Stretchable Circuits Research Articles

Experimental Characterization of Inkjet-Printed Stretchable Circuits for Wearable Sensor Applications.

This paper introduces a cost-effective method for the fabrication of stretchable circuits on polydimethylsiloxane (PDMS) using inkjet printing of silver nanoparticle ink. The fabrication method, presented here, allows for the development of fully stretchable and wearable sensors. Inkjet-printed sinusoidal and horseshoe patterns are experimentally characterized in terms of the effect of their geometry on stretchability, while maintaining adequate electrical conductivity. The optimal fabricated circuit, with a horseshoe pattern at an angle of 45°, is capable of undergoing an axial stretch up to a strain of 25% with a resistance under 800 Ω. The conductivity of the circuit is fully reversible once it is returned to its pre-stretching state. The circuit could also undergo up to 3000 stretching cycles without exhibiting a significant change in its conductivity. In addition, the successful development of a novel inkjet-printed fully stretchable and wearable version of the conventional pulse oximeter is demonstrated. Finally, the resulting sensor is evaluated in comparison to its commercially available counterpart.

Geometry Analysis in Screen-Printed Stretchable Interconnects

Deformability of interconnects and conductors as the skeleton of soft electronic devices plays an important role in the stretchability of the whole system. To make the interconnects stretchable, either employing deformable materials or tailoring the design are the primary approaches. It is also possible to combine the two strategies. In advanced stretchable electronic circuits, there is a frequent need for the interconnects to transform from a narrow to a wide geometry. Therefore, this paper assesses three different geometries that accommodate a narrow-to-wide transition along the interconnects. First, the geometry is modeled using finite-element (FE) analysis. Second, in order to verify the accuracy of the FE model, screen-printed interconnects are fabricated accordingly by using silver flake ink on a deformable substrate. The geometrical modification shows a considerable improvement in the stretchability of the whole system. In addition, the effect of encapsulation with thermoplastic polyurethane on the performance of stretchable interconnects is investigated.

Stretchability-The Metric for Stretchable Electrical Interconnects.

Stretchable circuit technology, as the name implies, allows an electronic circuit to adapt to its surroundings by elongating when an external force is applied. Based on this, early authors proposed a straightforward metric: stretchability—the percentage length increase the circuit can survive while remaining functional. However, when comparing technologies, this metric is often unreliable as it is heavily design dependent. This paper aims to demonstrate this shortcoming and proposes a series of alternate methods to evaluate the performance of a stretchable interconnect. These methods consider circuit volume, material usage, and the reliability of the technology. This analysis is then expanded to the direct current (DC) resistance measurement performed on these stretchable interconnects. A simple dead reckoning approach is demonstrated to estimate the magnitude of these measurement errors on the final measurement.

Laser-Enabled Processing of Stretchable Electronics on a Hydrolytically Degradable Hydrogel.

Degradable electronics represent a rapidly emerging field of science and technology with the potential to serve short-term medical implantation applications where the device disappears once its function is complete. Despite many efforts in developing new types of degradable electronics, many of such systems are nonelastic and incompatible with the dynamic motion of native soft/elastic biological tissues. Herein, a photo-crosslinkable hydrogel with integrated electronics that are highly stretchable and degradable in liquid environments is demonstrated. The fabrication process takes advantage of facile laser micromachining of conductive patterns directly onto the hydrogel under ambient conditions and permanent hydrogel-hydrogel bonding. The robustness and degradation rate of hydrogel and the laser-processed encapsulated stretchable circuits is systematically investigated in different solutions under various conditions. Biocompatibility tests with non-neoplastic cells (HMT 3522 S1) and cancer cells (T4-2 and MDA-MB-231) are performed in 2D and 3D cell culture systems to confirm instead of evaluate the safety of the hydrogel and its byproducts during degradation as well as the zinc metal used in this technology. As a proof of concept, a stretchable hydrogel-based device that can be used for remote/wireless delivery of thermal energy into the tissue in contact with the hydrogel is fabricated.

