Soft Self-Regulating Heating Elements for Thermoplastic Elastomer-Based Electronic Skin Applications

Resistive heating elements can be of particular interest for many applications, such as e-skin. In this study, soft heating elements were developed by combining thermoplastic polyurethane (TPU) with carbon black. In contrast to previous studies on thermoplastic polymer-based thermistors, the heating elements could endure elongations above 100%. Due to the high melting point of the TPU and the carbon filler, the thermistors could be heated up to 180°C without significant deformation. The heating elements were extruded on TPU substrates using material extrusion additive manufacturing in one-step process. Self-regulating behavior to control the maximum temperature was achieved with the application of two different voltages (20 and 25 V) and different current thresholds, between 100 and 800 mA. The heating performance was adjusted by changing the geometry of the sensing elements; an increase in cross section resulted in a lower current density and lower temperature. For the heating elements, variation of the additive manufacturing parameters such as offset, layer height, nozzle speed, and extrusion multiplier resulted in a different width/height aspect ratio of the cross section of the extruded lines, affecting the initial resistivity of the thermistor. Orientation of the carbon filler during extrusion process is one reason for the small change of the longitudinal conductivity of the heating elements. The resulting skin with the integrated heating elements allowed the possibility to perform the in situ heating for the localized healing of structural damage, while maintaining the softness required for the application of soft robotic electronic skin.

Evaluating the Effect of Iron(III) in the Preparation of a Conductive Porous Composite Using a Biomass Waste-Based Starch Template

In this work, the effect of iron(III) in the preparation of a conductive porous composite using a biomass waste-based starch template was evaluated. Biopolymers are obtained from natural sources, for instance, starch from potato waste, and its conversion into value-added products is highly significant in a circular economy. The biomass starch-based conductive cryogel was polymerized via chemical oxidation of 3,4-ethylenedioxythiophene (EDOT) using iron(III) p-toluenesulfonate as a strategy to functionalize porous biopolymers. Thermal, spectrophotometric, physical, and chemical properties of the starch template, starch/iron(III), and the conductive polymer composites were evaluated. The impedance data of the conductive polymer deposited onto the starch template confirmed that at a longer soaking time, the electrical performance of the composite was improved, slightly modifying its microstructure. The functionalization of porous cryogels and aerogels using polysaccharides as raw materials is of great interest for applications in electronic, environmental, and biological fields.

Soft Wearable Piezoresistive Sensors Based on Natural Rubber Fabricated with a Customized Vat-Based Additive Manufacturing Process

Piezoresistive sensors for monitoring human motions are essential for the prevention and treatment of injury. Natural rubber is a material of renewable origin that can be used for the development of soft wearable sensors. In this study, natural rubber was combined with acetylene black to develop a soft piezoresistive sensing composite for monitoring the motion of human joints. An additive manufacturing technique based on stereolithography was used, and it was seen that the sensors produced with the method could detect even small strains (<10%) successfully. With the same sensor composite fabricated by mold casting, it was not possible to detect low strains reliably. TEM microscopy revealed that the distribution of the filler was not homogeneous for the cast samples, suggesting a directionality of the conductive filler network. For the sensors fabricated through the stereolithography-based method, a homogeneous distribution could be achieved. Based on mechano-electrical characterization, it was seen that the samples produced with AM combined the ability to endure large elongations with a monotonic sensor response. Under dynamic conditions, the sensor response of the samples produced by 3D printing showed lower drift and lower signal relaxation. The piezoresistive sensors were examined for monitoring the motion of the human finger joints. By increasing the bending angle of the sensor, it was possible to increase the sensitivity of the response. With the renewable origin of natural rubber and manufacturing method, the featured sensors can expand the applicability of soft flexible electronics in biomedical applications and devices.

Effect of Red Mud Addition on Electrical and Magnetic Properties of Hemp-Derived-Biochar-Containing Epoxy Composites

Waste stream valorization is a difficult task where the economic and environmental issues must be balanced. The use of complex metal-rich waste such as red mud is challenging due to the wide variety of metal oxides present such as iron, aluminum, and titanium. The simple separation of each metal is not economically feasible, so alternative routes must be implemented. In this study, we investigated the use of red mud mixed with hemp waste to produce biochar with high conductivity and good magnetic properties induced by the reduction of the metal oxides present in the red mud through carbothermal processes occurring during the co-pyrolysis. The resulting biochar enriched with thermally-reduced red mud is used for the preparation of epoxy-based composites that are tested for electric and magnetic properties. The electric properties are investigated under DC (direct current) regime with or without pressure applied and under AC (alternating current) in a frequency range from 0.5 up to 16 GHz. The magnetic measurements show the effective tailoring of hemp-derived biochar with magnetic structures during the co-pyrolytic process.

