Direct Patterning of Highly Conductive PEDOT:PSS/Ionic Liquid Hydrogel via Microreactive Inkjet Printing

Rapid prototyping and facile customization of conductive hydrogel bioelectronics based on all laser process

Proper customization in size and shape is essential in implantable bioelectronics for stable bio-signal recording. Over the past decades, many researchers have heavily relied on conventional photolithography processes to fabricate implantable bioelectronics. Therefore, they could not avoid the critical limitation of high cost and complex processing steps to optimize bioelectronic devices for target organs with various sizes and shapes. Here, we propose rapid prototyping using all laser processes to fabricate customized bioelectronics. PEDOT:PSS is selectively irradiated by an ultraviolet (UV) pulse laser to form wet-stable conductive hydrogels that can softly interact with biological tissues (50 μm line width). The encapsulation layer is selectively patterned using the same laser source by UV-curing polymer networks (110 μm line width). For high stretchability (over 100%), mesh structures are made by the selective laser cutting process. Our rapid prototyping strategy minimizes the use of high-cost equipment, using only a single UV laser source to process the electrodes, encapsulation, and substrates that constitute bioelectronics without a photomask, enabling the prototyping stretchable microelectrode array with an area of 1 cm2 less than 10 min. We fabricated an optimized stretchable microelectrode array with low impedances (∼1.1 kΩ at 1 kHz) that can effectively record rat's cardiac signals with various health states.

Engineering biomaterials by inkjet printing of hydrogels with functional particulates

Hydrogels with particulates, including proteins, drugs, nanoparticles, and cells, enable the development of new and innovative biomaterials. Precise control of the spatial distribution of these particulates is crucial to produce advanced biomaterials. Thus, there is a high demand for manufacturing methods for particle-laden hydrogels. In this context, 3D printing of hydrogels is emerging as a promising method to create numerous innovative biomaterials. Among the 3D printing methods, inkjet printing, so-called drop-on-demand (DOD) printing, stands out for its ability to construct biomaterials with superior spatial resolutions. However, its printing processes are still designed by trial and error due to a limited understanding of the ink behavior during the printing processes. This review discusses the current understanding of transport processes and hydrogel behaviors during inkjet printing for particulate-laden hydrogels. Specifically, we review the transport processes of water and particulates within hydrogel during ink formulation, jetting, and curing. Additionally, we examine current inkjet printing applications in fabricating engineered tissues, drug delivery devices, and advanced bioelectronics components. Finally, the challenges and opportunities for next-generation inkjet printing are also discussed.

Graphical Abstract

Engineering Proteins for PEDOT Dispersions: A New Horizon for Highly Mixed Ionic-Electronic Biocompatible Conducting Materials

Poly (3,4-ethylenedioxythiophene) (PEDOT) doped with polystyrene sulfonate (PSS) is the most used conducting polymer from energy to biomedical applications. Despite its exceptional properties, there is a need for developing new materials that can improve some of its inherent limitations, e.g., biocompatibility. In this context, doping PEDOT is propose with a robust recombinant protein with tunable properties, the consensus tetratricopeptide repeated protein (CTPR). The doping consists of an oxidative polymerization, where the PEDOT chains are stabilized by the negative charges of the CTPR protein. CTPR proteins are evaluated with three different lengths (3, 10, and 20 identical CTPR units) and optimized varied synthetic conditions. These findings revealed higher doping rate and oxidized state of the PEDOT chains when doped with the smallest scaffold (CTPR3). These PEDOT:CTPR hybrids possess ionic and electronic conductivity. Notably, PEDOT:CTPR3 displayed an electronic conductivity of 0.016 S cm-1, higher than any other reported protein-doped PEDOT. This result places PEDOT:CTPR3 at the level of PEDOT-biopolymer hybrids, and brings it closer in performance to PEDOT:PSS gold standard. Furthermore, PEDOT:CTPR3 dispersion is successfully optimized for inkjet printing, preserving its electroactivity properties after printing. This approach opens the door to the use of these novel hybrids for bioelectronics.

