Liquid Metal Alloy Research Articles

Nanotip Formation from Liquid Metals for Soft Electronic Junctions.

Liquid metals and alloys with high-aspect-ratio nanodimensional features are highly sought-after for emerging electronic applications. However, high surface tension, water-like fluidity, and the existence of self-limiting oxides confer specific peculiarities to their characteristics. Here, we introduce a high accuracy nanometric three-dimensional pulling and stretching method to fabricate liquid-metal-based nanotips from room- or near-room-temperature gallium-based alloys. The pulling rate and step size were controlled with a resolution of up to 10 nm and yielded different nanotip morphologies and lengths as a function of the base liquid metal alloy composition and the pulling parameters. The obtained nanotips presented high aspect ratios over lengths of a few microns and apexes between 10 and 100 nm. The liquid metal alloys were found confined within nanotips with about 10 nm apexes when vertically pulled at 100 nm/s. An amorphous gallium oxide skin was shown to cover the surface of the nanotips, while the liquid core was composed of the initial liquid metal alloys. The electrical contact established at the nanotips was characterized under dynamic conditions. The liquid metal nanotips showed an Ohmic resistance when a continuous liquid metal channel was formed, and a controllable semiconductor state corresponding to a heterojunction formed at the junction between the liquid metal phase and the gallium oxide semiconductor skin. The variable threshold voltages of the heterojunction were controlled via stretching of the nanotips with a 10 nm step resolution. The liquid metal nanotips were also used for establishing soft electronic junctions. This novel method of liquid metal nanotip fabrication with Ohmic and semiconducting behaviors will lead to exciting avenues for developing electronic and sensing devices.

Liquid metal derived MOF functionalized nanoarrays with ultra-wideband electromagnetic absorption

Low melting point liquid metal alloys are progressively utilized in different research fields due to their unique physicochemical properties. Among them, EGaIn is liquid at room temperature with an excellent solubility for reactive metal atoms such as Al. Combined with their characteristic flexible surface, large area and atomically flat interfaces, a library of two-dimensional materials can be generated. Liquid metal synthesis routes provide a highly reproducible thickness of nanosheets with fast, simple, scalable, inexpensive, high yield and non-toxic methods, especially for Al oxides and hydroxides. At the same time, Al-based heterojunction structure also shows a good application prospect in the field of electromagnetic wave absorption, therefore, the use of liquid metal synthesis methods to find the synthesis methods of Al-based layered double hydroxide (LDH) and its derivatives remains to be explored. In this work, EGaIn was used as an aluminum reservoir to prepare LDH and metal organic framework (MOFs) nano-arrays. The prepared CoAl-LDH@ZIF 67 can be transformed into CoAl-LDO@Co-C in the subsequent annealing process performed under nitrogen environments. Interestingly, a series of samples with different morphologies can be obtained by changing the synthesis parameters. The excellent electromagnetic wave interactions are fully characterized. It has an effective absorption bandwidth of 8.48 GHz at 2.6 mm. The findings demonstrated in this work pave the way for the application of lightwave and ductile complex nanoarrays obtained from liquid metals.

Magnetohydrodynamic velocity and pressure drop in manifolds of a WCLL TBM

In the frame of the EUROfusion breeding blanket research activities, the water cooled lead lithium (WCLL) blanket is considered as reference liquid metal blanket design to be tested in ITER and to be used in a DEMO reactor. The design of breeding blankets represents a major challenge for fusion reactor engineering because of the performance requirements and the severe operating conditions in terms of heat load and neutron flux. Liquid metal alloys such as lead-lithium, PbLi, are considered as breeder material, due to their lithium content required for tritium production, and as heat transfer medium because of their large thermal conductivity and the possibility to be operated at high temperature. On the other hand, the motion of the electrically conducting breeder in the plasma-confining magnetic field induces electric currents and generates strong electromagnetic forces that modify significantly the velocity distribution in the blanket compared to hydrodynamic conditions and increase pressure losses. Magnetohydrodynamic (MHD) pressure drops have to be carefully quantified, since excessive values can jeopardize the feasibility of the considered blanket concept. The present work investigates numerically liquid metal MHD flows in manifolds of a WCLL test blanket module. Velocity and pressure distributions are analyzed.