Printable Metal-Polymer Conductors for Highly Stretchable Bio-Devices

SummaryStretchable, biocompatible devices can bridge electronics and biology. However, most stretchable conductors for such devices are toxic, costly, and regularly break/degrade after several large deformations. Here we show printable, highly stretchable, and biocompatible metal-polymer conductors by casting and peeling off polymers from patterned liquid metal particles, forming surface-embedded metal in polymeric hosts. Our printable conductors present good stretchability (2,316 S/cm at a strain of 500%) and repeatability (ΔR/R <3% after 10,000 cycles), which can satisfy most electrical applications in extreme deformations. This strategy not only overcomes large surface tension of liquid metal but also avoids the undesirable sintering of its particles by stress in deformations, such that stretchable conductors can form on various substrates with high resolution (15 μm), high throughput (∼2,000 samples/hour), and low cost (one-quarter price of silver). We use these conductors for stretchable circuits, motion sensors, wearable glove keyboards, and electroporation of live cells.

A study of screen printing of stretchable circuits on polyurethane substrates

The interest in flexible stretchable printed electronics has increased because of the wide applications, especially for wearables devices. The conventional manufacturing processes were time consuming and expensive, which led to developing of stretchable interconnects using screen printing. In this research, meander patterns of varying meander angles were designed and screen-printed on thermoplastic polyurethane substrates. Silver inks and carbon inks were used to print the circuits, which were subjected to tensile tests while their changes in resistance were measured. The electrical characteristics were utilised to determine the elastic limits of the circuits and the conditions for cyclic tests of up to 10,000 cycles. It was found that the maximum strain at break of the silver ink was 47%. Carbon ink had a higher initial resistance value and the maximum strain at break was 125%. The best stretchability was obtained at the 0° meander angle, a curing time of 30 min and curing temperature of 130 °C with oven cooling.

3D Multifunctional Composites Based on Large‐Area Stretchable Circuit with Thermoforming Technology

AbstractFiber‐reinforced polymer composites with integrated intelligence, such as sensors, actuators, and communication capabilities, are desirable as infrastructures for the next generation of “internet of things.” However, the shape mismatch between the 3D composites and a planar electronic circuit causes difficulties in integrating electronic circuit‐based intelligences. Here, an easily scalable approach, by incorporating a large‐area stretchable circuit with thermoforming technology, to fabricate 3D multifunctional composites is reported. The stretchable circuit is first fabricated on a rigid and planar carrier board, then transferred and sandwiched between thermoplastic composites through lamination processes. A thermoforming step shapes the sandwiched and planar structure by heating up the encapsulating polymers beyond their glass transition temperature and pushing them and the circuit against a mold. Using the proposed process, large‐sized composites with integrated matrices of light‐emitting diodes (LEDs) and capacitive sensors are successfully fabricated. A giant (with a size of 0.5 m × 1 m) seven‐segment display is assembled using the fabricated composites with integrated LEDs and capacitive sensors to display 128 symbols. The results demonstrate the potential of the proposed approach as a facile, reproducible, and scalable process for creating 3D multifunctional composites.

A stretchable flexible electronic platform for mechanical and electrical collaborative design

With the extensive application of stretchable flexible electronic circuits to wearable equipment and biomedicine, research on the electrical properties of such circuits has become a hot topic. In this paper, a flexible electronic design platform is established for the first time, realizing co-simulation of the mechanical and electronic aspects. The main functions of this platform include the design of stretchable interconnects, flexible devices, stretchable flexible electronic circuits, and stretchable flexible circuit-layout wiring. The following conclusions can be obtained: (1) With increased applied strain, the inductance of a stretchable interconnect will increase, while the delay and crosstalk will become non-negligible. (2) Although the performance of flexible passive devices does not change after transfer printing, the gate capacitor of the flexible MOS at the cut-off area does decrease. (3) Taking a flexible comparator as an example, the function and electrical performance of a flexible circuit are verified. (4) Taking a flexible amplifier circuit as an example, the flexible interconnection layout and wiring are simulated and verified.

Wireless, intraoral hybrid electronics for real-time quantification of sodium intake toward hypertension management

Recent wearable devices offer portable monitoring of biopotentials, heart rate, or physical activity, allowing for active management of human health and wellness. Such systems can be inserted in the oral cavity for measuring food intake in regard to controlling eating behavior, directly related to diseases such as hypertension, diabetes, and obesity. However, existing devices using plastic circuit boards and rigid sensors are not ideal for oral insertion. A user-comfortable system for the oral cavity requires an ultrathin, low-profile, and soft electronic platform along with miniaturized sensors. Here, we introduce a stretchable hybrid electronic system that has an exceptionally small form factor, enabling a long-range wireless monitoring of sodium intake. Computational study of flexible mechanics and soft materials provides fundamental aspects of key design factors for a tissue-friendly configuration, incorporating a stretchable circuit and sensor. Analytical calculation and experimental study enables reliable wireless circuitry that accommodates dynamic mechanical stress. Systematic in vitro modeling characterizes the functionality of a sodium sensor in the electronics. In vivo demonstration with human subjects captures the device feasibility for real-time quantification of sodium intake, which can be used to manage hypertension.