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.

ZrB2/SiCN Thin-Film Strain Gauges for In-Situ Strain Detection of Hot Components

The in-situ strain/stress detection of hot components in harsh environments remains a challenging task. In this study, ZrB₂/SiCN thin-film strain gauges were fabricated on alumina substrates by direct writing. The effects of ZrB₂ content on the electrical conductivity and strain sensitivity of ZrB₂/SiCN composites were investigated, and based on these, thin film strain gauges with high electrical conductivity (1.71 S/cm) and a gauge factor of 4.8 were prepared. ZrB₂/SiCN thin-film strain gauges exhibit excellent static, cyclic strain responses and resistance stability at room temperature. In order to verify the high temperature performance of the ZrB₂/SiCN thin-film strain gauges, the temperature-resistance characteristic curves test, high temperature resistance stability test and cyclic strain test were conducted from 25 °C to 600 °C. ZrB₂/SiCN thin-film strain gauges exhibit good resistance repeatability and stability, and highly sensitive strain response, from 25 °C to 600 °C. Therefore, ZrB₂/SiCN thin-film strain gauges provide an effective approach for the measurement of in-situ strain of hot components in harsh environments.

Fabrication of Conductive, High Strength and Electromagnetic Interference (EMI) Shielded Green Composites Based on Waste Materials

Conventional conductive homopolymers such as polypyrrole and poly-3,4-ethylenedioxythiophene (PEDOT) have poor mechanical properties, for the solution to this problem, we tried to construct hybrid composites with higher electrical properties coupled with high mechanical strength. For this purpose, Kevlar fibrous waste, conductive carbon particles, and epoxy were used to make the conductive composites. Kevlar waste was used to accomplish the need for economics and to enhance the mechanical properties. At first, Kevlar fibrous waste was converted into a nonwoven web and subjected to different pretreatments (chemical, plasma) to enhance the bonding between fiber-matrix interfaces. Similarly, conductive carbon particles were converted into nanofillers by the action of ball milling to make them homogeneous in size and structure. The size and morphological structures of ball-milled particles were analyzed by Malvern zetasizer and scanning electron microscopy. In the second phase of the study, the conductive paste was made by adding the different concentrations of ball-milled carbon particles into green epoxy. Subsequently, composite samples were fabricated via a combination of prepared conductive pastes and a pretreated Kevlar fibers web. The influence of different concentrations of carbon particles into green epoxy resin for electrical conductivity was studied. Additionally, the electrical conductivity and electromagnetic shielding ability of conductive composites were analyzed. The waveguide method at high frequency (i.e., at 2.45 GHz) was used to investigate the EMI shielding. Furthermore, the joule heating response was studied by measuring the change in temperature at the surface of the conductive composite samples, while applying a different range of voltages. The maximum temperature of 55 °C was observed when the applied voltage was 10 V. Moreover, to estimate the durability and activity in service the ageing performance (mechanical strength and moisture regain) of developed composite samples were also analyzed.

Biomass-Derived, Highly Conductive Aqueous Inks for Superior Electromagnetic Interference Shielding, Joule Heating, and Strain Sensing

Conductive composite inks are widely used in various applications such as flexible electronics. However, grand challenges still remain associated with their relatively low electrical conductivity and require heavy use of organic solvents, which may limit their high performance in broad applications and cause environmental concerns. Here, we report a generalized and eco-friendly strategy to fabricate highly conductive aqueous inks using silver nanowires (AgNWs) and biomass-derived organic salts, including succinic acid-chitosan (SA-chitosan) and sebacic acid-chitosan. SA-chitosan/AgNW composite coatings can be prepared by directly casting conductive aqueous inks on various substrates, followed by subsequently heating for cross-linking. The composite coatings exhibit an ultrahigh electrical conductivity up to 1.4 × 10⁴ S/cm, which are stable after being treated with various organic solvents and/or kept at a high temperature of 150 °C, indicating their high chemical and thermal resistance. The flexibility and performance durability of these composite coatings were demonstrated by a suite of characterization methods, including bending, folding, and adhesion tests. Moreover, a high electromagnetic interference shielding (EMI) effectiveness of 73.3 dB is achieved for SA-chitosan/AgNW composite coatings at a thickness of only 10 μm due to the ultrahigh electrical conductivity. Additionally, we further demonstrated that such conductive composite inks can be used for fabricating functional textiles for a variety of applications with high performance, such as EMI shielding, Joule heating, and strain sensing. The robust and highly conductive inks prepared by this simple and environmental-friendly method hold great promise as important material candidates for the potential large-scale manufacturing of flexible and wearable electronics.