Direct electron beam patterning of electro-optically active PEDOT:PSS

The optical and electronic tunability of the conductive polymer poly(3,4-ethylenedioxythiophene):poly(styrene sulfonate) (PEDOT:PSS) has enabled emerging applications as diverse as bioelectronics, flexible electronics, and micro- and nano-photonics. High-resolution spatial patterning of PEDOT:PSS opens up opportunities for novel active devices in a range of fields. However, typical lithographic processes require tedious indirect patterning and dry etch processes, while solution-processing methods such as ink-jet printing have limited spatial resolution. Here, we report a method for direct write nano-patterning of commercially available PEDOT:PSS through electron-beam induced solubility modulation. The written structures are water stable and maintain the conductivity as well as electrochemical and optical properties of PEDOT:PSS, highlighting the broad utility of our method. We demonstrate the potential of our strategy by preparing prototypical nano-wire structures with feature sizes down to 250 nm, an order of magnitude finer than previously reported direct write methods, opening the possibility of writing chip-scale microelectronic and optical devices. We finally use the high-resolution writing capabilities to fabricate electrically-switchable optical diffraction gratings. We show active switching in this archetypal system with >95 % contrast at CMOS-compatible voltages of +2 V and -3 V, offering a route towards highly-miniaturized dynamic optoelectronic devices.

Seamless Integration of Conducting Hydrogels in Daily Life: From Preparation to Wearable Application

Conductive hydrogels (CHs) have received significant attention for use in wearable devices because they retain their softness and flexibility while maintaining high conductivity. CHs are well suited for applications in skin-contact electronics and biomedical devices owing to their high biocompatibility and conformality. Although highly conductive hydrogels for smart wearable devices are extensively researched, a detailed summary of the outstanding results of CHs is required for a comprehensive understanding. In this review, the recent progress in the preparation and fabrication of CHs is summarized for smart wearable devices. Improvements in the mechanical, electrical, and functional properties of high-performance wearable devices are also discussed. Furthermore, recent examples of innovative and highly functional devices based on CHs that can be seamlessly integrated into daily lives are reviewed.

Electrochemical and Electrical Biosensors for Wearable and Implantable Electronics Based on Conducting Polymers and Carbon-Based Materials

Bioelectronic devices are designed to translate biological information into electrical signals and vice versa, thereby bridging the gap between the living biological world and electronic systems. Among different types of bioelectronics devices, wearable and implantable biosensors are particularly important as they offer access to the physiological and biochemical activities of tissues and organs, which is significant in diagnosing and researching various medical conditions. Organic conducting and semiconducting materials, including conducting polymers (CPs) and graphene and carbon nanotubes (CNTs), are some of the most promising candidates for wearable and implantable biosensors. Their unique electrical, electrochemical, and mechanical properties bring new possibilities to bioelectronics that could not be realized by utilizing metals- or silicon-based analogues. The use of organic- and carbon-based conductors in the development of wearable and implantable biosensors has emerged as a rapidly growing research field, with remarkable progress being made in recent years. The use of such materials addresses the issue of mismatched properties between biological tissues and electronic devices, as well as the improvement in the accuracy and fidelity of the transferred information. In this review, we highlight the most recent advances in this field and provide insights into organic and carbon-based (semi)conducting materials' properties and relate these to their applications in wearable/implantable biosensors. We also provide a perspective on the promising potential and exciting future developments of wearable/implantable biosensors.

Manipulation of cross-linking in PEDOT:PSS hydrogels for biointerfacing

Conducting hydrogels can be used to fabricate bioelectronic devices that are soft for improved cell- and tissue-interfacing. Those based on conjugated polymers, such as poly(3,4-ethylene-dioxythiophene):polystyrene sulfonate (PEDOT:PSS), can be made simply with solution-based processing techniques, yet the influence of fabrication variables on final gel properties is not fully understood. In this study, we investigated if PEDOT:PSS cross-linking could be manipulated by changing the concentration of a gelling agent, ionic liquid, in the hydrogel precursor mixture. Rheology and gelation kinetics of precursor mixtures were investigated, and aqueous stability, swelling, conductivity, stiffness, and cytocompatibility of formed hydrogels were characterized. Increasing ionic liquid concentration was found to increase cross-linking as measured by decreased swelling, decreased non-network fraction, increased stiffness, and increased conductivity. Such manipulation of IL concentration thus afforded control of final gel properties and was utilized in further investigations of biointerfacing. When cross-linked sufficiently, PEDOT:PSS hydrogels were stable in sterile cell culture conditions for at least 28 days. Additionally, hydrogels supported a viable and proliferating population of human dermal fibroblasts for at least two weeks. Collectively, these characterizations of stability and cytocompatibility illustrate that these PEDOT:PSS hydrogels have significant promise for biointerfacing applications that require soft materials for direct interaction with cells.