Ni‐GaIn Amalgams Enabled Rapid and Customizable Fabrication of Wearable and Wireless Healthcare Electronics

Recent advances in functional low‐melting liquid metals (LMs) provide routes to quickly fabricate wearable devices, which can offer excellent mechanical compliance on human skin compared to conventional rigid wafer‐based electronics. Particularly, the Gallium‐based LM mixtures are promising materials for use as stretchable and flexible circuits in wearable healthcare electronics due to their fantastic electrical conductivity, favorable fluidity, super compliance, and benign biocompatibility. Here, the authors develop a kind of directly‐printed Ni‐GaIn functional amalgams, which can efficiently construct wearable healthcare monitors. Unlike EGaIn, Ni‐GaIn amalgam owns a tunable and enhanced adhesion, which makes it easy to directly paint on various substrate for customized circuits. A wireless power transfer coil printed with these amalgams is presented to demonstrate the electrical stability under different tensile states. Finally, the authors design a wearable healthcare monitor for pulse wave measurement via collecting pulse wave signals from the wrist steadily. With the advantages of stretchability and rapid manufacture, the functional Ni‐GaIn amalgams as currently presented shows a promising approach for individualized wearable electronics.

EGaIn–Metal Interfacing for Liquid Metal Circuitry and Microelectronics Integration

AbstractEutectic gallium–indium (EGaIn) has attracted significant attention in recent years for its use in soft and stretchable electronics. However, advances in scalable fabrication approaches and effective electromechanical interfaces between liquid metal (LM) traces and microelectronics are still needed to create functional soft and stretchable electronics. In this study, EGaIn–metal interfacing for the effective integration of surface‐mount microelectronics with LM interconnects is investigated. The electrical interconnects are produced by creating copper patterns on a soft‐elastomer substrate, and subsequently exposing the substrate to EGaIn, which selectively wets the Cu traces. To create strong electromechanical connection between EGaIn and microelectronics, the terminals of the LM‐coated traces are “soldered” to the metal pins of the packaged microelectronic circuits using a novel HCl‐vapor treatment. In combination, the fabrication and microelectronics‐interfacing approaches enable creating stretchable circuits composed of LM wiring and packaged microelectronics. It is found that the HCl‐vapor treatment significantly improves electrical conductivity at the LM–pin interface while enhancing the strain limit of the soft circuits and the reproducibility of the interface. The applicability of this approach in creating soft‐matter circuits is demonstrated through two illustrative examples—a circuit with a digital 9‐axis inertial measurement unit and a temperature sensor; and a circuit with a 3‐axis analog accelerometer.

Electronic Circuits Integration in Textiles for Data Processing in Wearable Technologies

AbstractTo become an integral part of the everyday outfits, wearable electronics are expected to be lightweight, conformable, imperceptible for the user and life‐proof. The prospect of integrating modern technologies in clothes requires electronic circuits in textiles which are able to perform complex computing with high reliability. Four approaches to smart textile fabrication are described in this review: textile circuits, functionalized fibers, flexible circuits, and hybrid stretchable circuits. In the first two, fabric serves as a substrate for the electronic circuit to maintain essential textile properties. In basic textile circuits, standard electronic components directly attached to fiber tracks insure elementary electronic functionalities while remaining a noninvasive solution. Then, functionalized fibers replace the rigid electronic parts, to make the electronics even more integrated, merging inside the core of the fiber. These most recent works are today limited to basic logic circuitry and quasi‐static applications. The third and fourth approaches have shown the advantages to rely on well‐established technologies with dedicated flexible/stretchable hybrid substrates processed separately from the garment. Despite a loss in wearing comfort, this axis of research is driven by the superior computational performances.

