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Precisely Patterning Liquid Metal Microfibers Through Electrohydrodynamic Printing for Soft Conductive Composites and

Jiexian Ma1, Zihan Liu1, Pu Zhang1

  • 1Department of Mechanical Engineering, State University of New York at Binghamton, Binghamton, NY, 13902, USA.

Advanced Materials (Deerfield Beach, Fla.)
|July 2, 2025
PubMed
Summary

Electrohydrodynamic printing creates precise liquid metal microfibers, overcoming electrospinning limitations for advanced soft electronics. These fibers offer superior conductivity and stability in flexible devices.

Keywords:
conductive compositeselectrohydrodynamic printingfiber networksliquid metalsoft electronics

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Area of Science:

  • Materials Science
  • Nanotechnology
  • Electrical Engineering

Background:

  • Liquid metal particle-based microfibers are crucial for soft and wearable electronics.
  • Electrospinning is a common fabrication method but suffers from poor patterning and defects, limiting conductivity.
  • A need exists for advanced manufacturing techniques for high-quality, precisely deposited liquid metal fibers.

Purpose of the Study:

  • To develop a superior method for fabricating liquid metal microfibers with enhanced precision and quality.
  • To overcome the limitations of traditional electrospinning techniques in patterning and defect control.
  • To explore the application potential of these advanced liquid metal fibers in soft electronics and conductive composites.

Main Methods:

  • Development of an electrohydrodynamic printing process for precise patterning of liquid metal microfibers.
  • Characterization of microfiber resolution, defects, and electrical conductivity.
  • Fabrication and testing of soft conductive composites and electronic devices utilizing the printed microfibers.

Main Results:

  • Achieved ultra-high resolution (≈1.5 µm) liquid metal microfibers with minimal defects.
  • Demonstrated high electrical conductivity (up to 214 S cm⁻¹) in the patterned fibers.
  • Developed conductive composites with strain-insensitive resistance (7.3% change at 200% strain) and excellent cyclic stability.

Conclusions:

  • Electrohydrodynamic printing offers a precise and effective method for fabricating high-performance liquid metal microfibers.
  • The developed microfibers and composites show significant promise for applications in soft sensors, stretchable heaters, and transparent electrodes.
  • This technique advances the field of soft and wearable electronics by enabling customized microscale features and improved performance.