Stencil Printing of Liquid Metal upon Electrospun Nanofibers Enables High-Performance Flexible Electronics

Microconfined Assembly of High-Resolution and Mechanically Robust EGaIn Liquid Metal Stretchable Electrodes for Wearable Electronic Systems

Stretchable electrodes based on liquid metals (LM) are widely used in human-machine interfacing, wearable bioelectronics, and other emerging technologies. However, realizing the high-precision patterning and mechanical stability remains challenging due to the poor wettability of LM. Herein, a method is reported to fabricate LM-based multilayer solid-liquid electrodes (m-SLE) utilizing electrohydrodynamic (EHD) printed confinement template. In these electrodes, LM self-assembled onto these high-resolution templates, assisted by selective wetting on the electrodeposited Cu layer. This study shows that a m-SLE composed of PDMS/Ag/Cu/EGaIn exhibits line width of ≈20 µm, stretchability of ≈100%, mechanical stability ≈10 000 times (stretch/relaxation cycles), and recyclability. The multi-layer structure of m-SLE enables the adjustability of strain sensing, in which the strain-sensitive Ag part can be used for non-distributed detection in human health monitoring and the strain-insensitive EGaIn part can be used as interconnects. In addition, this study demonstrates that near field communication (NFC) devices and multilayer displays integrated by m-SLEs exhibit stable wireless signal transmission capability and stretchability, suggesting its applicability in creating highly-integrated, large-scale commercial, and recyclable wearable electronics.

Patterning Techniques Based on Metallized Electrospun Nanofibers for Advanced Stretchable Electronics

Stretchable electronics have experienced remarkable progress, especially in sensors and wireless communication systems, attributed to their ability to conformably contact with rough or uneven surfaces. However, the development of complex, multifunctional, and high-precision stretchable electronics faces substantial challenges, including instability at rigid-soft interfaces and incompatibility with traditional high-precision patterning technologies. Metallized electrospun nanofibers emerge as a promising conductive filler, offering exceptional stretchability, electrical conductivity, transparency, and compatibility with existing patterning technologies. Here, this review focuses on the fundamental properties, preparation processes, patterning technologies, and application scenarios of conductive stretchable composites based on metallized nanofibers. Initially, it introduces the fabrication processes of metallized electrospun nanofibers and their advantages over alternative materials. It then highlights recent progress in patterning technologies, including collector collection, vapor deposition with masks, and lithography, emphasizing their role in enhancing precision and integration. Furthermore, the review shows the broad applicability and potential influence of metallized electrospun nanofibers in various fields through their use in sensors, wireless systems, semiconductor devices, and intelligent healthcare solutions. Ultimately, this review seeks to spark further innovation and address the prevailing challenges in stretchable electronics, paving the way for future breakthroughs in this dynamic field.

Recent progress in multifunctional, reconfigurable, integrated liquid metal-based stretchable sensors and standalone systems

Possessing a unique combination of properties that are traditionally contradictory in other natural or synthetical materials, Ga-based liquid metals (LMs) exhibit low mechanical stiffness and flowability like a liquid, with good electrical and thermal conductivity like metal, as well as good biocompatibility and room-temperature phase transformation. These remarkable properties have paved the way for the development of novel reconfigurable or stretchable electronics and devices. Despite these outstanding properties, the easy oxidation, high surface tension, and low rheological viscosity of LMs have presented formidable challenges in high-resolution patterning. To address this challenge, various surface modifications or additives have been employed to tailor the oxidation state, viscosity, and patterning capability of LMs. One effective approach for LM patterning is breaking down LMs into microparticles known as liquid metal particles (LMPs). This facilitates LM patterning using conventional techniques such as stencil, screening, or inkjet printing. Judiciously formulated photo-curable LMP inks or the introduction of an adhesive seed layer combined with a modified lift-off process further provide the micrometer-level LM patterns. Incorporating porous and adhesive substrates in LM-based electronics allows direct interfacing with the skin for robust and long-term monitoring of physiological signals. Combined with self-healing polymers in the form of substrates or composites, LM-based electronics can provide mechanical-robust devices to heal after damage for working in harsh environments. This review provides the latest advances in LM-based composites, fabrication methods, and their novel and unique applications in stretchable or reconfigurable sensors and resulting integrated systems. It is believed that the advancements in LM-based material preparation and high-resolution techniques have opened up opportunities for customized designs of LM-based stretchable sensors, as well as multifunctional, reconfigurable, highly integrated, and even standalone systems.

