Multimaterial Three-Dimensional Printing of Ultraviolet-Curable Ionic Conductive Elastomers with Diverse Polymers for Multifunctional Flexible Electronics

Photo-crosslinkable organic materials for flexible and stretchable electronics

As technology advances to enhance human perceptual experiences of the surrounding environment, significant research on stretchable electronics is actively progressing, spanning from the synthesis of materials to their applications in fully integrated devices. A critical challenge lies in developing materials that can maintain their electrical properties under substantial stretching. Photo-crosslinkable organic materials have emerged as a promising solution due to their ability to be precisely modified with light to achieve desired properties, such as enhanced durability, stable conductivity, and micropatterning. This review examines recent research on photo-crosslinkable organic materials, focusing on their components and integration within stretchable electronic devices. We explore the essential characteristics required for each device component (insulators, semiconductors, and conductors) and explain how photo-crosslinking technology addresses these needs through its principles and implementation. Additionally, we discuss the integration and utilization of these components in real-world applications, including physical sensors, organic field-effect transistors (OFETs), and organic solar cells (OSCs). Finally, we offer a concise perspective on the future directions and potential challenges in ongoing research on photo-crosslinkable organic materials.

Regio-Selective Mechanical Enhancement of Polymer-Grafted Nanoparticle Composites via Light-Mediated Crosslinking

Polymer-brush-grafted nanoparticles (PGNPs) that can be covalently crosslinked post-processing enable the fabrication of mechanically robust and chemically stable polymer nanocomposites with high inorganic filler content. Modifying PGNP brushes to append UV-activated crosslinkers along the polymer chains would permit a modular crosslinking strategy applicable to a diverse range of nanocomposite compositions. Further, light-activated crosslinking reactions enable spatial control of crosslink density to program intentionally inhomogeneous mechanical responses. Here, a method of synthesizing composites using UV-crosslinkable brush-coated nanoparticles (referred to as UV-XNPs) is introduced that can be applied to various monomer compositions by incorporating photoinitiators into the polymer brushes. UV crosslinking of processed UV-XNP structures can increase their tensile modulus up to 15-fold without any noticeable alteration to their appearance or shape. By using photomasks to alter UV intensity across a sample, intentionally designed inhomogeneities in crosslink density result in predetermined anisotropic shape changes under strain. This unique capability of UV-XNP materials is applied to stiffness-patterned flexible electronic substrates that prevent the delamination of rigid components under deformation. The potential of UV-XNPs as functional, soft device components is further demonstrated by wearable devices that can be modified post-fabrication to customize their performance, permitting the ability to add functionality to existing device architectures.

Additive Manufacturing of Organic Electrochemical Transistors: Methods, Device Architectures, and Emerging Applications

Organic electrochemical transistors (OECTs) are key devices in a large set of application fields including bioelectronics, neuromorphics, sensing, and flexible electronics. This review explores the advancements in additive manufacturing techniques accounting for printing technologies, device architectures, and emerging applications. The promising applications of printed OECTs, ranging from biochemical sensors to neuromorphic computing are examined, showcasing their versatility. Despite significant advancements, ongoing challenges persist, such as material-related issues, inconsistencies in film homogeneity, and the scalability of integration processes. This review identifies these critical obstacles and offers targeted solutions and future research directions aimed at enhancing the performance and reliability of fully-printed OECTs. By addressing these challenges, the aim of this study is to facilitate the development of next-generation OECTs that can meet the demands of emerging applications in sustainable and intelligent electronic and bioelectronic systems.