Fabrication of Piezo-Resistance Composites Containing Thermoplastic Polyurethane/Hybrid Filler Using 3D Printing

In this study, 3D-printable flexible piezoresistive composites containing various amounts of cilia-like hybrid fillers were developed. In the hybrid fillers, micro-scale Cu particles with a 0D structure may allow them to easily disperse into the flexible TPU matrix. Furthermore, nanoscale multi-walled carbon nanotubes (MWCNTs) with a high aspect ratio, present on the surface of the Cu particles, form an electrical network when the polymer matrix is strained, thus providing good piezoresistive performance as well as good flowability of the composite materials. With an optimal hybrid filler content (17.5 vol.%), the 3D-printed piezoresistive composite exhibits a gauge factor of 6.04, strain range of over 20%, and durability of over 100 cycles. These results highlight the potential applications of piezoresistive pressure sensors for health monitoring, touch sensors, and electronic skin.

Soldering of Electronics Components on 3D-Printed Conductive Substrates

Rapid development of additive manufacturing and new composites materials with unique properties are promising tools for fabricating structural electronics. However, according to the typical maximum resolution of additive manufacturing methods, there is no possibility to fabricate all electrical components with these techniques. One way to produce complex structural electronic circuits is to merge 3D-printed elements with standard electronic components. Here, different soldering and surface preparation methods before soldering are tested to find the optimal method for soldering typical electronic components on conductive, 3D-printed, composite substrates. To determine the optimal soldering condition, the contact angles of solder joints fabricated in different conditions were measured. Additionally, the mechanical strength of the joints was measured using the shear force test. The research shows a possibility of fabricating strong, conductive solder joints on composites substrates prepared by additive manufacturing. The results show that mechanical cleaning and using additional flux on the composite substrates are necessary to obtain high-quality solder joints. The most repeatable joints with the highest shear strength values were obtained using reflow soldering together with low-temperature SnBiAg solder alloy. A fabricated demonstrator is a sample of the successful merging of 3D-printed structural electronics with standard electronic components.

Biocompatible SWCNT Conductive Composites for Biomedical Applications

The efficiency of devices for biomedical applications, including tissue engineering and neuronal stimulation, heavily depends on their biocompatibility and performance level. Therefore, it is important to find adequate materials that meet the necessary requirements such as (i) being intrinsically compatible with biological systems, (ii) providing a sufficient electronic conductivity that promotes efficient signal transduction, (iii) having "soft" mechanical properties comparable to biological structures, and (iv) being degradable in physiological solution. We have developed organic conducting biocompatible single-walled carbon nanotubes (SWCNT) composites based on bovine serum albumin, carboxymethylcellulose, and acrylic polymer and investigated their properties, which are relevant for biomedical applications. This includes ζ-potential measurements, conductivity analyses, and SEM micrographs, the latter providing a local analysis of SWCNT distribution in the base material. We observed the development of the electrical conductivity of the SWCNT composites exposed to 1 mM KCl electrolyte for 40 days, representing a high stability of the samples. The conductivity of samples reaches 1300 S/m for 0.45 wt.% nanotubes. Moreover, we demonstrated the biocompatibility of the composites via cultivating fibroblast cell culture. Finally, we showed that composite coating results in the longer lifespan of cells on the surface. Overall, the SWCNT-based conductive composites might be a promising material for extended biomedical applications.