Liquid Metal-Polymer Conductor-Based Conformal Cyborg Devices

Gallium-based liquid metal (LM) exhibits exceptional properties such as high conductivity and biocompatibility, rendering it highly valuable for the development of conformal bioelectronics. When combined with polymers, liquid metal-polymer conductors (MPC) offer a versatile platform for fabricating conformal cyborg devices, enabling functions such as sensing, restoration, and augmentation within the human body. This review focuses on the synthesis, fabrication, and application of MPC-based cyborg devices. The synthesis of functional materials based on LM and the fabrication techniques for MPC-based devices are elucidated. The review provides a comprehensive overview of MPC-based cyborg devices, encompassing their applications in sensing diverse signals, therapeutic interventions, and augmentation. The objective of this review is to serve as a valuable resource that bridges the gap between the fabrication of MPC-based conformal devices and their potential biomedical applications.

Room-Temperature Liquid Metals for Flexible Electronic Devices

Room-temperature gallium-based liquid metals (RT-GaLMs) have garnered significant interest recently owing to their extraordinary combination of fluidity, conductivity, stretchability, self-healing performance, and biocompatibility. They are ideal materials for the manufacture of flexible electronics. By changing the composition and oxidation of RT-GaLMs, physicochemical characteristics of the liquid metal can be adjusted, especially the regulation of rheological, wetting, and adhesion properties. This review highlights the advancements in the liquid metals used in flexible electronics. Meanwhile related characteristics of RT-GaLMs and underlying principles governing their processing and applications for flexible electronics are elucidated. Finally, the diverse applications of RT-GaLMs in self-healing circuits, flexible sensors, energy harvesting devices, and epidermal electronics, are explored. Additionally, the challenges hindering the progress of RT-GaLMs are discussed, while proposing future research directions and potential applications in this emerging field. By presenting a concise and critical analysis, this paper contributes to the advancement of RT-GaLMs as an advanced material applicable for the new generation of flexible electronics.

Porous Conductive Textiles for Wearable Electronics

Over the years, researchers have made significant strides in the development of novel flexible/stretchable and conductive materials, enabling the creation of cutting-edge electronic devices for wearable applications. Among these, porous conductive textiles (PCTs) have emerged as an ideal material platform for wearable electronics, owing to their light weight, flexibility, permeability, and wearing comfort. This Review aims to present a comprehensive overview of the progress and state of the art of utilizing PCTs for the design and fabrication of a wide variety of wearable electronic devices and their integrated wearable systems. To begin with, we elucidate how PCTs revolutionize the form factors of wearable electronics. We then discuss the preparation strategies of PCTs, in terms of the raw materials, fabrication processes, and key properties. Afterward, we provide detailed illustrations of how PCTs are used as basic building blocks to design and fabricate a wide variety of intrinsically flexible or stretchable devices, including sensors, actuators, therapeutic devices, energy-harvesting and storage devices, and displays. We further describe the techniques and strategies for wearable electronic systems either by hybridizing conventional off-the-shelf rigid electronic components with PCTs or by integrating multiple fibrous devices made of PCTs. Subsequently, we highlight some important wearable application scenarios in healthcare, sports and training, converging technologies, and professional specialists. At the end of the Review, we discuss the challenges and perspectives on future research directions and give overall conclusions. As the demand for more personalized and interconnected devices continues to grow, PCT-based wearables hold immense potential to redefine the landscape of wearable technology and reshape the way we live, work, and play.

