Printed, Soft, Nanostructured Strain Sensors for Monitoring of Structural Health and Human Physiology

Soft Nanomembrane Sensor-Enabled Wearable Multimodal Sensing and Feedback System for Upper-Limb Sensory Impairment Assistance

Sensory rehabilitation in pediatric patients with traumatic spinal cord injury is challenging due to the ongoing development of their nervous systems. However, these sensory problems often result in nonuse of the impaired limb, which disturbs impaired limb rehabilitation and leads to overuse of the contralateral limb and other physical or psychological issues that may persist. Here, we introduce a soft nanomembrane sensor-enabled wearable glove system that wirelessly delivers a haptic sensation from the hand with tactile feedback responses for sensory impairment assistance. The smart glove system uses gold nanomembranes, copper-elastomer composites, and laser-induced graphene for the sensitive detection of pressure, temperature, and strain changes. The nanomaterial sensors are integrated with low-profile tactile actuators and wireless flexible electronics to offer real-time sensory feedback. The wearable system's thin-film sensors demonstrate 98% and 97% accuracy in detecting pressure and finger flexion, respectively, along with a detection coverage of real-life temperature changes as an effective rehabilitation tool. Collectively, the upper-limb sensory impairment assistance system embodies the latest in soft materials and wearable technology to incorporate soft sensors and miniaturized actuators and maximize its compatibility with human users, offering a promising solution for patient sensory rehabilitation.

Printed Nanomaterials for All-in-One Integrated Flexible Wearables and Bioelectronics

Recent advancements in printing technologies allow for fabricating various wearable sensors, circuits, and integrated electronics. However, most printing tools have limited ranges of handling ink viscosity, a short working distance, and a limited feature size for developing sophisticated electronics. Here, this paper introduces an all-in-one integrated wearable electronic system via multilayer, multinanomaterial printing. Versatile, high-resolution aerosol-jet printing could successfully print Cu nanoparticles, Ag nanoparticles, PEDOT:PSS, and polyimide (PI) to manufacture nanomembrane composite structures, including skin-contact electrodes and wireless circuits. The printed polymer, PEDOT:PSS deposited on the Cu, ensures biocompatibility when making direct skin contact while enhancing electrical conductivity for electrodes. A self-assembled monolayer facilitates better adhesion of Cu nanoparticles on the PI. Also, using intensive pulsed light, a photonic sintering method minimizes Cu-oxidation while avoiding thermal damage. The combined experimental and computational study shows the mechanical flexibility and reliability of the printed integrated device. With human subjects, the flexible wireless bioelectronic system demonstrates superior performance in detecting high-fidelity physiological signals on the skin, including electromyograms, electrooculograms, electrocardiograms, and motions, proving its potential applications in portable human healthcare and persistent human-machine interfaces.

A Simple Method to Manufacture a Force Sensor Array Based on a Single-Material 3D-Printed Piezoresistive Foam and Metal Coating

Nowadays, 3D printing is becoming an increasingly common option for the manufacturing of sensors, primarily due to its capacity to produce intricate geometric shapes. However, a significant challenge persists in integrating multiple materials during printing, for various reasons. In this study, we propose a straightforward approach that combines 3D printing with metal coating to create an array of resistive force sensors from a single material. The core concept involves printing a sensing element using a conductive material and subsequently separating it into distinct parts using metal-coated lines connected to the electrical ground. This post-printing separation process involves manual intervention utilizing a stencil and metallic spray. The primary obstacle lies in establishing a sufficient contact surface between the sprayed metal and the structure, to ensure effective isolation among different zones. To address this challenge, we suggest employing a lattice structure to augment the contact surface area. Through experimental validation, we demonstrate the feasibility of fabricating two sensing elements from a single-material 3D-printed structure, with a maximum electrical isolation ratio between the sensors of above 30. These findings hold promise for the development of a new generation of low-tech 3D-printed force/displacement sensor arrays.