Omnidirectional Printing of PEDOT:PSS for High-Conductivity Spanning Structures

Poly(3,4-ethylenedioxythiophene):poly(styrenesulfonate) (PEDOT:PSS), a prominent conducting polymer, holds significance in both industry and academia. However, prevailing fabrication techniques struggle to build spanning features of PEDOT:PSS with both high electrical conductivity and fine resolution due to layerwise assembly in the xy plane. Here, we report an "omnidirectional printing and secondary doping" strategy to construct spanning, filamentary and out-of-plane 3D PEDOT:PSS with high conductivity. The pristine PEDOT:PSS suspension is homogeneously concentrated to form a printable ink with high solids (∼15 wt %) consisting of entangled PEDOT:PSS nanofibrils. Such ink shows a high storage modulus G' (43531 Pa) and a high yield stress τy (4325 Pa), thereby enabling omnidirectional printing. Secondary doping with sulfuric acid or other polar solvents is used to induce a synergetic process of PSS loss, conformational change, phase separation, and crystallinity enhancement in the printed structures, resulting in a remarkable enhancement of conductivity in dehydrated (65,378 S/m) and swollen (7190 S/m) states. As a proof-of-concept, 2D grids with a feature size of 15 μm and 3D overhanging arches are fabricated for high-performance transparent glass heaters and 3D interconnection, respectively. This work promises great potential for the development of advanced flexible electronics, wearable devices, and bioelectronics.

Recent advances in 3D printable conductive hydrogel inks for neural engineering

Recently, the 3D printing of conductive hydrogels has undergone remarkable advances in the fabrication of complex and functional structures. In the field of neural engineering, an increasing number of reports have been published on tissue engineering and bioelectronic approaches over the last few years. The convergence of 3D printing methods and electrically conducting hydrogels may create new clinical and therapeutic possibilities for precision regenerative medicine and implants. In this review, we summarize (i) advancements in preparation strategies for conductive materials, (ii) various printing techniques enabling the fabrication of electroconductive hydrogels, (iii) the required physicochemical properties of the printed constructs, (iv) their applications in bioelectronics and tissue regeneration for neural engineering, and (v) unconventional approaches and outlooks for the 3D printing of conductive hydrogels. This review provides technical insights into 3D printable conductive hydrogels and encompasses recent developments, specifically over the last few years of research in the neural engineering field.

Towards biodegradable conducting polymers by incorporating seaweed cellulose for decomposable wearable heaters

Thermotherapy shows significant potential for pain relief and enhanced blood circulation in wildlife rehabilitation, particularly for injured animals. However, the widespread adoption of this technology is hindered by the lack of biodegradable, wearable heating pads and concerns surrounding electronic waste (E-waste) in natural habitats. This study addresses this challenge by investigating an environmentally-friendly composite comprising poly(3,4-ethylenedioxythiophene):polystyrene sulfonate (PEDOT:PSS), seaweed cellulose, and glycerol. Notably, this composite exhibits remarkable biodegradability, losing half of its weight within one week and displaying noticeable edge degradation by the third week when placed in soil. Moreover, it demonstrates impressive heating performance, reaching a temperature of 51 °C at a low voltage of 1.5 V, highlighting its strong potential for thermotherapy applications. The combination of substantial biodegradability and efficient heating performance offers a promising solution for sustainable electronic applications in wildlife rehabilitation and forest monitoring, effectively addressing the environmental challenges associated with E-waste.

Transparent Electronics for Wearable Electronics Application

Recent advancements in wearable electronics offer seamless integration with the human body for extracting various biophysical and biochemical information for real-time health monitoring, clinical diagnostics, and augmented reality. Enormous efforts have been dedicated to imparting stretchability/flexibility and softness to electronic devices through materials science and structural modifications that enable stable and comfortable integration of these devices with the curvilinear and soft human body. However, the optical properties of these devices are still in the early stages of consideration. By incorporating transparency, visual information from interfacing biological systems can be preserved and utilized for comprehensive clinical diagnosis with image analysis techniques. Additionally, transparency provides optical imperceptibility, alleviating reluctance to wear the device on exposed skin. This review discusses the recent advancement of transparent wearable electronics in a comprehensive way that includes materials, processing, devices, and applications. Materials for transparent wearable electronics are discussed regarding their characteristics, synthesis, and engineering strategies for property enhancements. We also examine bridging techniques for stable integration with the soft human body. Building blocks for wearable electronic systems, including sensors, energy devices, actuators, and displays, are discussed with their mechanisms and performances. Lastly, we summarize the potential applications and conclude with the remaining challenges and prospects.

