Pervasive liquid metal printed electronics: From concept incubation to industry

Gallium-based liquid metals as smart responsive materials: Morphological forms and stimuli characterization

Gallium-based liquid metals (GaLMs) have garnered monumental attention from the scientific community due to their diverse actuation characteristics. These metals possess remarkable characteristics, including high surface tension, excellent electrical and thermal conductivity, phase transformation behaviour, minimal viscosity and vapour pressure, lack of toxicity, and biocompatibility. In addition, GaLMs have melting points that are either lower or near room temperature, making them incredibly beneficial when compared to solid metals since they can be easily deformed. Thus, there has been significant progress in developing multifunctional devices using GaLMs, including bio-devices, flexible and self-healing circuits, and actuators. Despite numerous reports on these liquid metals (LMs), there is an urgent need for consolidated and coherent literature regarding their actuation principles linked to the targeted application. This will ensure that the reader gets the flavour of physics behind the actuation mechanism and how it can be utilized in diverse fields. Moreover, the actuation mechanism has been scattered in the literature, and thus, the primary motive of this review is to provide a one-stop solution for the actuation mechanism and the associated dynamics while directing the readers to specialized literature. Thus, addressing this issue, we thoroughly examine and present a detailed account of the actuation mechanisms of GaLMs while highlighting the science behind them. We also discuss the various morphologies of GaLMs and their crucial physical characteristics which decide their targeted application. Furthermore, we also delve into commonly held beliefs about GaLMs in the literature, such as their toxicity and antibacterial properties, to offer readers a more accurate understanding. Finally, we have explored several key unanswered aspects of the LM that should be explored in future research. The core strength of this review lies in its simplistic approach in offering a starting point for researchers venturing this innovative field, while we make use of existing literature to develop a comprehensive understanding.

Bismuth-based liquid metals: advances, applications, and prospects

Bismuth-based liquid metals (LMs) are a large group of alloys with melting points slightly above room temperature. They are associated with fewer encapsulation constraints than room temperature LMs such as mercury, sodium-potassium alloys, and gallium-based alloys and are more likely to remain stable in the natural environment. In addition, their low melting point properties enable them to soften and melt via easy control. Bismuth-based alloys can also be modified with metal-based, carbon-based, and ceramic-based micro/nano particles as well as polymeric materials to create a series of novel composites owing to their outstanding functions. Based on these considerations, this review provides a comprehensive overview of bismuth-based LMs. The categories of bismuth and bismuth-based LMs are first briefly introduced to better systematize the physical and chemical properties of bismuth-based LMs. Based on these properties, bismuth-based LMs have been prepared using various methods, and this review briefly categorizes these preparation methods based on their finished forms (lumps, powders, and films). In addition, this review details the research progress of bismuth-based LMs in the fields of printed electronics, 3D printing, thermal management, biomedicine, chemical engineering, and deformable robotics. Finally, the challenges and future opportunities of bismuth-based LMs in the development process are discussed and visualized from different perspectives.

Surface Oxidation and Wetting Synergistic Effect of Liquid Metals

Various functions of liquid metals are closely related to their surface performances, among which oxidation and wetting are the two most important surface processes. The two processes of liquid metals are inseparable in most practical applications; however, the coupling of oxidation and wetting of liquid metals has received little attention. Here, we demonstrate the synergistic effect of oxidation and wetting of liquid metals through establishing a liquid system containing the copper ion acid solution. By modulating the concentrations of copper ions and hydrogen ions, three different modes of the liquid metal surface are presented, where the oxidation process and the wetting process are in a competitive relationship. Whichever of the two processes is dominant can determine the stability of copper particles produced on the surface of liquid metals, that is, affect whether the "phagocytosis" process can occur. It is revealed that the magnitude of current density on the surface of liquid metals, caused by galvanic corrosion behavior between liquid metals and copper particles, is the key factor influencing the dominance of different surface processes of liquid metals. Utilizing the synergistic effect, we prepare a liquid metal film with adjustable reflectivity, in which surface states can be changed repeatedly between the bright state and the darken state by simple solution immersion. The liquid metal film with different surface states can show obvious difference in optical performance, which has application potential in color camouflage. Understanding the surface synergistic effect will facilitate further exploration of the abundant exotic liquid metal interface phenomena.

