Customizable, conformal, and stretchable 3D electronics via predistorted pattern generation and thermoforming

Area of Science:

• Materials Science
• Electrical Engineering
• Electronics Manufacturing

Background:

• Growing demand for integrating electronic systems onto three-dimensional (3D) curvilinear surfaces.
• Existing challenges in fabricating 3D electronics (3DE) with high customizability, conformability, and stretchability.

Purpose of the Study:

• To present a novel fabrication method for creating highly customizable, conformable, and stretchable 3DE.
• To demonstrate the potential of this technology for advanced wearable electronics.

Main Methods:

• Utilizing predistorted pattern generation combined with thermoforming for 3DE fabrication.
• Employing thermoplastic elastomers and liquid metal-based conductive electrodes for enhanced material properties.

Main Results:

• Successfully fabricated custom-designed 3DE with high 3D conformability, replicating mold shapes and textures.
• Achieved high thermoformability during fabrication and high stretchability during device operation.

Conclusions:

• The developed thermoforming-based fabrication method offers a viable solution for producing advanced 3DE.
• This technology opens possibilities for new functionalities and complex 3D structures in wearable electronics.