Flexible and Stretchable Liquid Metal Electrodes Working at Sub-Zero Temperature and Their Applications.

We investigated characteristics of highly flexible and stretchable electrodes consisting of Galinstan (i.e., a gallium-based liquid metal alloy) under various conditions including sub-zero temperature (i.e., <0 °C) and demonstrated solar-blind photodetection via the spontaneous oxidation of Galinstan. For this work, a simple and rapid method was introduced to fabricate the Galinstan electrodes with precise patterns and to exfoliate their surface oxide layers. Thin conductive films possessing flexibility and stretchability can be easily prepared on flexible substrates with large areas through compression of a dried suspension of Galinstan microdroplets. Furthermore, a laser marking machine was employed to facilitate patterning of the Galinstan films at a high resolution of 20 μm. The patterned Galinstan films were used as flexible and stretchable electrodes. The electrical conductivity of these electrodes was measured to be ~1.3 × 106 S m−1, which were still electrically conductive even if the stretching ratio increased up to 130% below 0 °C. In addition, the surface oxide (i.e., Ga2O3) layers possessing photo-responsive properties were spontaneously formed on the Galinstan surfaces under ambient conditions, which could be solely exfoliated using elastomeric stamps. By combining Galinstan and its surface oxide layers, solar-blind photodetectors were successfully fabricated on flexible substrates, exhibiting a distinct increase of up to 14.7% in output current under deep ultraviolet irradiation (254 nm wavelength) with an extremely low light intensity of 0.1 mW cm−2, whereas no significant change was observed under visible light irradiation.

MHD flow in liquid metal blankets: Major design issues, MHD guidelines and numerical analysis

The design of breeding blankets represents the major challenge for fusion reactor engineering because of performance requirements and severe operating conditions in terms of heat load and neutron flux. Liquid metal alloys such as lead-lithium, due to their lithium content, can be used to breed tritium, one of the plasma fuel components, and owing to their high thermal conductivity, they may serve as coolants. On the other hand, there are technical issues related to the fact that the liquid metals are electrically conducting and interact with the plasma-confining magnetic field. Induced electric currents and generated electromagnetic forces affect velocity and pressure distribution in the blankets. Magnetohydrodynamic (MHD) flows for fusion applications have been often investigated in simplified geometries, such as pipes, ducts, bends, with focus on their fundamental features. These analyses are essential, since results remain valid as background for the development of blanket designs, even when a concept is dismissed. However, the conceptual study of fusion blankets requires to take into account the global multiple effects, that arise when the full system is considered. Progress made in fusion-related MHD research results from combined numerical and experimental activities. In this paper we review and summarize features of 2D and 3D MHD flows that are typical in liquid metal blankets, together with available correlations for MHD pressure losses. This knowledge can provide simple design MHD guidelines that support a preliminary estimate of MHD effects in a blanket concept, in terms of pressure drop and flow distribution.

Alkaline-Driven Liquid Metal Janus Micromotor with a Coating Material-Dependent Propulsion Mechanism.

Micro/nanomotors have achieved huge progress in driving power divergence and accurate maneuver manipulations in the last two decades. However, there are still several obstacles to the potential biomedical applications, with respect to their biotoxicity and biocompatibility. Gallium- and indium-based liquid metal (LM) alloys are outstanding candidates for solving these issues due to their good biocompatibility and low biotoxicity. Hereby, we fabricate LM Janus micromotors (LMJMs) through ultrasonically dispersing GaInSn LM into microparticles and sputtering different materials as demanded to tune their moving performance. These LMJMs can move in alkaline solution due to the reaction between Ga and NaOH. There are two driving mechanisms when sputtering materials are metallic or nonmetallic. One is self-electrophoresis when sputtering materials are metallic, and the other one is self-diffusiophoresis when sputtering materials are nonmetallic. Our LMJMs can flip between those two modes by varying the deposited materials. The self-electrophoresis-driven LMJMs' moving speed is much faster than the self-diffusiophoresis-driven LMJMs' speed. The reason is that the former occurs galvanic corrosion reaction, while the latter is correlated to chemical corrosion reaction. The switching of the driving mechanism of the LMJMs can be used to fit into different biochemical application scenarios.