Liquid Metal-Based Electronics for On-Skin Healthcare

Wearable devices are receiving growing interest in modern technologies for realizing multiple on-skin purposes, including flexible display, flexible e-textiles, and, most importantly, flexible epidermal healthcare. A 'BEER' requirement, i.e., biocompatibility, electrical elasticity, and robustness, is first proposed here for all the on-skin healthcare electronics for epidermal applications. This requirement would guide the designing of the next-generation on-skin healthcare electronics. For conventional stretchable electronics, the rigid conductive materials, e.g., gold nanoparticles and silver nanofibers, would suffer from an easy-to-fail interface with elastic substrates due to a Young's modulus mismatch. Liquid metal (LM) with high conductivity and stretchability has emerged as a promising solution for robust stretchable epidermal electronics. In addition, the fundamental physical, chemical, and biocompatible properties of LM are illustrated. Furthermore, the fabrication strategies of LM are outlined for pure LM, LM composites, and LM circuits based on the surface tension control. Five dominant epidermal healthcare applications of LM are illustrated, including electrodes, interconnectors, mechanical sensors, thermal management, and biomedical and sustainable applications. Finally, the key challenges and perspectives of LM are identified for the future research vision.

Toxicity and Biocompatibility of Liquid Metals

Recently, room-temperature liquid metals have attracted increasing attention from researchers owing to their excellent material properties. Systematic interpretation of the potential toxicity issues involved is essential for a wide range of applications, especially in the biomedical and healthcare fields. However, even with the exponential growth of related studies, investigation of the toxicological impact and possible hazards of liquid metals to organisms is still in its infancy. This review aims to provide a comprehensive summary of the current frontier of knowledge on liquid metal toxicology and biocompatibility in different environments. Based on recent studies, this review focuses on Ga and Bi-based in different states. It is necessary to evaluate their toxicity considering the rapid increase in research and utilization of such liquid metal composites. Finally, existing challenges are discussed and suggestions are provided for further investigation of liquid metal toxicology to clarify the toxicological mechanisms and strategies are provided to avoid adverse effects. In addition to resolving the doubts of public concern about the toxicity of liquid metals, this review is expected to promote the healthy and sustainable development of liquid metal-based materials and their use in diverse areas, especially those related to health care.

Electric current-assisted manipulation of liquid metals using a stylus at micro-and nano-scales

A novel methodology, based on wetting and electromigration, for transporting liquid metal, over long distances, at micro-and nano-scale using a stylus is reported. The mechanism is analogous to a dropper that uses 'suction and release' actions to 'collect and dispense' liquid. In our methodology, a stylus coated with a thin metal film acts like the dropper that collects liquid metal from a reservoir upon application of an electric current, holds the liquid metal via wetting while carrying the liquid metal over large distances away from the reservoir and drops it on the target location by reversing the direction of electric current. Essentially, the working principle of the technique relies on the directionality of electromigration force and adhesive force due to wetting. The working of the technique is demonstrated by using an Au-coated Si micropillar as the stylus, liquid Ga as the liquid metal to be transported, and a Kleindiek-based position micro-manipulator to traverse the stylus from the liquid reservoir to the target location. For demonstrating the potential applications, the technique is utilized for closing a micro-gap by dispensing a minuscule amount of liquid Ga and conformally coating the desired segment of the patterned thin films with liquid Ga. This study confirms the promising potential of the developed technique for reversible, controlled manipulation of liquid metal at small length scales.

Amphiphilic Silver Nanoparticles for Inkjet-Printable Conductive Inks

The large-scale manufacturing of flexible electronics is nowadays based on inkjet printing technology using specially formulated conductive inks, but achieving adequate wetting of different surfaces remains a challenge. In this work, the development of a silver nanoparticle-based functional ink for printing on flexible paper and plastic substrates is demonstrated. Amphiphilic silver nanoparticles with narrow particle size distribution and good dispersibility were prepared via a two-step wet chemical synthesis procedure. First, silver nanoparticles capped with poly(acrylic acid) were prepared, followed by an amidation reaction with 3-morpholynopropylamine (MPA) to increase their lipophilicity. Density functional theory (DFT) calculations were performed to study the interactions between the particles and the dispersion medium in detail. The amphiphilic nanoparticles were dispersed in solvents of different polarity and their physicochemical and rheological properties were determined. A stable ink containing 10 wt% amphiphilic silver nanoparticles was formulated and inkjet-printed on different surfaces, followed by intense pulsed light (IPL) sintering. Low sheet resistances of 3.85 Ω sq^-1, 0.57 Ω sq^-1 and 19.7 Ω sq^-1 were obtained for the paper, coated poly(ethylene terephthalate) (PET) and uncoated polyimide (PI) flexible substrates, respectively. Application of the nanoparticle ink for printed electronics was demonstrated via a simple flexible LED circuit.