Fully 3D-Printed Soft Capacitive Sensor of High Toughness and Large Measurement Range

Soft capacitive sensors are widely utilized in wearable devices, flexible electronics, and soft robotics due to their high sensitivity. However, they may suffer delamination and/or debonding due to their low interfacial toughness. In addition, they usually exhibit a small measurement range resulting from their limited stiffness variation range. In this paper, soft silicone-based capacitive sensors are developed by using a customized multimaterial 3D printer. By curing silicone materials simultaneously, the continuous conductive and dielectric layers achieve a substantial interfacial toughness of 1036 J·m-2. The sensor with tilted thin-plate dielectrics exhibits interfacial toughness of 645 J·m-2 or 339 J·m-2 in the transverse or longitudinal direction, respectively. Additionally, the sensors demonstrate a broad measurement range from 0.85 Pa to 5000 kPa. This extended range is facilitated by the significant stiffness variation of the separated tilted thin-plate dielectrics, ranging from 0.56 kPa to 19.76 MPa. Two applications of these fully printed soft sensors, including an intelligent sensorized insole and a robotic hand combining both soft actuators and soft sensors are showcased. It is believed that the strategy, employing 3D printing for soft microstructured sensors, is a general approach not only applicable for improving the performance of soft sensors, but also conducive to designing powerful soft functional devices.

Recent innovations in interfacial strategies for DLP 3D printing process optimization

Three-dimensional (3D) printing, also known as additive manufacturing, is capable of transforming computer-aided designs into intricate structures directly and on demand. This technology has garnered significant attention in recent years. Among the various approaches, digital light processing (DLP) 3D printing, which utilizes polymers or prepolymers as the ink, has emerged as the leading new technology, driven by high demand across diverse fields such as customized production, healthcare, education, and art design. DLP 3D printing technology employs cured slices as molding units and is recognized for its potential to achieve both high printing speed and resolution. Recent insights into the DLP printing process highlight its inherent interface transformations between liquid and solid states. This review summarizes key aspects of the printing process, speed, precision, and material diversity optimization, from the view of interfacial interactions between solid and liquid phases which are influenced by resin formation, curing surfaces and light source properties. These interactions include those at the liquid resin-UV pattern interface, the cured structure-curing surface interface, the liquid resin-curing surface interface, and the liquid resin-cured structure interface, each contributing to the unique characteristics of the printed results. Finally, this review addresses the current challenges and limitations of DLP 3D printing, providing valuable insights for future improvements and guiding potential innovations in the field.

Additively manufactured micro-lattice dielectrics for multiaxial capacitive sensors

Soft sensors that can perceive multiaxial forces, such as normal and shear, are of interest for dexterous robotic manipulation and monitoring of human performance. Typical planar fabrication techniques have substantial design constraints that often prohibit the creation of functionally compelling and complex architectures. Moreover, they often require multiple-step operations for production. Here, we use an additive manufacturing process based on continuous liquid interface production to create high-resolution (30-micrometer) three-dimensional elastomeric polyurethane lattices for use as dielectric layers in capacitive sensors. We show that the capacitive responses and sensitivities are highly tunable through designs of lattice type, thickness, and material-void volume percentage. Microcomputed tomography and finite element simulation are used to elucidate the influence of lattice design on the deformation mechanism and concomitant sensing behavior. The advantage of three-dimensional printing is exhibited with examples of fully printed representative athletic equipment with integrated sensors.

Highly conductive and stretchable nanostructured ionogels for 3D printing capacitive sensors with superior performance

Ionogels are promising material candidates for ionotronics due to their excellent ionic conductivity, stretchability, and thermal stability. However, it is challenging to develop 3D printable ionogels with both excellent electrical and mechanical properties. Here, we report a highly conductive and stretchable nanostructured (CSN) ionogel for 3D printing ionotronic sensors. We propose the photopolymerization-induced microphase separation strategy to prepare the CSN ionogels comprising continuous conducting nanochannels intertwined with cross-linked polymeric framework. The resultant CSN ionogels simultaneously achieves high ionic conductivity (over 3 S m-1), high stretchability (over 1500%), low degree of hysteresis (0.4% at 50% strain), wide-temperature-range thermostability (-72 to 250 °C). Moreover, its high compatible with DLP 3D printing enables the fabrication of complex ionogel micro-architectures with high resolution (up to 5 μm), which allows us to manufacture capacitive sensors with superior sensing performances. The proposed CSN ionogel paves an efficient way to manufacture the next-generation capacitive sensors with enhanced performance.