Photopatternable and Highly Conductive PEDOT:PSS Electrodes for Flexible Perovskite Light-Emitting Diodes

Flexible perovskite light-emitting diodes (PeLEDs) constitute an emerging technology opening new opportunities in the fields of lighting and display for portable and wearable electronics. Poly(3,4-ethylenedioxythiophene):poly(stryrenesulfonate) (PEDOT:PSS) as one of the most promising flexible electrode materials has attracted extensive attention. However, the patterning and conductivity issues of PEDOT:PSS electrodes should be addressed primarily. Here, a photopolymerizable additive is proposed to endow the PEDOT:PSS electrodes with photopatternability. Moreover, this additive can also improve the conductivity of the PEDOT:PSS electrode from 0.16 to 627 S/cm because of the phase separation between PEDOT and PSS components and conformation transition of PEDOT chains. Eventually, highly conductive PEDOT:PSS electrodes with various patterns are applied in flexible PeLEDs, demonstrating a high luminance of 25972 cd/m² and a current efficiency of 25.1 cd/A. This work provides a facile and effective method of patterning and improving the conductivity of PEDOT:PSS electrodes simultaneously, demonstrating the great potential of PEDOT:PSS electrodes in flexible perovskite optoelectronics.

Highly conductive tissue-like hydrogel interface through template-directed assembly

Over the past decade, conductive hydrogels have received great attention as tissue-interfacing electrodes due to their soft and tissue-like mechanical properties. However, a trade-off between robust tissue-like mechanical properties and good electrical properties has prevented the fabrication of a tough, highly conductive hydrogel and limited its use in bioelectronics. Here, we report a synthetic method for the realization of highly conductive and mechanically tough hydrogels with tissue-like modulus. We employed a template-directed assembly method, enabling the arrangement of a disorder-free, highly-conductive nanofibrous conductive network inside a highly stretchable, hydrated network. The resultant hydrogel exhibits ideal electrical and mechanical properties as a tissue-interfacing material. Furthermore, it can provide tough adhesion (800 J/m²) with diverse dynamic wet tissue after chemical activation. This hydrogel enables suture-free and adhesive-free, high-performance hydrogel bioelectronics. We successfully demonstrated ultra-low voltage neuromodulation and high-quality epicardial electrocardiogram (ECG) signal recording based on in vivo animal models. This template-directed assembly method provides a platform for hydrogel interfaces for various bioelectronic applications.

Micro/Nano-Fabrication of Flexible Poly(3,4-Ethylenedioxythiophene)-Based Conductive Films for High-Performance Microdevices

With the increasing demands for novel flexible organic electronic devices, conductive polymers are now becoming the rising star for reaching such targets, which has witnessed significant breakthroughs in the fields of thermoelectric devices, solar cells, sensors, and hydrogels during the past decade due to their outstanding conductivity, solution-processing ability, as well as tailorability. However, the commercialization of those devices still lags markedly behind the corresponding research advances, arising from the not high enough performance and limited manufacturing techniques. The conductivity and micro/nano-structure of conductive polymer films are two critical factors for achieving high-performance microdevices. In this review, the state-of-the-art technologies for developing organic devices by using conductive polymers are comprehensively summarized, which will begin with a description of the commonly used synthesis methods and mechanisms for conductive polymers. Next, the current techniques for the fabrication of conductive polymer films will be proffered and discussed. Subsequently, approaches for tailoring the nanostructures and microstructures of conductive polymer films are summarized and discussed. Then, the applications of micro/nano-fabricated conductive films-based devices in various fields are given and the role of the micro/nano-structures on the device performances is highlighted. Finally, the perspectives on future directions in this exciting field are presented.

Recent advances in inkjet-printing technologies for flexible/wearable electronics

The rapid development of flexible/wearable electronics requires novel fabricating strategies. Among the state-of-the-art techniques, inkjet printing has aroused considerable interest due to the possibility of large-scale fabricating flexible electronic devices with good reliability, high time efficiency, a low manufacturing cost, and so on. In this review, based on the working principle, recent advances in the inkjet printing technology in the field of flexible/wearable electronics are summarized, including flexible supercapacitors, transistors, sensors, thermoelectric generators, wearable fabric, and for radio frequency identification. In addition, some current challenges and future opportunities in this area are also addressed. We hope this review article can give positive suggestions to the researchers in the area of flexible electronics.

