Scalable Microwires through Thermal Drawing of Co-Extruded Liquid Metal and Thermoplastic Elastomer

This article demonstrates scalable production of liquid metal (LM)-based microwires through the thermal drawing of extrudates. These extrudates were first co-extruded using a eutectic alloy of gallium and indium (EGaIn) as a core element and a thermoplastic elastomer, styrene-ethylene/butylene-styrene (SEBS), as a shell material. By varying the feed speed of the co-extruded materials and the drawing speed of the extrudate, it was possible to control the dimensions of the microwires, such as core diameter and shell thickness. How the extrusion temperature affects the dimensions of the microwire was also analyzed. The smallest microwire (core diameter: 52 ± 14 μm and shell thickness: 46 ± 10 μm) was produced from a drawing speed of 300.1 mm s^-1 (the maximum attainable speed of the apparatus used), SEBS extrusion speed of 1.50 mm³ s^-1, and LM injection rate of 5 × 105 μL s^-1 at 190 °C extrusion temperature. The same extrusion condition without thermal drawing generated significantly large extrudates with a core diameter of 278 ± 26 μm and shell thickness of 430 ± 51 μm. The electrical properties of the microwires were also characterized under different degrees of stretching and wire kinking deformation which proved that these LM-based microwires change electrical resistance as they are deformed and fully self-heal once the load is removed. Finally, the sewability of these microwires was qualitatively tested by using a manual sewing machine to pattern microwires on a traditional cotton fabric.