Poly(lactic acid)-Based Ink for Biodegradable Printed Electronics With Conductivity Enhanced through Solvent Aging

Biodegradable electronics is a rapidly growing field, and the development of controllably biodegradable, high-conductivity materials suitable for additive manufacturing under ambient conditions remains a challenge. In this report, printable conductive pastes that employ poly(lactic acid) (PLA) as a binder and tungsten as a conductor are demonstrated. These composite conductors can provide enhanced stability in applications where moisture may be present, such as environmental monitoring or agriculture. Post-processing the printed traces using a solvent-aging technique increases their conductivity by up to 2 orders of magnitude, with final conductivities approaching 5000 S/m. Such techniques could prove useful when thermal processes including heating or laser sintering are limited by the temperature constraints of typical biodegradable substrates. Both accelerated oxidative and hydrolytic degradation of the printed composite conductors are examined, and a fully biodegradable capacitive soil moisture sensor is fabricated and tested.

Unusual Two-Step Assembly of a Minimalistic Dipeptide-Based Functional Hypergelator

Self-assembled peptide hydrogels represent the realization of peptide nanotechnology into biomedical products. There is a continuous quest to identify the simplest building blocks and optimize their critical gelation concentration (CGC). Herein, a minimalistic, de novo dipeptide, Fmoc-Lys(Fmoc)-Asp, as an hydrogelator with the lowest CGC ever reported, almost fourfold lower as compared to that of a large hexadecapeptide previously described, is reported. The dipeptide self-assembles through an unusual and unprecedented two-step process as elucidated by solid-state NMR and molecular dynamics simulation. The hydrogel is cytocompatible and supports 2D/3D cell growth. Conductive composite gels composed of Fmoc-Lys(Fmoc)-Asp and a conductive polymer exhibit excellent DNA binding. Fmoc-Lys(Fmoc)-Asp exhibits the lowest CGC and highest mechanical properties when compared to a library of dipeptide analogues, thus validating the uniqueness of the molecular design which confers useful properties for various potential applications.

Graphene/Carbon Nanotube Hybrid Nanocomposites: Effect of Compression Molding and Fused Filament Fabrication on Properties

The present work reports on the production and characterization of acrylonitrile butadiene styrene (ABS) hybrid nanocomposite filaments incorporating graphene nanoplatelets (GNPs) and carbon nanotubes (CNTs) suitable for fused filament fabrication (FFF). At first, nanocomposites with a total nanofiller content of GNP and/or CNT of 6 wt.% and a GNP/CNT relative percentage ratio of 0, 10, 30, 50, 70, and 100 were produced by melt compounding and compression molding. Their mechanical, electrical resistivity, and electromagnetic interference shielding effectiveness (EMI SE) properties were evaluated. The hybrid nanocomposites showed a linear increase in modulus and decrease in strength as a function of GNP content; on the other hand, the addition of CNT in hybrid nanocomposites determined a positive increase in electrical conductivity, but a potentially critical decrease of melt flow index. Due to the favorable compromise between processability and enhancement of performance (i.e., mechanical and electrical properties), the hybrid composition of 50:50 GNP/CNT was selected as the most suitable for the filament production of 6 wt.% carbonaceous nanocomposites. EMI SE of ABS-filled single CNT and hybrid GNP/CNT nanofillers obtained from compression molding reached the requirement for applications (higher than -20 dB), while slightly lower EMI SE values (in the range -12/-16 dB) were obtained for FFF parts dependent on the building conditions.

Matrix-Independent Highly Conductive Composites for Electrodes and Interconnects in Stretchable Electronics

Electrically conductive composites (ECCs) hold great promise in stretchable electronics because of their printability, facile preparation, elasticity, and possibility for large-area fabrication. A high conductivity at steady state and during mechanical deformation is a critical property for ECCs, and extensive efforts have been made to improve the conductivity. However, most of those approaches are exclusively functional to a specific polymer matrix, restricting their capability to meet other requirements, such as mechanical, adhesive, and thermomechanical properties. Here, we report a generic approach to prepare ECCs with conductivity close to that of bulk metals and maintain their conductivity during stretching. This approach iodizes the surfactants on the commercial silver flakes, and subsequent photo exposure converts these silver iodide nanoparticles to silver nanoparticles. The ECCs based on silver nanoparticle-covered silver flakes exhibit high conductivity because of the removal of insulating surfactants as well as the enhanced contact between flakes. The treatment of silver flakes is independent of the polymer matrix and provides the flexibility in matrix selection. In the development of stretchable interconnects, ECCs can be prepared with the same polymer as the substrate to ensure strong adhesion between interconnects and the substrate. For the fabrication of on-skin electrodes, a polymer matrix of low modulus can be selected to enhance conformal contact with the skin for reduced impedance.