Fully-Printed Flexible Aqueous Rechargeable Sodium-Ion Batteries

The flexible aqueous rechargeable sodium-ion batteries (ARSIBs) are a promising portable energy storage system that can meet the flexibility and safety requirements of wearable electronic devices. However, it faces huge challenges in mechanical stability and facile manufacturing processes. Herein, the first fully-printed flexible ARSIBs with appealing mechanical performance by screen-printing technique is prepared, which utilizes Na3 V2 (PO4 )2 F3 /C (NVPF/C) as the cathode and 2% nitrogenous carbon-loaded Na3 MnTi(PO4 )3 /C (NMTP/C/NC) as the anode. In particular, the organic co-solvent ethylene glycol (EG) is cleverly added to 17 m (mol kg-1 ) NaClO4 electrolyte to prepare a 17 m NaClO4 -EG mixed electrolyte. This mixed electrolyte can withstand low temperatures of -20 °C in practical applications. Encouragingly, the fully-printed flexible ARSIBs (NMTP/C/NC//NVPF/C) exhibit a discharge capacity of 40.1 mAh g-1 , an energy density of 40.1 Wh kg-1 , and outstanding cycle performance. Moreover, these batteries with various shapes can be used as an energy wristband for an electronic watch in the bending states. The fully-printed flexible ARSIBs in this work are expected to shed light on the development of energy for wearable electronics.

Highly Stretchable, Biodegradable, and Recyclable Green Electronic Substrates

As a steady stream of electronic devices being discarded, a vast amount of electronic substrate waste of petroleum-based nondegradable polymers is generated, raising endless concerns about resource depletion and environmental pollution. With coupled reagent (CR)-grafted artificial marble waste (AMW@CR) as functional fillers, polylactic acid (PLA)-based highly stretchable biodegradable green composite (AMW@CR-SBGC) is prepared, with elongation at break up to more than 250%. The degradation mechanism of AMW@CR-SBGC is deeply revealed. AMW@CR not only contributed to the photodegradation of AMW@CR-SBGC but also significantly promoted the water degradation of AMW@CR-SBGC. More importantly, AMW@CR-SBGC showed great potential as sustainable green electronic substrates and AMW@CR-SBGC-based electronic skin can simulate the perception of human skin to strain signals. The outstanding programmable degradability, recyclability, and reusability of AMW@CR-SBGC enabled its application in transient electronics. As the first demonstration of artificial marble waste in electronic substrates, AMW@CR-SBGC killed three birds with one stone in terms of waste resourcing, e-waste reduction, and saving nonrenewable petroleum resources, opening up vast new opportunities for green electronics applications in areas such as health monitoring, artificial intelligence, and security.

Flexible Sensors with a Multilayer Interlaced Tunnel Architecture for Distinguishing Different Strains

The diversity of body joints and the complexity of joint motions cause flexible strain sensors to undergo complex strains such as stretching, compression, bending, and extrusion, which results in sensors that do not recognize different strains, facing great challenges in detecting the true motion characteristics of joints. Here, the monitoring of body joints' real motion characteristics has been realized by the sensor that can output response signals with different resistance trends for different strains. The sensor prepared by the sacrificial template method is characterized by a multilayered interlaced tunnel architecture and carbon black embedded in the inner wall of the tunnel. Stretching, compressive, and bending strains result in increasing, decreasing, and increasing resistance, followed by a decrease in resistance of the sensor, respectively. The sensor can still output distinguishable response signals, even in the presence of complex strains induced by squeezing. Low strain detection limits (0.03%) and wide detection ranges (>600%) are achieved due to the localized strain enhancement caused by the unique structure. The sensor can detect the motion characteristics of different joints in flexion-extension, abduction-adduction, and internal-external rotation, which, in turn, can be used for real-time monitoring of complex joint motions involved in limb rehabilitation. In addition, the sensor recognizes the 26 letters of the alphabet represented by sign language gestures. The above studies demonstrate the potential application of our prepared sensors in flexible, wearable devices.

Enhanced Mechanical Strength of Metal Ion-Doped MXene-Based Double-Network Hydrogels for Highly Sensitive and Durable Flexible Sensors

Development of conductive hydrogels with high sensitivity and excellent mechanical properties remains a challenge for constructing flexible sensor devices. Herein, a universal strategy is presented for enhancing the mechanical strength of Mxene-based double-network hydrogels through metal ion coordination effects. Polyacrylamide (PAM)/sodium alginate (SA)/Mxene double-network (PSM-DN) hydrogels were prepared by metal ion impregnation of PAM/SA/Mxene (PSM) hydrogels. High electrical conductivity is achieved due to MXene nanosheets, while the strong coordination bond between metal ions and SA constructs a second network that increases the mechanical strength of the hydrogel by an order of magnitude. Mechanical tests demonstrated that the elastic modulus of hydrogels matches that of human tissues. Hence, they can be used as a highly sensitive electronic skin sensor to recognize the movement of different joints in humans and also as a pressure sensing interface to recognize characters for anticounterfeiting and information transfer. This work can promote the practical application of conductive hydrogels in high-tech fields, such as flexible electronic skin and interface interaction.