Surface Tension of the Oxide Skin of Gallium-Based Liquid Metals.

Gallium-based alloys have garnered considerable attention in the scientific community, particularly as they are in an atypical liquid state at and near room temperature. Though physical parameters, such as thermal conductivity, electrical conductivity, viscosity, yield stress, and surface tension, of these alloys are broadly known, the surface tension (surface free energy) of the oxide skin remains intangible due to the high yield stress of the oxide skin. In this article, we propose to employ gradually attenuated vibrations to obtain equilibrium shapes, which are analyzed along the lines of the puddle height method. The surface tension of the oxide skin was determined on quartz glass and liquid metal-phobic diamond coating to be around 350-365 mN/m, thus independent of the substrate surface or employed liquid metal (i.e., eutectic Ga-In (EGaIn) and galinstan). The similarity of the surface tension for different alloys was ascribed to the composition of the oxide skin, which predominantly comprises gallium oxides due to thermodynamic constraints. We envision that this method can also be applied to other liquid metal alloys and liquid metal marble systems facilitating modeling, simulation, and optimization processes.

Enhanced efficiency in CO2-free hydrogen production from methane in a molten liquid alloy bubble column reactor with zirconia beads

The CO2-free production of hydrogen is an important criterion for the development of future hydrogen economy along with environmental protection. In this work, a new and efficient strategy for catalytic methane pyrolysis to hydrogen production was proposed using a multi-stage bubble column reactor containing molten Ni-Bi alloy, zirconia and molten NaBr. Compared to the 2-stage bubble column reactor, the3-stage bubble column reactor was found to enhance the methane conversion rate from 32% to 37%at 985 °C.The analysis of the carbon products revealed that similar kinds of amorphous and graphitic carbon-based materials can be obtained from both reactors. The enhanced methane pyrolysis rates with the use of zirconia beads indicate that they can be employed to control the bubble behavior and to enhance the contact area between bubbles and the liquid catalyst surface for an efficient bubble column reactor with liquid metal alloy catalysts.

Addition of V2O5 and V2O3 to the CaO–FeO–Fe2O3–MgO–SiO2 database for vanadium distribution and viscosity calculations

Vanadium oxides were added to the existing GTOx database because of its important role in the ferro-titanium metallurgy as well as in petroleum coke gasification. The CaO–FeO–Fe2O3–MgO–SiO2 system is a part of GTOx database and is chosen because of the existence of experimentally determined vanadium distributions between vanadium ferroalloys and metallurgical slags. The CaO–FeO–Fe2O3–MgO–SiO2–V2O3–V2O5 system including all binary and ternary sub-systems was thermodynamically assessed using all available experimental data. Vanadium was introduced into the thermodynamic description of solid solution phases such as MeO, Spinel, Corundum and Ca2SiO4-α using available experimental information. Particular attention was given to the phase Spinel which forms the wide completely miscible solid solution Fe3O4–FeV2O4–MgV2O4–MgFe2O4. The thermodynamic description of the metallic vanadium containing systems was taken from the SGTE alloy database. With the knowledge about the complex behavior of vanadium in slags as well as in liquid metal alloys it is possible to calculate the vanadium distribution ratios (V)/[V] between iron melts and slags in a wide range of temperatures and compositions, corroborating the validity of the model under reducing conditions. The additionally developed viscosity model shows good agreement between the calculated and experimental values in vanadium-containing slags.

Thermodynamic characteristics of liquid metallic alloys containing lead, antimony and bismuth

An improved construction of the electrochemical cell and optimized technique for measuring the electromotive forces (EMF) of liquid metallic Pb-Bi-Sb, Pb-Bi and Pb-Sb alloys in the KCl-PbCl2 melt are described in this paper. Proposed extensions allowed studying alloys of three different compositions simultaneously and increasing the reliability of the experimental EMF values. A simplified procedure for calculating integral molar thermodynamic functions of binary and ternary systems by the Darken method using only standard Excel tools is described in detail. Dependences of the integral excess Gibbs energy and entropy, integral molar Gibbs energy, mixing entropy and mixing enthalpy on the antimony mole fraction are calculated at 973 K for the Bi-Sb system, which cannot be studied by the EMF method due to the proximity of Bi and Sb potentials in the electrochemical series. The results confirm that the developed techniques are promising for determining thermodynamic characteristics of one of the binary systems without experimental study.