Heat-Driven Iontronic Nanotransistors

Thermoelectric polyelectrolytes are emerging as ideal material platform for self-powered bio-compatible electronic devices and sensors. However, despite the nanoscale nature of the ionic thermodiffusion processes underlying thermoelectric efficiency boost in polyelectrolytes, to date no evidence for direct probing of ionic diffusion on its relevant length and time scale has been reported. This gap is bridged by developing heat-driven hybrid nanotransistors based on InAs nanowires embedded in thermally biased Na⁺ -functionalized (poly)ethyleneoxide, where the semiconducting nanostructure acts as a nanoscale probe sensitive to the local arrangement of the ionic species. The impact of ionic thermoelectric gating on the nanodevice electrical response is addressed, investigating the effect of device architecture, bias configuration and frequency of the heat stimulus, and inferring optimal conditions for the heat-driven nanotransistor operation. Microscopic quantities of the polyelectrolyte such as the ionic diffusion coefficient are extracted from the analysis of hysteretic behaviors rising in the nanodevices. The reported experimental platform enables simultaneously the ionic thermodiffusion and nanoscale resolution, providing a framework for direct estimation of polyelectrolytes microscopic parameters. This may open new routes for heat-driven nanoelectronic applications and boost the rational design of next-generation polymer-based thermoelectric materials.

Stretchable conductors for stretchable field-effect transistors and functional circuits

Stretchable electronics have received intense attention due to their broad application prospects in many areas, and can withstand large deformations and form close contact with curved surfaces. Stretchable conductors are vital components of stretchable electronic devices used in wearables, soft robots, and human-machine interactions. Recent advances in stretchable conductors have motivated basic scientific and technological research efforts. Here, we outline and analyse the development of stretchable conductors in transistors and circuits, and examine advances in materials, device engineering, and preparation technologies. We divide the existing approaches to constructing stretchable transistors with stretchable conductors into the following two types: geometric engineering and intrinsic stretchability engineering. Finally, we consider the challenges and outlook in this field for delivering stretchable electronics.

Self-Healing, Flexible and Smart 3D Hydrogel Electrolytes Based on Alginate/PEDOT:PSS for Supercapacitor Applications

Hydrogel electrolytes for energy storage devices have made great progress, yet they present a major challenge in the assembly of flexible supercapacitors with high ionic conductivity and self-healing properties. Herein, a smart self-healing hydrogel electrolyte based on alginate/poly (3,4-ethylenedioxythiophene):poly(styrenesulfonate) (alginate/PEDOT:PSS)(A/P:P) was prepared, wherein H₂SO₄ was employed as a polymeric initiator, as well as a source of ions. PEDOT:PSS is a semi-interpenetrating network (IPN) that has been used in recent studies to exhibit quick self-healing properties with the H₂SO₃ additive, which further improves its mechanical strength and self-healing performance. A moderate amount of PEDOT:PSS in the hydrogel (5 mL) was found to significantly improve the ionic conductivity compared to the pure hydrogel of alginate. Interestingly, the alginate/PEDOT:PSS composite hydrogel exhibited an excellent ability to self-heal and repair its original composition within 10 min of cutting. Furthermore, the graphite conductive substrate-based supercapacitor with the alginate/PEDOT:PSS hydrogel electrolyte provided a high specific capacitance of 356 F g^-1 at 100 mV/s g^-1. The results demonstrate that the A/P:P ratio with 5 mL PEDOT:PSS had a base sheet resistance of 0.9 Ω/square. This work provides a new strategy for designing flexible self-healing hydrogels for application in smart wearable electronics.