A Review of Manufacturing Methods for Flexible Devices and Energy Storage Devices

Given the advancements in modern living standards and technological development, conventional smart devices have proven inadequate in meeting the demands for a high-quality lifestyle. Therefore, a revolution is necessary to overcome this impasse and facilitate the emergence of flexible electronics. Specifically, there is a growing focus on health detection, necessitating advanced flexible preparation technology for biosensor-based smart wearable devices. Nowadays, numerous flexible products are available on the market, such as electronic devices with flexible connections, bendable LED light arrays, and flexible radio frequency electronic tags for storing information. The manufacturing process of these devices is relatively straightforward, and their integration is uncomplicated. However, their functionality remains limited. Further research is necessary for the development of more intricate applications, such as intelligent wearables and energy storage systems. Taking smart wear as an example, it is worth noting that the current mainstream products on the market primarily consist of bracelet-type health testing equipment. They exhibit limited flexibility and can only be worn on the wrist for measurement purposes, which greatly limits their application diversity. Flexible energy storage and flexible display also face the same problem, so there is still a lot of room for development in the field of flexible electronics manufacturing. In this review, we provide a brief overview of the developmental history of flexible devices, systematically summarizing representative preparation methods and typical applications, identifying challenges, proposing solutions, and offering prospects for future development.

Recent progress in liquid metal printing and its applications

This paper focuses on the latest research printing technology and broad application for flexible liquid metal (LM) materials. Through the newest template printing method, centrifugal force assisted method, pen lithography technology, and laser method, the precision of liquid metal printing on the devices was improved to 10 nm. The development of novel liquid metal inks, such as PVA-LM ink and ethanol/PDMS/LM double emulsion ink, have further enhanced the recovery, rapid printing, high conductivity, and strain resistance. At the same time, liquid metals also show promise in the application of biochemical sensors, photocatalysts, composite materials, driving machines, and electrode materials. Liquid metals have been applied to biomedical, pressure/gas, and electrochemical sensors. The sensitivity, biostability, and electrochemical performance of these LM sensors were improved rapidly. They could continue to be used in healthy respiratory, heartbeat monitoring, and dopamine detection. Meanwhile, the applications of liquid metal droplets in catalytic-assisted MoS2 deposition, catalytic growth of two-dimensional (2D) lamellar, catalytic free radical polymerization, catalytic hydrogen absorption/dehydrogenation, photo/electrocatalysis, and other fields were also summarized. Through improving liquid metal composites, magnetic, thermal, electrical, and tensile enhancement alloys, and shape memory alloys with excellent properties could also be prepared. Finally, the applications of liquid metal in micro-motors, intelligent robot feet, nanorobots, self-actuation, and electrode materials were also summarized. This paper comprehensively summarizes the practical application of liquid metals in different fields, which helps understand LMs development trends, and lays a foundation for subsequent research.

Liquid Metal Fibers with a Knitted Structure for Wearable Electronics

Flexible conductive fibers have shown tremendous potential in diverse fields, including health monitoring, intelligent robotics, and human-machine interaction. Nevertheless, most conventional flexible conductive materials face challenges in meeting the high conductivity and stretchability requirements. In this study, we introduce a knitted structure of liquid metal conductive fibers. The knitted structure of liquid metal fiber significantly reduces the resistance variation under tension and exhibits favorable durability, as evidenced by the results of cyclic tensile testing, which indicate that their resistance only undergoes a slight increase (<3%) after 1300 cycles. Furthermore, we demonstrate the integration of these liquid metal fibers with various rigid electronic components, thereby facilitating the production of pliable LED arrays and intelligent garments for electrocardiogram (ECG) monitoring. The LED array underwent a 30 min machine wash, during which it consistently retained its normal functionality. These findings evince the devices' robust stable circuit functionality and water resistance that remain unaffected by daily human activities. The liquid metal knitted fibers offer great promise for advancing the field of flexible conductive fibers. Their exceptional electrical and mechanical properties, combined with compatibility with existing electronic components, open new possibilities for applications in the physiological signal detection of carriers, human-machine interaction, and large-area electronic skin.