Performance analysis of solution-processed nanosheet strain sensors-a systematic review of graphene and MXene wearable devices

Nanotechnology has led to the realisation of many potentialInternet of Thingsdevices that can be transformative with regards to future healthcare development. However, there is an over saturation of wearable sensor review articles that essentially quote paper abstracts without critically assessing the works. Reported metrics in many cases cannot be taken at face value, with researchers overly fixated on large gauge factors. These facts hurt the usefulness of such articles and the very nature of the research area, unintentionally misleading those hoping to progress the field. Graphene and MXenes are arguably the most exciting organic and inorganic nanomaterials for polymer nanocomposite strain sensing applications respectively. Due to their combination of cost-efficient, scalable production and device performances, their potential commercial usage is very promising. Here, we explain the methods for colloidal nanosheets suspension creation and the mechanisms, metrics and models which govern the electromechanical properties of the polymer-based nanocomposites they form. Furthermore, the many fabrication procedures applied to make these nanosheet-based sensing devices are discussed. With the performances of 70 different nanocomposite systems from recent (post 2020) publications critically assessed. From the evaluation of these works using universal modelling, the prospects of the field are considered. Finally, we argue that the realisation of commercial nanocomposite devices may in fact have a negative effect on the global climate crisis if current research trends do not change.

Conformal Fabrication of Thick Film Platinum Strain Gauge Via Error Regulation Strategies for In Situ High-Temperature Strain Detection

Monitoring high-temperature strain on curved components in harsh environments is a challenge for a wide range of applications, including in aircraft engines, gas turbines, and hypersonic vehicles. Although there are significant improvements in the preparation of high-temperature piezoresistive film on planar surfaces using 3D printing methods, there are still difficulties with poor surface compatibility and high-temperature strain testing on curved surfaces. Herein, a conformal direct ink writing (CDIW) system coupled with an error feedback regulation strategy was used to fabricate high-precision, thick films on curved surfaces. This strategy enabled the maximum amount of error in the distance between the needle and the substrate on a curved surface to be regulated from 155 to 4 μm. A conformal Pt thick-film strain gauge (CPTFSG) with a room-temperature strain coefficient of 1.7 was created on a curved metallic substrate for the first time. The resistance drift rate at 800 °C for 1 h was 1.1%, which demonstrated the excellent stability and oxidation resistance of the CPTFSG. High-temperature dynamic strain tests up to 769 °C revealed that the sensor had excellent high-temperature strain test performance. Furthermore, the CPTFSG was conformally deposited on an aero-engine turbine blade to perform in situ tensile and compressive strain testing at room temperature. High-temperature strain tests were conducted at 100 and 200 °C for 600 and 580 με, respectively, demonstrating a high steady-state response consistent with the commercial high-temperature strain transducer. In addition, steady-state strain tests at high temperatures up to 496 °C were tested. The CDIW error modulation strategy provides a highly promising approach for the high-precision fabrication of Pt thick films on complex surfaces and driving in situ sensing of high-temperature parameters on curved components toward practical applications.

An Ionic Liquid-Based Stretchable Sensor for Measuring Normal and Shear Force

Soft and stretchable force sensors are widely used for health monitoring, robotics, prosthetics, and other applications. Soft force sensors with the capability of measuring both normal and shear force could offer even greater functionality and provide more information, particularly in the field of biomechanics. In this work, a new solid-state force sensor is proposed that can measure both normal and shear forces at the same time. The soft and stretchable sensor was fabricated using an ionic liquid (IL)/polymer network. Two separate IL-based polymer membranes were used to detect normal and shear forces. Sensor architecture and electrical wiring for normal, shear, and combined sensing were developed, and various material compositions for different sensor layers were investigated to find the combination that could achieve the optimum sensor performance. A basic material formulation for carbon nanotube-based electrodes, the IL/polymer network, and polymeric insulation layers was proposed. To configure a combined (normal and shear) sensor, separate sensors for normal and shear deformations were first designed and investigated. Later, a combined sensor was fabricated using a mold via screen printing, photocuring, and thermal curing. The combined sensor was evaluated under different force conditions. The results show that the sensor can reliably measure normal and shear forces. Moreover, the findings demonstrate a way to successfully modulate the sensitivity for normal and shear sensing by varying the material composition or geometric configuration, which provides flexibility for application-specific designs.