Thermo-hydraulic analysis of PbLi ancillary system of WCLL TBM undergoing in-box LOCA

The European liquid Test Blanket Module (TBM) concept named Water Cooled Lithium Lead makes use of the liquid metal alloy PbLi as tritium breeder/neutron multiplier and water as coolant. A dedicated PbLi ancillary system feeds the detritiated liquid metal alloy to the TBM and returns the PbLi enriched with tritium. The object of this study is developing a numerical model able to simulate the thermo-hydraulic behavior of the PbLi ancillary system under both normal operation and accidental scenario, with the aim to investigate the propagation of pressure waves generated by an in-box LOCA. The accident consists of a tube rupture of the coolant circuit inside the TBM, leading to the interaction between PbLi and water. As a consequence, a pressure increase occurs inside the breeder zone. The accident might affect the ancillary systems due to the propagation of the pressure waves generated inside the TBM. The PbLi loop is modelled by means of the thermo-hydraulics system code RELAP5/Mod3.3 and an instantaneous pressure peak is applied inside the control volume simulating the TBM soon after reaching the steady state conditions inside the whole loop. The propagation of the pressure wave inside the circuit and the hydraulic behavior of the individual components is studied. The present paper represents a first step towards the investigation of the PbLi system and its safety features with the aim to support the R&D activities carried out in the framework of the ITER project.

Hand Gesture Recognition Using EGaIn-Silicone Soft Sensors.

Exploiting hand gestures for non-verbal communication has extraordinary potential in HCI. A data glove is an apparatus widely used to recognize hand gestures. To improve the functionality of the data glove, a highly stretchable and reliable signal-to-noise ratio sensor is indispensable. To do this, the study focused on the development of soft silicone microchannel sensors using a Eutectic Gallium-Indium (EGaIn) liquid metal alloy and a hand gesture recognition system via the proposed data glove using the soft sensor. The EGaIn-silicone sensor was uniquely designed to include two sensing channels to monitor the finger joint movements and to facilitate the EGaIn alloy injection into the meander-type microchannels. We recruited 15 participants to collect hand gesture dataset investigating 12 static hand gestures. The dataset was exploited to estimate the performance of the proposed data glove in hand gesture recognition. Additionally, six traditional classification algorithms were studied. From the results, a random forest shows the highest classification accuracy of 97.3% and a linear discriminant analysis shows the lowest accuracy of 87.4%. The non-linearity of the proposed sensor deteriorated the accuracy of LDA, however, the other classifiers adequately overcame it and performed high accuracies (>90%).

Probing the Ag – liquid gallium system and its interaction with redox active solutions for catalysis and AgTCNQ formation

The creation of liquid metal alloys that are reacted with species in solution is a relatively new approach to the synthesis of functional nanomaterials. In this work we explore the liquid Ag–Ga system and its interaction with redox active species in aqueous solution in the areas of heterogeneous catalysis and charge transfer complex formation. It was found that when Ag is alloyed with Ga that solid microwires of Ag2Ga were formed over time with a width of ca. 1–1.5 µm of up to 160 µm in length. This Ga/Ag2Ga composite was then investigated for the discolouration of methylene blue dye in both the liquid and solid state where little difference in activity was found resulting in 40% discolouration after 30 min. However, if nitrogen gas was passed through the liquid form of the catalyst the conversion efficiency of the catalyst increased significantly up to 99% after 1 min and could be re-used for up to 10 cycles. In addition, the catalytic conversion of 4-nitrophenol to 4-aminophenol at the liquid Ga/Ag2Ga catalyst was significantly greater than liquid Ga and could be reused for up to 5 cycles. The interaction of liquid Ag–Ga with the well-known electron acceptor 7,7,8,8-tetracyanoquinodimethane (TCNQ) was also studied where it was found that a reaction only occurred immediately after mixing Ag microparticles with liquid Ga and before any Ag2Ga microwires were formed. The reaction conditions of bubbling nitrogen gas through the liquid Ag–Ga catalysts in an acetonitrile solution of TCNQ resulted in the time dependent formation of various morphologies of the semi-conducting charge transfer complex AgTCNQ. This work shows that alloying metals with Ga can result in the time dependent formation of a variety of materials under different reaction conditions when exposed to solution based redox active species.