A Review of Epidermal Flexible Pressure Sensing Arrays

In recent years, flexible pressure sensing arrays applied in medical monitoring, human-machine interaction, and the Internet of Things have received a lot of attention for their excellent performance. Epidermal sensing arrays can enable the sensing of physiological information, pressure, and other information such as haptics, providing new avenues for the development of wearable devices. This paper reviews the recent research progress on epidermal flexible pressure sensing arrays. Firstly, the fantastic performance materials currently used to prepare flexible pressure sensing arrays are outlined in terms of substrate layer, electrode layer, and sensitive layer. In addition, the general fabrication processes of the materials are summarized, including three-dimensional (3D) printing, screen printing, and laser engraving. Subsequently, the electrode layer structures and sensitive layer microstructures used to further improve the performance design of sensing arrays are discussed based on the limitations of the materials. Furthermore, we present recent advances in the application of fantastic-performance epidermal flexible pressure sensing arrays and their integration with back-end circuits. Finally, the potential challenges and development prospects of flexible pressure sensing arrays are discussed in a comprehensive manner.

Shaping a Soft Future: Patterning Liquid Metals

This review highlights the unique techniques for patterning liquid metals containing gallium (e.g., eutectic gallium indium, EGaIn). These techniques are enabled by two unique attributes of these liquids relative to solid metals: 1) The fluidity of the metal allows it to be injected, sprayed, and generally dispensed. 2) The solid native oxide shell allows the metal to adhere to surfaces and be shaped in ways that would normally be prohibited due to surface tension. The ability to shape liquid metals into non-spherical structures such as wires, antennas, and electrodes can enable fluidic metallic conductors for stretchable electronics, soft robotics, e-skins, and wearables. The key properties of these metals with a focus on methods to pattern liquid metals into soft or stretchable devices are summari.

Ultrastretchable High-Conductivity MXene-Based Organohydrogels for Human Health Monitoring and Machine-Learning-Assisted Recognition

Conductive hydrogels as promising candidates of wearable electronics have attracted considerable interest in health monitoring, multifunctional electronic skins, and human-machine interfaces. However, to simultaneously achieve excellent electrical properties, superior stretchability, and a low detection threshold of conductive hydrogels remains an extreme challenge. Herein, an ultrastretchable high-conductivity MXene-based organohydrogel (M-OH) is developed for human health monitoring and machine-learning-assisted object recognition, which is fabricated based on a Ti₃C₂T_x MXene/lithium salt (LS)/poly(acrylamide) (PAM)/poly(vinyl alcohol) (PVA) hydrogel through a facile immersion strategy in a glycerol/water binary solvent. The fabricated M-OH demonstrates remarkable stretchability (2000%) and high conductivity (4.5 S/m) due to the strong interaction between MXene and the dual-network PVA/PAM hydrogel matrix and the incorporation between MXene and LS, respectively. Meanwhile, M-OH as a wearable sensor enables human health monitoring with high sensitivity and a low detection limit (12 Pa). Furthermore, based on pressure mapping image recognition technology, an 8 × 8 pixelated M-OH-based sensing array can accurately identify different objects with a high accuracy of 97.54% under the assistance of a deep learning neural network (DNN). This work demonstrates excellent comprehensive performances of the ultrastretchable high-conductive M-OH in health monitoring and object recognition, which would further explore extensive potential application prospects in personal healthcare, human-machine interfaces, and artificial intelligence.

