highly stretchable skin-like strain sensor based on a silver nanowire (AgNW) layer and hydrogel substrate. Our facile fabrication method utilizes thermal annealing to modulate the gauge factor (GF) by forming multidimensional wrinkles and a layered conductive network. The developed AgNW-hydrogel (AGel) sensors sustain and exhibit a strain-sensitive profile (max. GF = ∼70) with high stretchability (200%). Due to its conformability, the sensor demonstrates efficacy in integration and motion monitoring with minimal mechanical constraints. We provide contextual cognizance of tooltip during a transoral procedure by incorporating AGel sensors and showing the fabrication methodology's versatility by developing a hybrid self-sensing actuator with real-time performance feedback.

Highly Sensitive On-Skin Temperature Sensors Based on Biocompatible Hydrogels with Thermoresponsive Transparency and Resistivity

The development of electrically responsive sensors that interact directly with human skin and at the same time produce a visual indication of the temperature is in great demand. Here, we report a highly sensitive electronic skin (E-skin) sensor that measures and visualizes skin temperature simultaneously using a biocompatible hydrogel displaying thermoresponsive transparency and resistivity resulting from a temperature dependence of the strength of the hydrogen bonding between its components. This thermoresponsive hydrogel (TRH) showed a temperature dependence of not only the proton conductivity but also of its transmittance of light through a change in polymer conformation. We were able to use our TRH temperature sensor (TRH-TS) to measure temperature in a wide range of temperatures based on a change in its intrinsic resistivity (-0.0289 °C^-1 ) and to visualize the temperature due to its thermoresponsive transmittance (from 7% to 96%). The TRH-TS exhibited high reliability upon multiple cycles of heating and cooling. The on-skin TRH-TS patch is also shown to successfully produce changes in its impedance and optical transparency as a result of changes in skin temperature during cardiovascular exercise. This work has shown that our biocompatible TRH-TS is potentially suitable as wearable E-skin for various emerging flexible healthcare monitoring applications.

Self-reconfigurable high-weight-per-volume-gelatin films for all-solution-processed on-skin electronics with ultra-conformal contact

Although conventional skin-attachable electronics exhibit good functionalities, their direct attachment (without any adhesive) to human skin with sufficient conformal contact is challenging. Herein, all-solution-processed on-skin electronics based on self-reconfigurable high-weight-per- volume-gelatin (HWVG) film constructed using an effective, biocompatible water absorption-evaporation technique are demonstrated. Completely conformal contact of self-reconfigurable HWVG films is realized by rapidly inducing anisotropic swelling in the perpendicular direction and covering any curvature on the skin without spatial gap or void after shrinking. A sufficiently thin HWVG film (~2 um) exhibited higher adhesion owing to van der Waals force and the carboxylic acid and amine groups in HWVG film form cross-linkages through intermolecular bonds with human skin. Self-reconfigurable HWVG films with high biocompatibility are optimized to afford a superior efficiency of 87.83 % at a concentration of 20 % (w/v) and a storage modulus of 1822 MPa at 36.5 °C. Furthermore, functional nanoelectrodes consisting of self-reconfigurable silver nanowires/HWVG films for high-performance on-skin sensors allowing the detection of sensitive motion and electrophysiological signals, as well as an armband-type sensor system incorporated with a smartphone for health-care monitoring are demonstrated. Outstanding performances, including stability, reliability, flexibility, re-usability, biocompatibility, and permeability of on-skin electronics based on HWVG films can open-up a prospective route to realizing breathable human-machine interfaces based on biocompatible materials and processes.

Polymer-Water Interaction Enabled Intelligent Moisture Regulation in Hydrogels

The water-vapor transition is critical for hydrogels in a collection of applications. However, how the polymer-water interaction along with the nature of the structure affect the macroscopic water-vapor transition remains a challenging question to answer. In this work, we tested the moisture transfer behaviors of a series of hydrogels at different humidities and found some hydrogels capable of lowering their surface vapor pressure to stop dehydration at low humidity and absorbing water from ambient air to recover toward initial states at high humidity. Through molecular dynamic simulations, we demonstrate that water inside these hydrogels undergoes increasing intensive intermolecular bonding during evaporation. The increased intermolecular bonding reduces the vapor pressure of the hydrogels and leads to the self-regulation. More interestingly, we demonstrate the self-regulation is closely related to the Young's modulus of hydrogels. These results provide further insight into the mechanism of the water-vapor transition in hydrogels and show potential in a broad range of future applications.

Wearable strain sensor for real-time sweat volume monitoring

Reliably monitoring sweat volume has attracted much attention due to its important role in the assessment of physiological health conditions and the prevention of dehydration. Here, we present the first example of wearable strain sensor for real-time sweat volume monitoring. Such sweat volume monitoring sensor is simply fabricated via embedding strain sensing fabric in super-absorbent hydrogels, the hydrogels can wick sweat up off the skin surface to swell and then trigger the strain sensing fabrics response. This sensor can realize real-time detection of sweat volume (0.15-700 μL), shows excellent repeatability and stability against movement or light interference, reliability in the non-pathological range (pH: 4-9 and salinity: 0-100 mM NaCl) in addition. Such sensor combing swellable hydrogels with strain sensing fabrics provides a novel measurement method of wearable devices for sweat volume monitoring.