Predicting the Pressure Behavior and Sensing Property of Elastic Pressure Exerting and Sensing Fabrics for Compression Textiles

Using compression textiles to exert an appropriate and steady pressure on human limbs is a primary treatment method in the medical area. Compression pressure is a crucial parameter that determines the treatment efficacy. However, there is a lack of pressure-sensing fabrics that can both apply and measure the pressure of compression textiles, particularly the theoretical study of the prediction of the pressure and sensing performance of such a sensing fabric. In this study, based on the developed elastic pressure-exerting and -sensing fabrics and a setup test protocol simulating the pressure-exerting process, the relationships between the displacement of the press head, resultant fabric extension, and pressure were theoretically explored. Two finite element (FE) models, continuum and discontinuous models, were first established to predict the pressure behavior of elastic pressure-exerting and -sensing fabrics. The simulation results present good agreement with the experimental results wherein the pressure generated increases with the increase of the fabric strain in a nonlinear form. Furthermore, with the above FE models for the relationship between fabric extension and pressure generated, as well as the measured electrical resistance of the sensing fabric, a model for the electrical resistance of the sensing fabric can thus be established. Among pressure-sensing fabrics in three different structures, the sensing fabric in sateen exhibits better pressure prediction accuracy and a faster response to the pressure change. Finally, a series of numerical simulations were conducted to investigate the effects of the press head diameter, the unit cell crimp factor of fabric and the fabric pretension on the fabric extension, the resultant pressure, and electrical resistance change. The simulation results show that the pressure decreases with the increase of the press head diameter. The crimp factor and pretension of the sensing fabric also have a significant effect on the pressure and electrical resistance change generated. This simulation approach provides a new theoretical understanding of the pressure behavior and mechanism of pressure-sensing fabrics for future smart compression textiles.

Plant-based Biomass/Polyvinyl Alcohol Gels for Flexible Sensors

Flexible sensors show great application potential in wearable electronics, human-computer interaction, medical health, bionic electronic skin and other fields. Compared with rigid sensors, hydrogel-based devices are more flexible and biocompatible and can easily fit the skin or be implanted into the body, making them more advantageous in the field of flexible electronics. In all designs, polyvinyl alcohol (PVA) series hydrogels exhibit high mechanical strength, excellent sensitivity and fatigue resistance, which make them promising candidates for flexible electronic sensing devices. This paper has reviewed the latest progress of PVA/plant-based biomass hydrogels in the construction of flexible sensor applications. We first briefly introduced representative plant biomass materials, including sodium alginate, phytic acid, starch, cellulose and lignin, and summarized their unique physical and chemical properties. After that, the design principles and performance indicators of hydrogel sensors are highlighted, and representative examples of PVA/plant-based biomass hydrogel applications in wearable electronics are illustrated. Finally, the future research is briefly prospected. We hope it can promote the research of novel green flexible sensors based on PVA/biomass hydrogel.

Droplets Patterning of Structurally Integrated 3D Conductive Networks-Based Flexible Strain Sensors for Healthcare Monitoring

Flexible strain sensors with significant extensibility, stability, and durability are essential for public healthcare due to their ability to monitor vital health signals noninvasively. However, thus far, the conductive networks have been plagued by the inconsistent interface states of the conductive components, which hampered the ultimate sensitivity performance. Here, we demonstrate structurally integrated 3D conductive networks-based flexible strain sensors of hybrid Ag nanorods/nanoparticles(AgNRs/NPs) by combining a droplet-based aerosol jet printing(AJP) process and a feasible transfer process. Structurally integrated 3D conductive networks have been intentionally developed by tweaking droplets deposition behaviors at multi-scale for efficient hybridization and ordered assembly of AgNRs/NPs. The hybrid AgNRs/NPs enhance interfacial conduction and mechanical properties during stretching. In a strain range of 25%, the developed sensor demonstrates an ideal gauge factor of 23.18. When real-time monitoring of finger bending, arm bending, squatting, and vocalization, the fabricated sensors revealed effective responses to human movements. Our findings demonstrate the efficient droplet-based AJP process is particularly capable of developing advanced flexible devices for optoelectronics and wearable electronics applications.