Flexible, Permeable, and Recyclable Liquid-Metal-Based Transient Circuit Enables Contact/Noncontact Sensing for Wearable Human-Machine Interaction

The past several years have witnessed a rapid development of intelligent wearable devices. However, despite the splendid advances, the creation of flexible human-machine interfaces that synchronously possess multiple sensing capabilities, wearability, accurate responsivity, sensitive detectivity, and fast recyclability remains a substantial challenge. Herein, a convenient yet robust strategy is reported to craft flexible transient circuits via stencil printing liquid metal conductor on the water-soluble electrospun film for human-machine interaction. Due to the inherent liquid conductor within porous substrate, the circuits feature high-resolution, customized patterning viability, attractive permeability, excellent electroconductivity, and superior mechanical stability. More importantly, such circuits display appealing noncontact proximity capabilities while maintaining compelling tactile sensing performance, which is unattainable by traditional systems with compromised contact sensing. As such, the flexible circuit is utilized as wearable sensors with practical multifunctionality, including information transfer, smart identification, and trajectory monitoring. Furthermore, an intelligent human-machine interface composed of the flexible sensors is fabricated to realize specific goals such as wireless object control and overload alarm. The transient circuits are quickly and efficiently recycled toward high economic and environmental values. This work opens vast possibilities of generating high-quality flexible and transient electronics for advanced applications in soft and intelligent systems.

Technology Roadmap for Flexible Sensors

Humans rely increasingly on sensors to address grand challenges and to improve quality of life in the era of digitalization and big data. For ubiquitous sensing, flexible sensors are developed to overcome the limitations of conventional rigid counterparts. Despite rapid advancement in bench-side research over the last decade, the market adoption of flexible sensors remains limited. To ease and to expedite their deployment, here, we identify bottlenecks hindering the maturation of flexible sensors and propose promising solutions. We first analyze challenges in achieving satisfactory sensing performance for real-world applications and then summarize issues in compatible sensor-biology interfaces, followed by brief discussions on powering and connecting sensor networks. Issues en route to commercialization and for sustainable growth of the sector are also analyzed, highlighting environmental concerns and emphasizing nontechnical issues such as business, regulatory, and ethical considerations. Additionally, we look at future intelligent flexible sensors. In proposing a comprehensive roadmap, we hope to steer research efforts towards common goals and to guide coordinated development strategies from disparate communities. Through such collaborative efforts, scientific breakthroughs can be made sooner and capitalized for the betterment of humanity.

Liquid Metal-Doped Conductive Hydrogel for Construction of Multifunctional Sensors

Interest in wearable and stretchable multifunctional sensors has grown rapidly in recent years. The sensing elements must accurately detect external stimuli to expand their applicability as sensors. However, the sensor's self-healing and adhesion to a target object have been major challenges in developing such practical and versatile devices. In this study, we prepared a hydrogel (LM-SA-PAA) composed of liquid metal (LM), sodium alginate (SA), and poly(acrylic acid) (PAA) with ultrastretchable, excellent self-healing, self-adhesive, and high-sensitivity sensing capabilities that enable the conformal contact between the sensor and skin even during dynamic movements. The excellent self-healing performance of the hydrogel stems from its double cross-linked networks, including physical and chemical cross-linked networks. The physical cross-link formed by the ionic interaction between the carboxyl groups of PAA and gallium ions provide the hydrogel with reversible autonomous repair properties, whereas the covalent bond provides the hydrogel with a stable and strong chemical network. Alginate forms a microgel shell around LM nanoparticles via the coordination of its carboxyl groups with Ga ions. In addition to offering exceptional colloidal stability, the alginate shell has sufficient polar groups, ensuring that the hydrogel adheres to diverse substrates. Based on the efficient electrical pathway provided by the LM, the hydrogel exhibited strain sensitivity and enabled the detection of various human motions and electrocardiographic monitoring. The preparation method is simple and versatile and can be used for the low-cost fabrication of multifunctional sensors, which have broad application prospects in human-machine interface compatibility and medical monitoring.

Liquid metal enabled conformal electronics

The application of three-dimensional common electronics that can be directly pasted on arbitrary surfaces in the fields of human health monitoring, intelligent robots and wearable electronic devices has aroused people's interest, especially in achieving stable adhesion of electronic devices on biological dynamic three-dimensional interfaces and high-quality signal acquisition. In recent years, liquid metal (LM) materials have been widely used in the manufacture of flexible sensors and wearable electronic devices because of their excellent tensile properties and electrical conductivity at room temperature. In addition, LM has good biocompatibility and can be used in a variety of biomedical applications. Here, the recent development of LM flexible electronic printing methods for the fabrication of three-dimensional conformal electronic devices on the surface of human tissue is discussed. These printing methods attach LM to the deformable substrate in the form of bulk or micro-nano particles, so that electronic devices can adapt to the deformation of human tissue and other three-dimensional surfaces, and maintain stable electrical properties. Representative examples of applications such as self-healing devices, degradable devices, flexible hybrid electronic devices, variable stiffness devices and multi-layer large area circuits are reviewed. The current challenges and prospects for further development are also discussed.