Architected Poly(ionic liquid) Composites with Spatially Programmable Mechanical Properties and Mixed Conductivity

Structural electrolytes present advantages over liquid varieties, which are critical to myriad applications. In particular, structural electrolytes based on polymerized ionic liquids or poly(ionic liquids) (pILs) provide wide electrochemical windows, high thermal stability, nonvolatility, and modular chemistry. However, current methods of fabricating structural electrolytes from pILs and their composites present limitations. Recent advances have been made in 3D printing pIL electrolytes, but current printing techniques limit the complexity of forms that can be achieved, as well as the ability to control mechanical properties or conductivity. We introduce a method for fabricating architected pIL composites as structural electrolytes via embedded 3D (EMB3D) printing. We present a modular design for formulating ionic liquid (IL) monomer composite inks that can be printed into sparse, lightweight, free-standing lattices with different functionalities. In addition to characterizing the rheological and mechanical behaviors of IL monomer inks and pIL lattices, we demonstrate the self-sensing capabilities of our printed structural electrolytes during cyclic compression. Finally, we use our inks and printing method to spatially program self-sensing capabilities in pIL lattices through heterogeneous architectures as well as ink compositions that provide mixed ionic-electronic conductivity. Our free-form approach to fabricating structural electrolytes in complex, 3D forms with programmable, anisotropic properties has broad potential use in next-generation sensors, soft robotics, bioelectronics, energy storage devices, and more.

Emerging Bioprinting for Wound Healing

Bioprinting has attracted much attention due to its suitability for fabricating biomedical devices. In particular, bioprinting has become one of the growing centers in the field of wound healing, with various types of bioprinted devices being developed, including 3D scaffolds, microneedle patches, and flexible electronics. Bioprinted devices can be designed with specific biostructures and biofunctions that closely match the shape of wound sites and accelerate the regeneration of skin through various approaches. Herein, a comprehensive review of the bioprinting of smart wound dressings is presented, emphasizing the crucial effect of bioprinting in determining biostructures and biofunctions. The review begins with an overview of bioprinting techniques and bioprinted devices, followed with an in-depth discussion of polymer-based inks, modification strategies, additive ingredients, properties, and applications. The strategies for the modification of bioprinted devices are divided into seven categories, including chemical synthesis of novel inks, physical blending, coaxial bioprinting, multimaterial bioprinting, physical absorption, chemical immobilization, and hybridization with living cells, and examples are presented. Thereafter, the frontiers of bioprinting and wound healing, including 4D bioprinting, artificial intelligence-assisted bioprinting, and in situ bioprinting, are discussed from a perspective of interdisciplinary sciences. Finally, the current challenges and future prospects in this field are highlighted.

Low-Temperature Resistant Stretchable Micro-Supercapacitor Based on 3D Printed Octet-Truss Design

Recently, stretchable micro-supercapacitors (MSCs) that can be easily integrated into electronic devices have attracted research and industrial attentions. In this work, three-dimensional (3D) stretchable MSCs with an octet-truss electrode (OTE) design have been demonstrated by a rapid digital light processing (DLP) process. The 3D-printed electrode structure is beneficial for electrode-electrolyte interface formation and consequently increases the number of ions adsorbed on the electrode surface. The designed MSCs can achieve a high capacitance as ≈74.76 mF cm^-3 under 1 mA cm^-3 at room temperature even under a high mechanical deformation, and can achieve 19.53 mF cm^-3 under 0.1 mA cm^-3 at a low temperature (-30 °C). Moreover, finite element analysis (FEA) reveals the OTE structure provides 8 times more contact area per unit volume at the electrode-electrolyte interface compared to the traditional interdigital electrode (IDE). This work combines structural design and 3D printing techniques, which provides new insights into highly stretchable MSCs for next-generation electronic devices.