Ultrasensitive Strain Sensor Utilizing a AgF-AgNW Hybrid Nanocomposite for Breath Monitoring and Pulmonary Function Analysis

Breath monitoring and pulmonary function analysis have been the prime focus of wearable smart sensors owing to the COVID-19 outbreak. Currently used lung function meters in hospitals are prone to spread the virus and can result in the transmission of the disease. Herein, we have reported the first-ever wearable patch-type strain sensor for enabling real-time lung function measurements (such as forced volume capacity (FVC) and forced expiratory volume (FEV) along with breath monitoring), which can avoid the spread of the virus. The noninvasive and highly sensitive strain sensor utilizes the synergistic effect of two-dimensional (2D) silver flakes (AgFs) and one-dimensional (1D) silver nanowires (AgNWs), where AgFs create multiple electron transmission paths and AgNWs generate percolation networks in the nanocomposite. The nanocomposite-based strain sensor possesses a high optimized conductivity of 7721 Sm^-1 (and a maximum conductivity of 83,836 Sm^-1), excellent stretchability (>1000%), and ultrasensitivity (GFs of 35 and 87 when stretched 0-20 and 20-50%, respectively), thus enabling reliable detection of small strains produced by the body during breathing and other motions. The sensor patching site was optimized to accurately discriminate between normal breathing, quick breathing, and deep breathing and analyze numerous pulmonary functions, including the respiratory rate, peak flow, FVC, and FEV. Finally, the observed measurements for different pulmonary functions were compared with a commercial peak flow meter and a spirometer, and a high correlation was observed, which highlights the practical feasibility of continuous respiratory monitoring and pulmonary function analysis.

Nanoparticle–Hydrogel Based Sensors: Synthesis and Applications

Hydrogels are hydrophilic three-dimensional (3D) porous polymer networks that can easily stabilize various nanoparticles. Loading noble metal nanoparticles into a 3D network of hydrogels can enhance the synergy of the components. It can also be modified to prepare intelligent materials that can recognize external stimuli. The combination of noble metal nanoparticles and hydrogels to produce modified or new composite materials has attracted considerable attention as to the use of these materials in sensors. However, there is limited review literature on nanoparticle–hydrogel-based sensors. This paper presents the detailed strategies of synthesis and design of the composites, and the latest applications of nanoparticle–hydrogel materials in the sensing field. Finally, the current challenges and future development directions of nanoparticle–hydrogel-based sensors are proposed.

Bending Sensor Based on Controlled Microcracking Regions for Application toward Wearable Electronics and Robotics

A soft bending sensor based on the inverse pyramid structure is demonstrated, revealing that it can effectively suppress microcrack formation in designated regions, thus allowing the cracks to open gradually with bending in a controlled manner. Such a feature enabled the bending sensor to simultaneously have a wide dynamic range of bending strain (0.025-5.4%), high gauge factor (∼74), and high linearity (R² ∼ 0.99). Furthermore, the bending sensor can capture repeated instantaneous changes in strain and various types of vibrations, owing to its fast response time. Moreover, the bending direction can be differentiated with a single layer of the sensor, and using an array of sensors integrated on a glove, object recognition was demonstrated via machine learning. Finally, a self-monitoring proprioceptive ionic electroactive polymer (IEAP) actuator capable of operating in liquid was demonstrated. Such features of our bending sensor will enable a simple and effective way of detecting sophisticated motion, thus potentially advancing wearable healthcare monitoring electronics and enabling proprioceptive soft robotics.

Silver Nanowires in Stretchable Resistive Strain Sensors

Silver nanowires (AgNWs), having excellent electrical conductivity, transparency, and flexibility in polymer composites, are reliable options for developing various sensors. As transparent conductive electrodes (TCEs), AgNWs are applied in optoelectronics, organic electronics, energy devices, and flexible electronics. In recent times, research groups across the globe have been concentrating on developing flexible and stretchable strain sensors with a specific focus on material combinations, fabrication methods, and performance characteristics. Such sensors are gaining attention in human motion monitoring, wearable electronics, advanced healthcare, human-machine interfaces, soft robotics, etc. AgNWs, as a conducting network, enhance the sensing characteristics of stretchable strain-sensing polymer composites. This review article presents the recent developments in resistive stretchable strain sensors with AgNWs as a single or additional filler material in substrates such as polydimethylsiloxane (PDMS), thermoplastic polyurethane (TPU), polyurethane (PU), and other substrates. The focus is on the material combinations, fabrication methods, working principles, specific applications, and performance metrics such as sensitivity, stretchability, durability, transparency, hysteresis, linearity, and additional features, including self-healing multifunctional capabilities.