Protic Ionic Liquids for Intrinsically Stretchable Conductive Polymers

Inspired by the classic hard-soft acid-base theory and intrigued by a theoretical prediction of spontaneous ion exchange between poly(3,4-ethylenedioxythiophene):poly(styrenesulfonate) (PEDOT:PSS) and hard-cation-soft-anion ionic liquid (IL), we treat PEDOT:PSS with a new IL composed of a protic (i.e., extremely hard) cation (3-methylimidazolium, p-MIM⁺) and an extremely soft anion (tetracyanoborate, TCB^-). In fact, this protic IL (p-MIM:TCB) accomplishes the same levels of ion-exchange-mediated PEDOT-PSS separation, PEDOT-rich nanofibril formation, and electrical conductivity enhancement (∼2500 S/cm) as its aprotic counterpart (EMIM:TCB with 1-ethyl-3-methylimidazolium), the best IL used for this purpose so far. Furthermore, p-MIM:TCB significantly outperforms EMIM:TCB in terms of improving the stretchability (i.e., the highest tensile strain) of the PEDOT:PSS thin film. This enhancement is a result of the aromatic and protic cation p-MIM⁺, which acts as a molecular adhesive holding the exchanged ion pairs (PEDOT⁺:TCB^----p-MIM⁺:PSS^-) via ionic intercalation (at the surface of TCB^--decorated PEDOT⁺ clusters) and hydrogen bonding (to PSS^-), in which washing p-MIM⁺ out of the film degrades the stretchability while keeping the morphology. Our results offer molecular-level insight into the morphological, electrical, and mechanical properties of PEDOT:PSS and a molecular-interaction-based enhancement strategy that can be used for intrinsically stretchable conductive polymers.

Three-Dimensional Printing of Double-Network Hydrogels: Recent Progress, Challenges, and Future Outlook

Hydrogels are widely used materials due to their biocompatibility, their ability to mimic the hydrated and porous extracellular microenvironment, as well as their ability to tune both mechanical and biochemical properties. However, most hydrogels lack mechanical toughness, and shaping them into complicated three-dimensional (3D) structures remains challenging. In the past decade, tough and stretchable double-network hydrogels (DN gels) were developed for tissue engineering, soft robotics, and applications that require a combination of high-energy dissipation and large deformations. Although DN gels were processed into simple shapes by using conventional casting and molding methods, new 3D printing methods have enabled the shaping of DN gels into structurally complex 3D geometries. This review will describe the state-of-art technologies for shaping tough and stretchable DN gels into custom geometries by using conventional molding and casting, extrusion, and optics-based 3D printing, as well as the key challenges and future outlook in this field.

Digital selective transformation and patterning of highly conductive hydrogel bioelectronics by laser-induced phase separation

The patterning of poly(3,4-ethylenedioxythiophene):poly(styrene sulfonate) (PEDOT:PSS) hydrogels with excellent electrical property and spatial resolution is a challenge for bioelectronic applications. However, most PEDOT:PSS hydrogels are fabricated by conventional manufacturing processes such as photolithography, inkjet printing, and screen printing with complex fabrication steps or low spatial resolution. Moreover, the additives used for fabricating PEDOT:PSS hydrogels are mostly cytotoxic, thus requiring days of detoxification. Here, we developed a previously unexplored ultrafast and biocompatible digital patterning process for PEDOT:PSS hydrogel via phase separation induced by a laser. We enhanced the electrical properties and aqueous stability of PEDOT:PSS by selective laser scanning, which allowed the transformation of PEDOT:PSS into water-stable hydrogels. PEDOT:PSS hydrogels showed high electrical conductivity of 670 S/cm with 6-μm resolution in water. Furthermore, electrochemical properties were maintained even after 6 months in a physiological environment. We further demonstrated stable neural signal recording and stimulation with hydrogel electrodes fabricated by laser.

Challenges, Prospects, and Emerging Applications of Inkjet-Printed Electronics: A Chemist's Point of View

Driven by the development of new functional inks, inkjet-printed electronics has achieved several milestones upon moving from the integration of simple electronic elements (e.g., temperature and pressure sensors, RFID antennas, etc.) to high-tech applications (e.g. in optoelectronics, energy storage and harvesting, medical diagnosis). Currently, inkjet printing techniques are limited by spatial resolution higher than several micrometers, which sets a redhibitorythreshold for miniaturization and for many applications that require the controlled organization of constituents at the nanometer scale. In this Review, we present the physico-chemical concepts and the equipment constraints underpinning the resolution limit of inkjet printing and describe the contributions from molecular, supramolecular, and nanomaterials-based approaches for their circumvention. Based on these considerations, we propose future trajectories for improving inkjet-printing resolution that will be driven and supported by breakthroughs coming from chemistry. Please check all text carefully as extensive language polishing was necessary. Title ok? Yes.

