Fabrication of circuits by multi-nozzle electrohydrodynamic inkjet printing for soft wearable electronics

Abstract: Wearable electronic devices are evolving from current rigid configurations to flexible and ultimately stretchable structures. These emerging systems require soft circuits for connecting the various working units of the overall system. This paper presents fabrication of soft circuits by electrohydrodynamic (EHD) inkjet-printing technique. Multi-nozzle EHD printing head is employed for rapid fabrication of electric circuits on a wide set of materials, including glass substrate (rigid), flexible polyethylene terephthalate (PET) films, and stretchable thermoplastic polyurethane (TPU) films. To avoid the effects of substrate materials on the jettability, the proposed multi-nozzle head is equipped with integrated individual counter electrodes (electrodes are placed above the printing substrate). High-resolution circuits (50 ± 5 µm) with high electrical conductivity (0.6 Ω □⁻¹) on soft substrate materials validate our well-controlled multi-nozzle EHD printing approach. The produced circuits showed excellent flexibility (bending radius ≈ 5 mm radius), high stretchability (strain ≈ 100%), and long-term mechanical stability (500 cycles at 30% strain). The concept is further demonstrated with a soft strain sensor based on a multi-nozzle EHD-printed circuit, employed for monitoring the human motion (finger bending), indicating the potential applications of these circuits in soft wearable electronic devices. Graphic Abstract: [Figure not available: see fulltext.]