Intelligent Nanomaterials for Wearable and Stretchable Strain Sensor Applications: The Science behind Diverse Mechanisms, Fabrication Methods, and Real-Time Healthcare

It has become a scientific obligation to unveil the underlying mechanisms and the fabrication methods behind wearable/stretchable strain sensors based on intelligent nanomaterials in order to explore their possible potential in the field of biomedical and healthcare applications. This report is based on an extensive literature survey of fabrication of stretchable strain sensors (SSS) based on nanomaterials in the fields of healthcare, sports, and entertainment. Although the evolution of wearable strain sensors (WSS) is rapidly progressing, it is still at a prototype phase and various challenges need to be addressed in the future in special regard to their fabrication protocols. The biocalamity of COVID-19 has brought a drastic change in humans' lifestyles and has negatively affected nations in all capacities. Social distancing has become a mandatory rule to practice in common places where humans interact with each other as a basic need. As social distancing cannot be ruled out as a measure to stop the spread of COVID-19 virus, wearable sensors could play a significant role in technologically impacting people's consciousness. This review article meticulously describes the role of wearable and strain sensors in achieving such objectives.

Fully portable continuous real-time auscultation with a soft wearable stethoscope designed for automated disease diagnosis

Modern auscultation, using digital stethoscopes, provides a better solution than conventional methods in sound recording and visualization. However, current digital stethoscopes are too bulky and nonconformal to the skin for continuous auscultation. Moreover, motion artifacts from the rigidity cause friction noise, leading to inaccurate diagnoses. Here, we report a class of technologies that offers real-time, wireless, continuous auscultation using a soft wearable system as a quantitative disease diagnosis tool for various diseases. The soft device can detect continuous cardiopulmonary sounds with minimal noise and classify real-time signal abnormalities. A clinical study with multiple patients and control subjects captures the unique advantage of the wearable auscultation method with embedded machine learning for automated diagnoses of four types of lung diseases: crackle, wheeze, stridor, and rhonchi, with a 95% accuracy. The soft system also demonstrates the potential for a sleep study by detecting disordered breathing for home sleep and apnea detection.

Humidity-Based Human-Machine Interaction System for Healthcare Applications

Human-machine interaction (HMI) systems are widely used in the healthcare field, and they play an essential role in assisting the rehabilitation of patients. Currently, a large number of HMI-related research studies focus on piezoresistive sensors, self-power sensors, visual and auditory receivers, and so forth. These sensing modalities do not possess high reliability with regard to breathing condition detection. The humidity signal conveyed by breathing provides excellent stability and a fast response; however, humidity-based HMI systems have rarely been studied. Herein, we integrate a humidity sensor and a graphene thermoacoustic device into a humidity-based HMI system (HHMIS), which is capable of monitoring respiratory signals and emitting acoustic signals. HHMIS has a practical value in healthcare to assist patients. For example, it works as a prewarning system for respiratory-related disease patients with abnormal respiratory rates, and as an artificial throat device for aphasia patients. Achieved based on a laser direct writing technology, this wearable device features low cost, high flexibility, and can be prepared on a large scale. This portable non-contact HMMIS has broad application prospects in many fields such as medical health and intelligent control.

Flexible and Stable Carbon Nanotube Film Strain Sensors with Self-Derived Integrated Electrodes

The development of flexible and wearable electronic devices has put an increasing demand on electrode systems with seamless connection and high compatibility with the main device, in order to accommodate complex deformation conditions and maintain stable performance. Here, we present a carbon nanotube-integrated electrode (CNTIE) by wet-pulling the ends of a carbon nanotube (CNT) film to form condensed thin fibers that resemble conventional conducting wire electrodes. A flexible strain sensor was constructed consisting of the middle CNT film as the main functional part and the CNTIE as self-derived electrodes, with inherent CNT connection between the two parts. The sensor can be transferred to versatile substrates (e.g., balloon surface) or encapsulated in thermoplastic polymers, exhibiting a large linear response range (up to 1000% in tensile strain), excellent durability and repeatability over 5000 cycles, and the ability to detect small- to large-degree human body motions. In addition, the strain sensor based on the CNTIE hybrid film (MXene/CNT and graphene/CNT) also shows superior linearity and stability at a strain range of 0-800%. Compared with the sensors using traditional silver wire electrodes and separately fabricated CNT fiber electrodes, our CNTIE plays an important role in achieving highly stable performance in the strain cycles. Our self-derived integrated electrodes provide a potential route to solve the incompatibility issues of conventional electrodes and to develop high-performance flexible and wearable systems based on CNTs and other nanomaterials.