Microfluidics-enabled functional 3D printing

Microfluidic technology has established itself as a powerful tool to enable highly precise spatiotemporal control over fluid streams for mixing, separations, biochemical reactions, and material synthesis. 3D printing technologies such as extrusion-based printing, inkjet, and stereolithography share similar length scales and fundamentals of fluid handling with microfluidics. The advanced fluidic manipulation capabilities afforded by microfluidics can thus be potentially leveraged to enhance the performance of existing 3D printing technologies or even develop new approaches to additive manufacturing. This review discusses recent developments in integrating microfluidic elements with several well-established 3D printing technologies, highlighting the trend of using microfluidic approaches to achieve functional and multimaterial 3D printing as well as to identify potential future research directions in this emergent area.

Resilient and Self-Healing Hyaluronic Acid/Chitosan Hydrogel With Ion Conductivity, Low Water Loss, and Freeze-Tolerance for Flexible and Wearable Strain Sensor

Conductive hydrogel is a vital candidate for the fabrication of flexible and wearable electric sensors due to its good designability and biocompatibility. These well-designed conductive hydrogel–based flexible strain sensors show great potential in human motion monitoring, artificial skin, brain computer interface (BCI), and so on. However, easy drying and freezing of conductive hydrogels with high water content greatly limited their further application. Herein, we proposed a natural polymer-based conductive hydrogel with excellent mechanical property, low water loss, and freeze-tolerance. The main hydrogel network was formed by the Schiff base reaction between the hydrazide-grafted hyaluronic acid and the oxidized chitosan, and the added KCl worked as the conductive filler. The reversible crosslinking in the prepared hydrogel resulted in its resilience and self-healing feature. At the same time, the synthetic effect of KCl and glycerol endowed our hydrogel with outstanding anti-freezing property, while glycerol also endowed this hydrogel with anti-drying property. When this hydrogel was assembled as a flexible strain sensor, it showed good sensitivity (GF = 2.64), durability, and stability even under cold condition (−37°C).

Direct Wiring of Liquid Metal on an Ultrasoft Substrate Using a Polyvinyl Alcohol Lift-off Method

In recent years, wiring and system construction on ultrasoft materials such as biological tissues and hydrogels have been proposed for advanced wearable devices, implantable devices, and soft robotics. Among the soft conductive materials, Ga-based liquid metals (LMs) are both biocompatible and ultrasoft, making them a good match for electrodes on the ultrasoft substrates. However, gels and tissues are softer and less wettable to the LMs than conventional soft substrates such as Ecoflex and polydimethylsiloxane. In this study, we demonstrated the transfer of LM paste composed of Ga-based LM and Ni nanoparticles onto ultrasoft substrates such as biological tissue and gels using sacrificial polyvinyl alcohol (PVA) films. The LM paste pattern fabricated on the PVA film adhered to the ultrasoft substrate along surface irregularities and was transferred without being destroyed by the PVA film before the PVA's dissolution in water. The minimum line width that could be wired was approximately 165 μm. Three-dimensional wiring, such as the helical structure on the gel fiber surface, is also possible. Application of this transfer method to tissues using LM paste wiring allowed the successful stimulation of the vagus nerve in rats. In addition, we succeeded in transferring a temperature measurement system fabricated on a PVA film onto the gel. The connection between the solid-state electrical element and the LM paste was stable and maintained the functionality of the temperature-sensing system. This fundamental study of wiring fabrication and system integration can contribute to the development of advanced electric devices based on ultrasoft substrates.

3D reactive inkjet printing of aliphatic polyureas using in-air coalescence technique

An in-flight coalescence reactive inkjet printer has been developed to facilitate the in-air collision of two reactive microdroplets. This way precise volumes of reactive inks can be mixed and subsequently deposited on the substrate to produce the desired product by polymer synthesis and patterning in a single step. In this work, we validate the printer capabilities by fabrication of a series of 3D structures using an aliphatic polyurea system (isophorone diisocyanate IPDI and poly(propylene glycol) bis(2-aminopropyl ether) PEA-400). The influence of temperature and ink ratio on the material properties has been investigated. An increase in both IPDI and temperature facilitates the production of materials with higher Young's Modulus E and higher ultimate strength U. The possibility of printing different materials i.e. ductile (U = 2 MPa, ε_B = 450%), quasi-brittle (U = 14 MPa, ε_B = 350%), and brittle (U = 10 MPa, ε_B = 11%) by varying the printing process parameters using one set of inks has been presented. The anisotropy of the material properties arising from different printing directions is at the 20% level.

