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Robotized Fabrication Strategy for Large-Scale 3D Conformal Electronics.

Jiaying Ge1,2,3, Hao Wu1,2,3, Hongyang Wang1,2,3

  • 1State Key Laboratory of Intelligent Manufacturing Equipment and Technology, Huazhong University of Science and Technology, Wuhan 430074, China.

Materials (Basel, Switzerland)
|November 13, 2025
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Summary
This summary is machine-generated.

A new robotized electrohydrodynamic (EHD) printing strategy enables large-scale conformal electronics fabrication on curved surfaces. This method achieves high resolution and adhesion for applications like smart wings and satellite shells.

Keywords:
additive manufacturingconformal electronicsconformal printingelectrohydrodynamic printing

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Area of Science:

  • Materials Science
  • Robotics
  • Additive Manufacturing

Background:

  • Conformal electronics integrate structure and function for applications like structural health monitoring and metasurfaces.
  • Large-scale curved electronic fabrication faces challenges due to a lack of specialized equipment and standardized methods.

Purpose of the Study:

  • To introduce a pioneering strategy for the conformal fabrication of large-scale curved electronics on 3D surfaces using robotized electrohydrodynamic (EHD) printing.
  • To address the limitations of traditional fabrication methods in producing complex, large-area conformal electronic devices.

Main Methods:

  • Development of a multi-robot EHD conformal printing strategy integrating plasma surface treatment, EHD printing, and near-infrared (NIR) sintering.
  • Utilization of 3D surface reconstruction and precise hybrid positioning for accurate fabrication on complex geometries.
  • Implementation of EHD lithography for high-resolution printing and NIR sintering for rapid processing.

Main Results:

  • Achieved 5 µm printing resolution and 35 µm repeatable positioning accuracy.
  • Demonstrated 5B-level adhesion strength for conductive patterns on FR4 substrates after plasma treatment.
  • Successfully fabricated large-area conformal electronics, including 400 mm × 1000 mm UAV wings and 650 mm × 350 mm satellite shells, with multi-layer systems.

Conclusions:

  • The developed multi-robot EHD conformal printing strategy overcomes traditional fabrication limitations for large-scale curved electronics.
  • This approach enables the creation of advanced conformal electronic systems for applications such as smart wings and satellite surfaces.
  • The strategy holds significant potential for future innovations in conformal electronics across diverse industries.