Wearable Sensors Based on Solid-Phase Molecular Self-Assembly: Moisture-Strain Dual Responsiveness Facilitated Extremely High and Damage-Resistant Sensitivity

Wearable sensing technologies have gained increasing interest in biomedical fields because they are convenient and could efficiently monitor health conditions by detecting various physiological signals in real time. However, common film sensors often neglect body moisture and enhance the sensitivity by enhancing the conductive dopants and self-healing ability. We report in this work a supramolecular film sensor based on solid-phase molecular self-assembly (SPMSA), which smartly utilizes the body moisture to enhance the sensitivity for human-machine interaction. The carbon nanotube (CNT)-doped SPMSA film is able to capture environmental moisture quickly. Upon contact to human skin, the moisture not only promotes the junction between CNTs but also contributes to the conductivity. As a result, the sensitivity can be enhanced 4 times. In this way, we are able to obtain the highest sensitivity of 700% with the lowest CNT doping rate of 0.5%. Furthermore, the current sensor displays damage-inert sensing performance. In the presence of a hole of up to 50% of the film area, the sensitivity remains unaffected due to the decreases in the absolute conductivity of the film sensor before and after a trigger to the same extent. In this way, we have developed a new principle in the design of a film sensor for human-machine interaction, which releases the sensor from focus on promoting conductivity and self-healing materials.

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.

Biomedical Implants with Charge-Transfer Monitoring and Regulating Abilities

Transmembrane charge (ion/electron) transfer is essential for maintaining cellular homeostasis and is involved in many biological processes, from protein synthesis to embryonic development in organisms. Designing implant devices that can detect or regulate cellular transmembrane charge transfer is expected to sense and modulate the behaviors of host cells and tissues. Thus, charge transfer can be regarded as a bridge connecting living systems and human-made implantable devices. This review describes the mode and mechanism of charge transfer between organisms and nonliving materials, and summarizes the strategies to endow implants with charge-transfer regulating or monitoring abilities. Furthermore, three major charge-transfer controlling systems, including wired, self-activated, and stimuli-responsive biomedical implants, as well as the design principles and pivotal materials are systematically elaborated. The clinical challenges and the prospects for future development of these implant devices are also discussed.

Inkjet Printing of a Benzocyclobutene-Based Polymer as a Low-k Material for Electronic Applications

Polymeric materials with a low dielectric constant are widely used in the electronic industry due to their properties. In particular, polymer adhesives can be used in many applications such as wafer bonding and three-dimensional integration. Benzocyclobutene (BCB) is a very interesting material thanks to its excellent bonding behavior and dielectric properties. Usually, BCB is applied by spin-coating, although this technology does not allow the fabrication of complex patterns. To obtain complex patterns, it is necessary to use a printing technology, such as inkjet printing. However, inkjet printing of BCB-based inks has not yet been investigated. Here, we show the feasibility of printing complex patterns with a BCB-based ink, reaching a resolution of 130 μm. We demonstrate that with a proper dilution, BCB-based inks enter the printability window and drop ejection is achieved without the formation of satellite drops. In addition, we present the conditions in which there is an appearance of the coffee ring effect. Inks that feature a too high interaction with the substrate are more likely to show the coffee ring effect, deteriorating the printing quality. We also observe that it is possible to achieve a better film uniformity by increasing the number of printed layers, due to redissolution of the BCB-based polymer that helps to level possible inhomogeneities. Our work represents the starting point for an in-depth study of BCB-based polymer fabrication using jet printing technologies, as a comparison of the bonding quality obtained with different materials and different technologies could give more information and broaden the perspective regarding this field.

Review of 3D-printing technologies for wearable and implantable bio-integrated sensors

Thin-film microfabrication-based bio-integrated sensors are widely used for a broad range of applications that require continuous measurements of biophysical and biochemical signals from the human body. Typically, they are fabricated using standard photolithography and etching techniques. This traditional method is capable of producing a precise, thin, and flexible bio-integrated sensor system. However, it has several drawbacks, such as the fact that it can only be used to fabricate sensors on a planar surface, it is highly complex requiring specialized high-end facilities and equipment, and it mostly allows only 2D features to be fabricated. Therefore, developing bio-integrated sensors via 3D-printing technology has attracted particular interest. 3D-printing technology offers the possibility to develop sensors on nonplanar substrates, which is beneficial for noninvasive bio-signal sensing, and to directly print on complex 3D nonplanar organ structures. Moreover, this technology introduces a highly flexible and precisely controlled printing process to realize patient-specific sensor systems for ultimate personalized medicine, with the potential of rapid prototyping and mass customization. This review summarizes the latest advancements in 3D-printed bio-integrated systems, including 3D-printing methods and employed printing materials. Furthermore, two widely used 3D-printing techniques are discussed, namely, ex-situ and in-situ fabrication techniques, which can be utilized in different types of applications, including wearable and smart-implantable biosensor systems.