Spirally Wrapped Carbon Nanotube Microelectrodes for Fiber Optoelectronic Devices beyond Geometrical Limitations toward Smart Wearable E-Textile Applications

Fiber optoelectronics technology has recently attracted attention as enabling various form factors of wearable electronics, and the issue of how to control and optimize the configuration and physical properties of the electrode micropatterns in the microfiber devices has become important. Here, spirally wrapped carbon nanotube (CNT) microelectrodes with a controlled dimension are demonstrated for high-performance fiber optoelectronic devices. Inkjet-printed CNT microelectrodes with the desired dimension on an agarose hydrogel template are rolling-transferred onto a microfiber surface with an efficient electrical interface. A fiber organic field-effect transistor with spirally wrapped CNT microelectrodes verifies the feasibility of this strategy, where the transferred microelectrodes intimately contact the organic semiconductor active layer and the output current characteristics are simply controlled, resulting in characteristics that exceed the previous structural limitations. Furthermore, a fiber organic photodiode with spirally wrapped CNT microelectrodes, when used as a transparent electrode, exhibits a high I_light/I_dark ratio and good durability of bending. This fiber photodiode can be successfully incorporated into a textile photoplethysmography bandage for the real-time monitoring of human vital signals. This work offers a promising and efficient strategy to overcome the geometric factors limiting the performance of fiber-optic optoelectronic devices.

Advances in Materials for Soft Stretchable Conductors and Their Behavior under Mechanical Deformation

Soft stretchable sensors rely on polymers that not only withstand large deformations while retaining functionality but also allow for ease of application to couple with the body to capture subtle physiological signals. They have been applied towards motion detection and healthcare monitoring and can be integrated into multifunctional sensing platforms for enhanced human machine interface. Most advances in sensor development, however, have been aimed towards active materials where nearly all approaches rely on a silicone-based substrate for mechanical stability and stretchability. While silicone use has been advantageous in academic settings, conventional silicones cannot offer self-healing capability and can suffer from manufacturing limitations. This review aims to cover recent advances made in polymer materials for soft stretchable conductors. New developments in substrate materials that are compliant and stretchable but also contain self-healing properties and self-adhesive capabilities are desirable for the mechanical improvement of stretchable electronics. We focus on materials for stretchable conductors and explore how mechanical deformation impacts their performance, summarizing active and substrate materials, sensor performance criteria, and applications.

High-Rate Printing of Micro/Nanoscale Patterns Using Interfacial Convective Assembly

Printing of electronics has been receiving increasing attention from academia and industry over the recent years. However, commonly used printing techniques have limited resolution of micro- or sub-microscale. Here, a directed-assembly-based printing technique, interfacial convective assembly, is reported, which utilizes a substrate-heating-induced solutal Marangoni convective flow to drive particles toward patterned substrates and then uses van der Waals interactions as well as geometrical confinement to trap the particles in the pattern areas. The influence of various assembly parameters including type of mixing solvent, substrate temperature, particle concentration, and assembly time is investigated. The results show successful assembly of various nanoparticles in patterns of different shapes with a high resolution down to 25 nm. In addition, the assembly only takes a few minutes, which is two orders of magnitude faster than conventional convective assembly. Small-sized (diameter below 5 nm) nanoparticles tend to coalesce during the assembly process and form sintered structures. The fabricated silver nanorods show single-crystal structure with a low resistivity of 8.58 × 10^-5 Ω cm. With high versatility, high resolution, and high throughput, the interfacial convective assembly opens remarkable opportunities for printing next generation nanoelectronics and sensors.

From design to applications of stimuli-responsive hydrogel strain sensors

Stimuli-responsive hydrogel strain sensors that synergize the advantages of both hydrogel and smart functional materials have attracted increasing interest from material design to emerging applications in health monitors and human–machine interfaces.

Recent advances in solid-contact ion-selective electrodes: functional materials, transduction mechanisms, and development trends

This article presents a comprehensive overview of recent progress in the design and applications of solid-contact ion-selective electrodes (SC-ISEs).

Polyvinyl Alcohol-Stabilized Liquid Metal Hydrogel for Wearable Transient Epidermal Sensors

Wearable epidermal sensors are attracting growing interests in human activity monitoring and flexible touch display, but they are still limited by the poor self-healing property and the difficult dissolvable feature. Herein, we report polyvinyl alcohol (PVA)-stabilized liquid metal particles (LMPs) (PVA-LMPs) hydrogels with excellent self-healing performance and the dissolvable feature for wearable epidermal sensors, constructed by dispersing LMPs of eutectic gallium and indium into the borate-modified PVA polymer networks. Interestingly, the PVA-LMPs hydrogels exhibited excellent electrically and mechanically self-healing ability. Moreover, the PVA-LMPs hydrogel can be fabricated as epidermal sensors, which can accurately monitor the human activities. Additionally, the epidermal sensors are dissolvable, showing an attractive feature for on demand transient electronics. It is demonstrated that the hydroxyl groups of PVA can stabilize LMPs via hydrogen-bonding interactions. Furthermore, the dynamic cross-linking bonds between hydrogels and LMPs can rupture and coalesce reversibly in the hydrogel network, which endow the hydrogels with both electrically and mechanically self-healing ability. This work shows the potential of constructing next-generation multifunctional hydrogel-based epidermal sensors for human activity monitoring, wearable healthcare diagnosis, portable electronics, and robot tactile systems.