Liquid Metal Patterning and Unique Properties for Next-Generation Soft Electronics

Room-temperature liquid metal (LM)-based electronics is expected to bring advancements in future soft electronics owing to its conductivity, conformability, stretchability, and biocompatibility. However, various difficulties arise when patterning LM because of its rheological features such as fluidity and surface tension. Numerous attempts are made to overcome these difficulties, resulting in various LM-patterning methods. An appropriate choice of patterning method based on comprehensive understanding is necessary to fully utilize the unique properties. Therefore, the authors aim to provide thorough knowledge about patterning methods and unique properties for LM-based future soft electronics. First, essential considerations for LM-patterning are investigated. Then, LM-patterning methods-serial-patterning, parallel-patterning, intermetallic bond-assisted patterning, and molding/microfluidic injection-are categorized and investigated. Finally, perspectives on LM-based soft electronics with unique properties are provided. They include outstanding features of LM such as conformability, biocompatibility, permeability, restorability, and recyclability. Also, they include perspectives on future LM-based soft electronics in various areas such as radio frequency electronics, soft robots, and heterogeneous catalyst. LM-based soft devices are expected to permeate the daily lives if patterning methods and the aforementioned features are analyzed and utilized.

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.

Recent progress in fiber-based soft electronics enabled by liquid metal

Soft electronics can seamlessly integrate with the human skin which will greatly improve the quality of life in the fields of healthcare monitoring, disease treatment, virtual reality, and human-machine interfaces. Currently, the stretchability of most soft electronics is achieved by incorporating stretchable conductors with elastic substrates. Among stretchable conductors, liquid metals stand out for their metal-grade conductivity, liquid-grade deformability, and relatively low cost. However, the elastic substrates usually composed of silicone rubber, polyurethane, and hydrogels have poor air permeability, and long-term exposure can cause skin redness and irritation. The substrates composed of fibers usually have excellent air permeability due to their high porosity, making them ideal substrates for soft electronics in long-term applications. Fibers can be woven directly into various shapes, or formed into various shapes on the mold by spinning techniques such as electrospinning. Here, we provide an overview of fiber-based soft electronics enabled by liquid metals. An introduction to the spinning technology is provided. Typical applications and patterning strategies of liquid metal are presented. We review the latest progress in the design and fabrication of representative liquid metal fibers and their application in soft electronics such as conductors, sensors, and energy harvesting. Finally, we discuss the challenges of fiber-based soft electronics and provide an outlook on future prospects.

Recent Advances in Printable Flexible Optical Devices: From Printing Technology and Optimization Strategies to Perspectives

Recently, flexible optical devices have triggered booming developments in various research fields, including display equipment, sensors, energy conversion, and so on, due to their high compatibility, portability, and wearability. With the advantages of strong design ability, high precision, and high integration, printing technologies have been recognized as promising methods to realize flexible optical devices. In this Perspective, recent progress on printing strategies for fabricating flexible optical devices are introduced systematically. First, through adjusting the composition of inks, selecting flexible substrates, and controlling external stimulation, fabrication of flexible optical devices based on inkjet printing is illustrated. Then, flexible optical devices fabricated by template-induced printing, 3D printing, slot-die printing, and screen printing are summarized. Finally, prospects and future development directions based on printing technology for flexible optical devices are proposed.