Microplotter printing of planar solid electrolytes in the CeO2-Y2O3 system

The formation process for planar solid electrolytes in the CeO₂-Y₂O₃ system has been studied using efficient, high-performance, high-resolution microplotter printing technology, using functional ink based on nanopowders (the average size of crystallites was 12-15 nm) of a similar composition obtained by programmed coprecipitation of metal hydroxides. The dependence of the microstructure of the oxide nanoparticles obtained and their crystal structure on yttrium concentration has been studied using a wide range of methods. According to X-ray diffraction (XRD), the nanopowders and coatings produced are single-phase, with a cubic crystal structure of the fluorite type, and the electronic state and content of cerium and yttrium in the printed coatings have been determined using X-ray photoelectron spectroscopy (XPS). The results of scanning electron (SEM) and atomic force microscopy (AFM) have shown that the coatings produced are homogeneous, they do not contain defects in the form of fractures and the height difference over an area of 1 µm² is 30-45 nm. The local electrophysical characteristics of the oxide coatings produced (the work function of the coating surface, capacitance values, maps of the surface potential and capacitive contrast distribution over the surface) have been studied using Kelvin-probe force microscopy (KPFM) and scanning capacitive microscopy (SCM). Using impedance spectroscopy, the dependence of the electrophysical characteristics of printed planar solid electrolytes in the CeO₂-Y₂O₃ system on yttrium content has been determined and the prospects of the technology developed for the manufacture of modern, intermediate-temperature, solid oxide fuel cells have been demonstrated.

Effects of 3D Printing-Line Directions for Stretchable Sensor Performances

Health monitoring sensors that are attached to clothing are a new trend of the times, especially stretchable sensors for human motion measurements or biological markers. However, price, durability, and performance always are major problems to be addressed and three-dimensional (3D) printing combined with conductive flexible materials (thermoplastic polyurethane) can be an optimal solution. Herein, we evaluate the effects of 3D printing-line directions (45°, 90°, 180°) on the sensor performances. Using fused filament fabrication (FDM) technology, the sensors are created with different print styles for specific purposes. We also discuss some main issues of the stretch sensors from Carbon Nanotube/Thermoplastic Polyurethane (CNT/TPU) and FDM. Our sensor achieves outstanding stability (10,000 cycles) and reliability, which are verified through repeated measurements. Its capability is demonstrated in a real application when detecting finger motion by a sensor-integrated into gloves. This paper is expected to bring contribution to the development of flexible conductive materials-based on 3D printing.

Printed, Wireless, Soft Bioelectronics and Deep Learning Algorithm for Smart Human-Machine Interfaces

Recent advances in flexible materials and wearable electronics offer a noninvasive, high-fidelity recording of biopotentials for portable healthcare, disease diagnosis, and machine interfaces. Current device-manufacturing methods, however, still heavily rely on the conventional cleanroom microfabrication that requires expensive, time-consuming, and complicated processes. Here, we introduce an additive nanomanufacturing technology that explores a contactless direct printing of aerosol nanomaterials and polymers to fabricate stretchable sensors and multilayered wearable electronics. Computational and experimental studies prove the mechanical flexibility and reliability of soft electronics, considering direct mounting to the deformable human skin with a curvilinear surface. The dry, skin-conformal graphene biosensor, without the use of conductive gels and aggressive tapes, offers an enhanced biopotential recording on the skin and multiple uses (over ten times) with consistent measurement of electromyograms. The combination of soft bioelectronics and deep learning algorithm allows classifying six classes of muscle activities with an accuracy of over 97%, which enables wireless, real-time, continuous control of external machines such as a robotic hand and a robotic arm. Collectively, the comprehensive study of nanomaterials, flexible mechanics, system integration, and machine learning shows the potential of the printed bioelectronics for portable, smart, and persistent human-machine interfaces.