Stretchable temperature-sensing circuits with strain suppression based on carbon nanotube transistors

For the next generation of wearable health monitors, it is essential to develop stretchable and conformable sensors with robust electrical performance. These sensors should, in particular, provide a stable electrical output without being affected by external variables such as induced strain. Here, we report circuit design strategies that can improve the accuracy and robustness of a temperature sensor based on stretchable carbon nanotube transistors. Using static and dynamic differential readout approaches, our circuits suppress strain-dependent errors and achieve a measured inaccuracy of only ±1 oC within a uniaxial strain range of 0–60%. We address device variability by using a one-time, single-point calibration approach. In contrast with previous approaches, which infer temperature change through a normalized measurement at two temperatures, our prototype devices provide an absolute output without temperature cycling. This is essential for practical deployment because heating and cooling the sensor is prohibitively slow and costly during real-time operation and production testing. Using carbon nanotube transistors, stretchable temperature sensor circuits can be designed that suppress strain-dependent errors and achieve a measured inaccuracy of only ±1 °C within a uniaxial strain range of 0–60%

Highly stretchable and conductive fibers enabled by liquid metal dip-coating

Highly stretchable and conductive fibers have been fabricated by dip-coating of a layer of liquid metal (eutectic gallium indium, EGaIn) on printed silicone elastomer filaments. This fabrication method exploits a nanolayer of oxide skin that rapidly forms on the surface of EGaIn when exposed to air. Through dip-coating, the sticky nature of the oxide skin leads to the formation of a thin EGaIn coating (∼5 μm thick) on the originally nonconductive filaments and renders these fibers excellent conductivity. Electrical characterization shows that the fiber resistance increases moderately as the fiber elongates but always maintains conductivity even when stretched by 800%. Besides this, these fibers possess good cyclic electrical stability with little degradation after hundreds of stretching cycles, which makes them an excellent candidate for stretchable conductors. We then demonstrate a highly stretchable LED circuit as well as a conductive stretchable net that extends the 1D fibers into a 2D configuration. These examples demonstrate potential applications for topologically complex stretchable electronics.

Simple and cost-effective method of highly conductive and elastic carbon nanotube/polydimethylsiloxane composite for wearable electronics

The development of various flexible and stretchable materials has attracted interest for promising applications in biomedical engineering and electronics industries. This interest in wearable electronics, stretchable circuits, and flexible displays has created a demand for stable, easily manufactured, and cheap materials. However, the construction of flexible and elastic electronics, on which commercial electronic components can be mounted through simple and cost-effective processing, remains challenging. We have developed a nanocomposite of carbon nanotubes (CNTs) and polydimethylsiloxane (PDMS) elastomer. To achieve uniform distributions of CNTs within the polymer, an optimized dispersion process was developed using isopropyl alcohol (IPA) and methyl-terminated PDMS in combination with ultrasonication. After vaporizing the IPA, various shapes and sizes can be easily created with the nanocomposite, depending on the mold. The material provides high flexibility, elasticity, and electrical conductivity without requiring a sandwich structure. It is also biocompatible and mechanically stable, as demonstrated by cytotoxicity assays and cyclic strain tests (over 10,000 times). We demonstrate the potential for the healthcare field through strain sensor, flexible electric circuits, and biopotential measurements such as EEG, ECG, and EMG. This simple and cost-effective fabrication method for CNT/PDMS composites provides a promising process and material for various applications of wearable electronics.

A Platform for Mechano(-Electrical) Characterization of Free-Standing Micron-Sized Structures and Interconnects.

A device for studying the mechanical and electrical behavior of free-standing micro-fabricated metal structures, subjected to a very large deformation, is presented in this paper. The free-standing structures are intended to serve as interconnects in high-density, highly stretchable electronic circuits. For an easy, damage-free handling and mounting of these free-standing structures, the device is designed to be fabricated as a single chip/unit that is separated into two independently movable parts after it is fixed in the tensile test stage. Furthermore, the fabrication method allows for test structures of different geometries to be easily fabricated on the same substrate. The utility of the device has been demonstrated by stretching the free-standing interconnect structures in excess of 1000% while simultaneously measuring their electrical resistance. Important design considerations and encountered processing challenges and their solutions are discussed in this paper.

Printed stretchable circuit on soft elastic substrate for wearable application * * Project supported by the National Program on Key Basic Research Project (No. 2015CB351901), the Strategic Priority Research Program of the Chinese Academy of Sciences (No. XDA09020201), and the National Science Foundation of China (Nos. 51603227, 51603228).

