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Physics-informed displacement control for variable pattern printing with V-shaped PDMS stamps in roll-to-roll
Jingyang Yan1, Huarui Du1, Xian Du2
1The authors are with the Department of Mechanical and Industrial of Engineering, and the Institute for Applied Life Sciences, University of Massachusetts, Amherst, MA, USA.
Communications Engineering
|December 11, 2025
Summary
This study introduces V-shaped polydimethylsiloxane (PDMS) stamps for versatile pattern printing in flexible electronics manufacturing. A novel control system enables a single V-shaped stamp to produce variable pattern sizes, enhancing adaptability and efficiency.
Area of Science:
- Materials Science and Engineering
- Nanotechnology
- Manufacturing Processes
Background:
- Roll-to-roll microcontact printing is key for high-throughput flexible electronics.
- Current polydimethylsiloxane (PDMS) stamps have limitations in pattern size versatility.
- Manufacturing adaptable and efficient flexible electronics requires innovative printing solutions.
Purpose of the Study:
- To develop V-shaped PDMS stamps for variable pattern printing using a single stamp geometry.
- To create a physics-based model for characterizing V-shaped PDMS deformation.
- To implement a control system for precise pattern dimension regulation.
Main Methods:
- Developed V-shaped polydimethylsiloxane (PDMS) stamps.
- Combined finite element simulations and experimental analysis for deformation modeling.
- Implemented a neural network-based model predictive control system for displacement regulation.
Main Results:
- Successfully characterized the out-of-plane behavior of V-shaped PDMS stamps.
- Achieved precise control over vertical displacement for desired pattern dimensions.
- Demonstrated reliable production of variable pattern sizes with high repeatability using a single V-shaped stamp.
Conclusions:
- V-shaped PDMS stamps offer enhanced versatility in roll-to-roll microcontact printing.
- The developed control system enables precise and repeatable variable pattern generation.
- This innovation improves adaptability and process efficiency in flexible electronics manufacturing.