3D printing of liquid metal EGaIn through laser induced forward transfer: A proof-of-concept study

In this work, we introduce Laser Induced Forward Transfer (LIFT) of Liquid Metal (LM) alloys, specifically Eutectic Gallium-Indium (EGaIn). LIFT for LM provides a fairly simple manufacturing method with better control and modularity for patterning LMs compared to existing methods such as imprinting, and extrusion. LIFT is a direct-write printing method which is used for a wide range of applications, such as, laser printing of electronic materials, biomolecules, and cells. Our preliminary results demonstrate great potential of LIFT process for LM deposition and patterning, and can help achieve finer and scalable features with high throughput.

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

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

Improving contact resistance in metal–ceramic heat exchangers running liquid metal by additive manufacturing and ceramic tubes with electroplated films

In the search for thermal management of advanced avionics packaging, materials such as eutectic liquid metal (LM) alloys and synthetic ceramics with superior thermophysical properties offer reliable and effective solutions. Conductive ceramic tubes can be used to contain LM as a coolant for heat exchangers. However, conductive ceramics will still need to be combined with metals to provide optimal thermal and structural performances. Additive manufacturing (AM) technologies have also shown they can facilitate novel approaches for fabricating efficient multi-material structures. Recently, we developed an in situ AM approach for embedding prefabricated components, such as ceramic tubes, inside a metallic block without parting surfaces for better sealing and more intimate contact between the metal and ceramic. In this selective laser sintering (SLS) approach, metal powders are melted near embedded ceramic tubes to close interfacial gaps associated with surface roughness and machining tolerances, resulting in a contact resistance at the metal–ceramic interface that is reduced relative to conventional packaging approaches. In this paper, we demonstrate how metallic cold plates can be fabricated with improved power dissipation by encapsulating highly conductive ceramic tubes with a SLS metal structure. To optimize the adhesion of the melt pool, the surface of the ceramics is electroplated to reduce surface defects and chemistry in order to improve the wettability of the ceramic. Experimental results of the cold plate prototypes fabricated by in situ AM technique revealed up to a 1.6× improvement in heat transfer compared to cold plates packaged by a conventional assembly technique, and results are validated through further numerical and analytical approaches.

Formation mechanism analysis and experimental investigation of single-step printing customized circuits by liquid-metal direct writing

Abstract. Liquid-metal direct writing is a cost-effective and green technology, which is very promising for the customized fabrication of flexible circuits and functional devices. However, owing to the high surface tension of metal ink, the printed circuits are prone to intermittent outflow, large forming size error, and unstable forming. The smooth flowing and conveying of liquid-metal ink are still huge challenges that need significant attention. Herein, the force mechanism of liquid-metal ink transported by ball rotation and translation of the printing head was analysed, and the wetting characteristics of liquid metal on the surface of different substrates and its influence on forming morphology were investigated. The stable output printing of gallium indium alloy (GaIn24.5) liquid metal was realized. The changing characteristics of the shape and size of the liquid-metal circuits formed under different printing speeds and writing pressures were experimentally studied. The effective process window for obtaining the best circuit quality was established. Based on this, a flexible printed circuit board and functional electronic pattern were successfully printed under the writing pressure W=1 N and printing speed F800 mm min−1. The printed lines of GaIn24.5 exhibited a smooth surface, uniform width, small size error, and ability to connect electronic components and conduct electricity. This research proposes a new technical approach for customized printing of personalized electronic circuits and has important application prospects in the future.