Recent Development of Flexible and Stretchable Antennas for Bio-Integrated Electronics

Wireless technology plays an important role in data communication and power transmission, which has greatly boosted the development of flexible and stretchable electronics for biomedical applications and beyond. As a key component in wireless technology, flexible and stretchable antennas need to be flexible and stretchable, enabled by the efforts with new materials or novel integration approaches with structural designs. Besides replacing the conventional rigid substrates with textile or elastomeric ones, flexible and stretchable conductive materials also need to be used for the radiation parts, including conductive textiles, liquid metals, elastomeric composites embedding conductive fillers, and stretchable structures from conventional metals. As the microwave performance of the antenna (e.g., resonance frequency, radiation pattern, and radiation efficiency) strongly depend on the mechanical deformations, the new materials and novel structures need to be carefully designed. Despite the rapid progress in the burgeoning field of flexible and stretchable antennas, plenty of challenges, as well as opportunities, still exist to achieve miniaturized antennas with a stable or tunable performance at a low cost for bio-integrated electronics.

Effects of the Nanofillers on Physical Properties of Acrylonitrile-Butadiene-Styrene Nanocomposites: Comparison of Graphene Nanoplatelets and Multiwall Carbon Nanotubes

The effects of carbonaceous nanoparticles, such as graphene (GNP) and multiwall carbon nanotube (CNT) on the mechanical and electrical properties of acrylonitrile–butadiene–styrene (ABS) nanocomposites have been investigated. Samples with various filler loadings were produced by solvent free process. Composites ABS/GNP showed higher stiffness, better creep stability and processability, but slightly lower tensile strength and electrical properties (low conductivity) when compared with ABS/CNT nanocomposites. Tensile modulus, tensile strength and creep stability of the nanocomposite, with 6 wt % of GNP, were increased by 47%, 1% and 42%, respectively, while analogous ABS/CNT nanocomposite showed respective values of 23%, 12% and 20%. The electrical percolation threshold was achieved at 7.3 wt % for GNP and 0.9 wt % for CNT. The peculiar behaviour of conductive CNT nanocomposites was also evidenced by the observation of the Joule’s effect after application of voltages of 12 and 24 V. Moreover, comparative parameters encompassing stiffness, melt flow and resistivity were proposed for a comprehensive evaluation of the effects of the fillers.

Filaments Production and Fused Deposition Modelling of ABS/Carbon Nanotubes Composites

Composite acrylonitrile-butadiene-styrene (ABS)/carbon nanotubes (CNT) filaments at 1, 2, 4, 6 and 8 wt %, suitable for fused deposition modelling (FDM) were obtained by using a completely solvent-free process based on direct melt compounding and extrusion. The optimal CNT content in the filaments for FDM was found to be 6 wt %; for this composite, a detailed investigation of the thermal, mechanical and electrical properties was performed. Presence of CNT in ABS filaments and 3D-printed parts resulted in a significant enhancement of the tensile modulus and strength, accompanied by a reduction of the elongation at break. As documented by dynamic mechanical thermal analysis, the stiffening effect of CNTs in ABS is particularly pronounced at high temperatures. Besides, the presence of CNT in 3D-printed parts accounts for better creep and thermal dimensional stabilities of 3D-printed parts, accompanied by a reduction of the coefficient of thermal expansion). 3D-printed nanocomposite samples with 6 wt % of CNT exhibited a good electrical conductivity, even if lower than pristine composite filaments.

3D Printing of Highly Conductive Nanocomposites for the Functional Optimization of Liquid Sensors

The utilization of 3D printing of highly conductive (σ ≈ 2350 S m^-1 ) polymer composite structures for the functional optimization of scaffold-shaped liquid sensors is demonstrated. This study can open the pathway of the application of 3D printing of conductive composites for optimization of structures useful for various applications such as smart sensors in textile or in the field of electronics.

Three-dimensional compressible and stretchable conductive composites

Three-dimensional (3D) conductive composites with remarkable flexibility, compressibility, and stretchability are fabricated by solution deposition of thin metal coatings on chemically modified, macroscopically continuous, 3D polyurethane sponges, followed by infiltration of the metallic sponges with polydimethylsiloxane (PDMS). These low-cost conductive composites are used as high-performance interconnects for flexible and stretchable light-emitting diode (LED) arrays, even with severe surface abrasion or cutting.