In this paper, a flexible and stretchable circuit has been fabricated by the printing method based on Ag NWs/PDMS composite. The randomly oriented Ag NWs were buried in PDMS to form a conductive and stretchable electrode. Stable conductivity was achieved with a large range of tensile strain (0–50%) after the initial stretching/releasing cycle. The stable electrical response is due to the buckling of the Ag NWs/PDMS composite layer. Furthermore, printed stretchable circuits integrated with commercial ICs have been demonstrated for wearable applications.

Finite element analysis on deformation of stretchable electronic interconnect substrate using polydimethylsiloxanes (PDMS)

Over the years, the technology of electronic industry has growth tremendously. Open ended research on how to make a better concept of electronic circuit is ongoing especially on the stretchable electronic devices. There are many designs to achieve stretchability in electronic circuits. The problem occurs when deformation applied to the stretchable electronic circuit, it cannot maintain its functionality. Fracture may happen on the conductor. In this research, the study on deformation of stretchable electronic interconnects substrate using Polydimethlysiloxanes is carried out. The purpose of this research are to study the axial deformation occur, to determine the optimum shape of the conductor designs (horseshoe, rectangular and u-shape design) for the stretchable electronic interconnect and to compare the mechanical properties of Polydimethlysiloxanes (PDMS) with Polyurethane (PU) using Finite Element Analysis (FEA). The simulation was done on the FE model of the stretchable circuit with dimension of 2.4 X 2.4 X 0.5 mm. The stretching of the FE model was simulated with the range of elongation at 10, 20 and 30 percent from its original length in order to find the strain value for all three of the conductor designs. The best conductor design is used to simulate with different types of substrate (PDMS and PU). From the simulation result, Horseshoe design record the lowest strain value for each elongation, followed by rectangular and U-shape design. Thus, Horseshoe is considered as the optimum design for the conductor compared to the other two designs. From the result also, it shows that PDMS substrate will offer more maximum allowable stretchability compared to PU substrates. Thus PDMS is considered as a better substrate compare to PU. PDMS is a good material to replace PU since it can perform under tension much better mechanically.

Surface-Embedded Stretchable Electrodes by Direct Printing and their Uses to Fabricate Ultrathin Vibration Sensors and Circuits for 3D Structures.

Printing is one of the easy and quick ways to make a stretchable wearable electronics. Conventional printing methods deposit conductive materials "on" or "inside" a rubber substrate. The conductors made by such printing methods cannot be used as device electrodes because of the large surface topology, poor stretchability, or weak adhesion between the substrate and the conducting material. Here, a method is presented by which conductive materials are printed in the way of being surface-embedded in the rubber substrate; hence, the conductors can be widely used as device electrodes and circuits. The printing process involves a direct printing of a metal precursor solution in a block-copolymer rubber substrate and chemical reduction of the precursor into metal nanoparticles. The electrical conductivity and sensitivity to the mechanical deformation can be controlled by adjusting the number of printing operations. The fabrication of highly sensitive vibration sensors is thus presented, which can detect weak pulses and sound waves. In addition, this work takes advantage of the viscoelasticity of the composite conductor to fabricate highly conductive stretchable circuits for complicated 3D structures. The printed electrodes are also used to fabricate a stretchable electrochemiluminescence display.

Digital light processing 3D printing of conductive complex structures

3D printing has gained significant research interest recently for directly manufacturing 3D components and structures for use in a variety of applications. In this paper, a digital light processing (DLP®) based 3D printing technique was explored to manufacture electrically conductive objects of polymer nanocomposites. Here, the ink was made of a mixture of photocurable resin with multi-walled carbon nanotubes (MWCNTs). The concentrations of MWCNT as well as the printing parameters were investigated to yield optimal conductivity and printing quality. We found that 0.3wt% loading of MWCNT in the resin matrix can provide the maximum electrical conductivity of 0.027S/m under the resin viscosity limit that allows high printing quality. With electric conductivity, the printed MWCNT nanocomposites can be used as smart materials and structures with strain sensitivity and shape memory effect. We demonstrate that the printed conductive complex structures as hollow capacitive sensor, electrically activated shape memory composites, stretchable circuits, showing the versatility of DLP® 3D printing for conductive complex structures. In addition, mechanical tests showed that the addition of MWCNT could slightly increase the modulus and ultimate tensile stress while decreasing slightly the ultimate stretch, indicating that the new functionality is not obtained at the price of sacrificing mechanical properties.