In flight coalescence of polyurea inks in different volume ratios produces materials with varied degrees of elasticity.

Conducting polymer hydrogels as a sustainable platform for advanced energy, biomedical and environmental applications

Environmentally friendly polymeric materials and derivative technologies play increasingly important roles in the sustainable development of our modern society. Conducting polymer hydrogels (CPHs) synergizing the advantageous characteristics of conventional hydrogels and conducting polymers are promising to satisfy the requirements of environmental sustainability. Beyond their use in energy and biomedical applications that require exceptional mechanical and electrical properties, CPHs are emerging as promising contaminant adsorbents owing to their porous network structure and regulable functional groups. Here, we review the currently available strategies for synthesizing CPHs, focusing primarily on multifunctional applications in energy storage/conversion, biomedical engineering and environmental remediation, and discuss future perspectives and challenges for CPHs in terms of their synthesis and applications. It is envisioned to stimulate new thinking and innovation in the development of next-generation sustainable materials.

Inkjet-Printed Highly Conductive Poly(3,4-ethylenedioxythiophene): Poly(styrenesulfonate) Electrode for Organic Light-Emitting Diodes

Recently, inkjet printing technology has attracted much attention due to the advantages of drop-on-demand deposition, low-cost and large-area production for organic light-emitting diode (OLED) displays. However, there are still some problems in industrial production and practical application, such as the complexity of ink modulation, high-quality films with homogeneous morphology, and the re-dissolution phenomenon at interfaces. In this work, a printable poly(3,4-ethylenedioxythiophene): poly(styrenesulfonate) (PEDOT:PSS) ink is developed and obtains an adjustable viscosity. Finally, a patterned PEDOT:PSS electrode is fabricated by inkjet printing, and achieves a high conductivity of 1213 S/cm, a transparency of 86.8% and a uniform morphology without coffee-ring effect. Furthermore, the vacuum-evaporated and solution-processed OLEDs are fabricated based on this electrode and demonstrate a current efficiency of 61 cd/A, which is comparable to that of the indium tin oxide counterpart. This work confirms the feasibility of inkjet printing technology to prepare patterned electrodes and expects that it can be used to fabricate highly efficient optoelectronic devices.

Additive Manufacturing of Conducting Polymers: Recent Advances, Challenges, and Opportunities

Conducting polymers (CPs) have been attracting great attention in the development of (bio)electronic devices. Most of the current devices are rigid two-dimensional systems and possess uncontrollable geometries and architectures that lead to poor mechanical properties presenting ion/electronic diffusion limitations. The goal of the article is to provide an overview about the additive manufacturing (AM) of conducting polymers, which is of paramount importance for the design of future wearable three-dimensional (3D) (bio)electronic devices. Among different 3D printing AM techniques, inkjet, extrusion, electrohydrodynamic, and light-based printing have been mainly used. This review article collects examples of 3D printing of conducting polymers such as poly(3,4-ethylene-dioxythiophene), polypyrrole, and polyaniline. It also shows examples of AM of these polymers combined with other polymers and/or conducting fillers such as carbon nanotubes, graphene, and silver nanowires. Afterward, the foremost applications of CPs processed by 3D printing techniques in the biomedical and energy fields, that is, wearable electronics, sensors, soft robotics for human motion, or health monitoring devices, among others, will be discussed.

Direct laser writing of nanoscale undoped conductive polymer

The fabrication of poly 3,4-ethylene dioxythiophene (PEDOT) devices generally requires a separated strategy for EDOT polymerization and PEDOT coating, thus increasing th difficulty of their integration. With the goal of insolubility of PEDOT in a common solution, material modifications including grafting vinyl moiety groups on the side chain of the PEDOT can increase its solubility, but also markedly reduce the conductivity. Here, we report direct laser writing of pure EDOT monomer into PEDOT with a feature size of 140 nm. The PEDOT nanowire possesses the high conductivity of 1.28 × 10⁵ S m^-1 and can be patterned on solid and flexible substrates with various structures, thus paving the way towards organic highly conductive device fabrication and integration.

Direct writing of 3D conjugated polymer micro/nanostructures for organic electronics and bioelectronics

3D direct writing and meniscus-guided pen writing methods, which are capable of fabricating 3D micro/nanostructures from soluble π-conjugated polymers (CPs) and CP precursors, and recent advances in these techniques are addressed in this review.