Connecting liquid metals with sound

A stretchable conductive circuit is formed using a liquid metal-polymer composite

A Liquid Metal-Enhanced Wearable Thermoelectric Generator

It is a key challenge to continuously power personal wearable health monitoring systems. This paper reports a novel liquid metal-enhanced wearable thermoelectric generator (LM-WTEG that directly converts body heat into electricity for powering the wearable sensor system. The gallium-based liquid metal alloys with room-temperature melting point (24~30 °C) and high latent heat density (about 500 MJ/m³) are used to design a new flexible finned heat sink, which not only absorbs the heat through the solid-liquid phase change of the LM and enhances the heat release to the ambient air due to its high thermal conduction. The LM finned is integrated with WTEG to present high biaxial flexibility, which could be tightly in contact with the skin. The LM-WTEG could achieve a super high output power density of 275 μW/cm² for the simulated heat source (37 °C) with the natural convective heat transfer condition. The energy management unit, the multi-parameter sensors (including temperature, humidity, and accelerometer), and Bluetooth module with a total energy consumption of about 65 μW are designed, which are fully powered from LM-WTEG through harvesting body heat.

Responsive Liquid Metal Droplets: From Bulk to Nano

Droplets exist widely in nature and play an extremely important role in a broad variety of industrial processes. Typical droplets, including water and oil droplets, have received extensive attention and research, however their single properties still cannot meet diverse needs. Fortunately, liquid metal droplets emerging in recent years possess outstanding properties, including large surface tension, excellent electrical and thermal conductivity, convenient chemical processing, easy transition between liquid and solid phase state, and large-scale deformability, etc. More interestingly, liquid metal droplets with unique features can respond to external factors, including the electronic field, magnetic field, acoustic field, chemical field, temperature, and light, exhibiting extraordinary intelligent response characteristics. Their development over the past decade has brought substantial breakthroughs and progress. To better promote the advancement of this field, the present article is devoted to systematically summarizing and analyzing the recent fundamental progress of responsive liquid metal droplets, not only involving droplet characteristics and preparation methods, but also focusing on their diverse response behaviors and mechanisms. On this basis, the challenges and prospects related to the following development of liquid metal droplets are also proposed. In the future, responsive liquid metal droplets with a rapid development trend are expected to play a key role in soft robots, biomedicine, smart matter, and a variety of other fields.

Liquid Metal Based Nano-Composites for Printable Stretchable Electronics

Liquid metal (LM) has attracted prominent attention for stretchable and elastic electronics applications due to its exceptional fluidity and conductivity at room temperature. Despite progress in this field, a great disparity remains between material fabrication and practical applications on account of the high surface tension and unavoidable oxidation of LM. Here, the composition and nanolization of liquid metal can be envisioned as effective solutions to the processibility-performance dilemma caused by high surface tension. This review aims to summarize the strategies for the fabrication, processing, and application of LM-based nano-composites. The intrinsic mechanism and superiority of the composition method will further extend the capabilities of printable ink. Recent applications of LM-based nano-composites in printing are also provided to guide the large-scale production of stretchable electronics.

Fluid pumping by liquid metal droplet utilizing ac electric field

We report a unique phenomenon in which liquid metal droplets (LMDs) under a pure ac electric field pump fluid. Unlike the directional pumping that occurs upon reversing the electric field polarity under a dc signal, this phenomenon allows the direction of fluid motion to be switched by simply shifting the position of the LMD within the cylindrical chamber. The physical mechanism behind this phenomenon has been termed Marangoni flow, caused by nonlinear electrocapillary stress. Under the influence of a localized, asymmetric ac electric field, the polarizable surface of the position-offset LMD produces a net time-averaged interfacial tension gradient that scales with twice the field strength, and thus pumps fluid unidirectionally. However, the traditional linear RC circuit polarization model of the LMD/electrolyte interface fails to capture the correct pump-flow direction when the thickness of the LMD oxide skin is non-negligible compared to the Debye length. Therefore, we developed a physical description by treating the oxide layer as a distributed capacitance with variable thickness and connected with the electric double layer. The flow profile is visualized via microparticle imaging velocimetry, and excellent consistency is found with simulation results obtained from the proposed nonlinear model. Furthermore, we investigate the effects of relevant parameters on fluid pumping and discuss a special phenomenon that does not exist in dc control systems. To our knowledge, no previous work addresses LMDs in this manner and uses a zero-mean ac electric field to achieve stable, adjustable directional pumping of a low-conductivity solution.