Gallium-based liquid metal alloy incorporating oxide-free copper nanoparticle clusters for high-performance thermal interface materials

Thermal interface materials (TIMs) with high thermal conductivity, fluidic characteristics, and surface wettability are crucial for the effective thermal management of high-power electronics. Gallium-based liquid metal (LM) can be a candidate for obtaining the purposes due to their thermo-physical properties. Several studies attempted to further increase the thermal conductivity of composites by adding conductive fillers. However, these efforts have been limited due to the oxidation and solidification issues at high vol% of fillers. In this work, we apply three strategies to obtain the enhanced thermal conductivity while maintaining the fluidity: 1) suppressing Ga-induced oxidation, 2) reducing the matrix-fillers interfacial resistance, and 3) forming additional heat-pathways within the LM matrix. An oxide-free ultrasonication-assisted particle internalization method has been developed, in which the copper nanoparticles (Cu NPs) are incorporated into the gallium-indium-tin (GaInSn) LM matrix. The fabricated composite shows ~180% enhancement of thermal conductivity (~64.8 Wm−1K−1) with only 4 vol% of nano-fillers compared to the untreated GaInSn. In the droplet impacting test, the synthesized GaInSn/Cu NPs composite presents almost identical spreading diameters with the untreated one, which confirms the maintained fluidity. The predicted thermal conductivity using the theoretical model, calculating the measured cluster fraction, is well-matched to the experimental data, which clarifies that the nanoparticle clusters created effective heat-pathways. A high-quality interface with a silicon substrate is confirmed by the X-ray photoelectron spectroscopy, demonstrating the presence of a thin-film Ga2O3 adhesion layer. In the cooling performance test, the developed TIM provides over 20% lower hot-spot temperature than that of the grease-type TIM at high heat flux regime (>150 W/cm2), showing excellent thermal stability over 230 cycles of acceleration test. This work will help develop high-performance TIMs, especially for high power density semiconductor applications.

Robust, Self-Healable Siloxane Elastomers Constructed by Multiple Dynamic Bonds for Stretchable Electronics and Microsystems

Self-healable siloxane elastomers have recently attracted much interest in research for applications in flexible electronic devices. However, it remains a challenge for self-healable siloxane elastomers to realize good mechanical and rapid high-efficiency self-healable properties at room temperature. Herein, a desirable siloxane polymer elastomer was designed by the synergy of multiple dynamic bonds. In this self-healable system, the disulfide bonds as sacrificial bonds and hydrogen bonds as weak bonds could endow elastomers with rapid self-healability and high stretchability. Whereas, the Fe-coordination bonds could tune the robustness of a siloxane elastomer. Due to the synergy of multiple dynamic bonds, the self-healable PDMS-SS-DOPA1-Fe2 elastomer achieved high stretchability of 1100%, tensile stress of 1.11 MPa, and high self-healable efficiency of 96% (within 3 h). Moreover, after healing for 3 min at room temperature, the damaged siloxane elastomers were able to obtain a breaking strain of 250% and tensile stress of 0.5 MPa. As a proof of concept, based on elastomer films integrated with liquid metal alloy EGaIn (eutectic gallium–indium), stretchable electrodes and strain sensors were subsequently developed, opening the avenue to potential applications in flexible electronics and microsystems.

Aerosol Spray Deposition of Liquid Metal and Elastomer Coatings for Rapid Processing of Stretchable Electronics.

We report a spray deposition technique for patterning liquid metal alloys to form stretchable conductors, which can then be encapsulated in silicone elastomers via the same spraying procedure. While spraying has been used previously to deposit many materials, including liquid metals, this work focuses on quantifying the spraying process and combining it with silicones. Spraying generates liquid metal microparticles (~5 μm diameter) that pass through openings in a stencil to produce traces with high resolution (~300 µm resolution using stencils from a craft cutter) on a substrate. The spraying produces sufficient kinetic energy (~14 m/s) to distort the particles on impact, which allows them to merge together. This merging process depends on both particle size and velocity. Particles of similar size do not merge when cast as a film. Likewise, smaller particles (<1 µm) moving at the same speed do not rupture on impact either, though calculations suggest that such particles could rupture at higher velocities. The liquid metal features can be encased by spraying uncured silicone elastomer from a volatile solvent to form a conformal coating that does not disrupt the liquid metal features during spraying. Alternating layers of liquid metal and elastomer may be patterned sequentially to build multilayer devices, such as soft and stretchable sensors.