Transparent, Ultra-Stretching, Tough, Adhesive Carboxyethyl Chitin/Polyacrylamide Hydrogel Toward High-Performance Soft Electronics

To date, hydrogels have gained increasing attentions as a flexible conductive material in fabricating soft electronics. However, it remains a big challenge to integrate multiple functions into one gel that can be used widely under various conditions. Herein, a kind of multifunctional hydrogel with a combination of desirable characteristics, including remarkable transparency, high conductivity, ultra-stretchability, toughness, good fatigue resistance, and strong adhesive ability is presented, which was facilely fabricated through multiple noncovalent crosslinking strategy. The resultant versatile sensors are able to detect both weak and large deformations, which owns a low detection limit of 0.1% strain, high stretchability up to 1586%, ultrahigh sensitivity with a gauge factor up to 18.54, as well as wide pressure sensing range (0-600 kPa). Meanwhile, the fabrication of conductive hydrogel-based sensors is demonstrated for various soft electronic devices, including a flexible human-machine interactive system, the soft tactile switch, an integrated electronic skin for unprecedented nonplanar visualized pressure sensing, and the stretchable triboelectric nanogenerators with excellent biomechanical energy harvesting ability. This work opens up a simple route for multifunctional hydrogel and promises the practical application of soft and self-powered wearable electronics in various complex scenes.

Surface-Embedded Liquid Metal Electrodes with Abrasion Resistance via Direct Magnetic Printing

Gallium-based liquid metals (LMs) featuring both high conductivity and fluidity are ideal conductors for soft and stretchable electronics. However, their liquid nature is a double-edged sword in many key applications since LMs are inherently prone to mechanical damage. Although additional encapsulation is frequently used for the protection of delicate LM electrodes, it hinders the electrical interfacing with other objects for interconnection, sensing, and stimulation. Here, different from conventional patterning methods that deposit LM on or inside substrates, we for the first time report a simple strategy to create surface-embedded LM of eutectic gallium-indium (EGaIn) circuits with mechanical damage endurance. This was achieved by using direct magnetic printing to overcome the high surface tension of LM, allowing it to be passively filled into the laser-patterned microgrooves on soft substrates. We show that the surface-embedded LM circuits are resistant to mechanical erasure, washing, and peeling. We also show the applications of our surface-embedded LM electrodes in respiration monitoring and electrical stimulation of nerves. This work provides a simple and efficient way to create mechanically reliable LM microelectrodes, holding great promise for wearable and implantable bioelectronics.

Challenges and Opportunities for Printed Electrical Gas Sensors

Printed electrical gas sensors are a low-cost, lightweight, low-power, and potentially disposable alternative to gas sensors manufactured using conventional methods such as photolithography, etching, and chemical vapor deposition. The growing interest in Internet-of-Things, smart homes, wearable devices, and point-of-need sensors has been the main driver fueling the development of new classes of printed electrical gas sensors. In this Perspective, we provide an insight into the current research related to printed electrical gas sensors including materials, methods of fabrication, and applications in monitoring food quality, air quality, diagnosis of diseases, and detection of hazardous gases. We further describe the challenges and future opportunities for this emerging technology.

Printable Carbon Nanotube-Liquid Elastomer-Based Multifunctional Adhesive Sensors for Monitoring Physiological Parameters

Developing a printed elastomeric wearable sensor with good conformity and proper adhesion to skin, coupled with the capability of monitoring various physiological parameters, is very crucial for the development of point-of-care sensing devices with high precision and sensitivity. While there have been previous reports on the fabrication of elastomeric multifunctional sensors, research on the printable elastomeric multifunctional adhesive sensor is not very well explored. Herein, we report the development of a stencil printable multifunctional adhesive sensor fabricated in a solvent-free condition, which demonstrated the capability of having good contact with skin and its ability to function as a temperature and strain sensor. Functionalized liquid isoprene rubber was selected as the matrix while carboxylated multiwalled carbon nanotubes (c-CNTs) were used as the nanofiller. The selection of the above model compounds facilitated the printability and also helped the same composition to demonstrate stretchability and adhesiveness. A realistic three-dimensional microstructure (representative volume element model) was generated through a computational framework for the current c-CNT-liquid elastomer. Further computational simulations were performed to test and validate the correlation between electrical responses to that of experimental studies. Various physiological parameters like motion sensing, pulse, respiratory rate, and phonetics detection were detected by leveraging the electrically resistive nature of the sensor. This development route can be extended toward developing different innovative adhesives for point-of-care sensing applications.

High-Strength and Extensible Electrospun Yarn for Wearable Electronics

Stretchable conductive yarns have received significant consideration in the direction of wearable and flexible electronics. Wearable electronic structures need strong materials to assure stability, durability, and an extensive range of strain to develop their applications. Therefore, manufacturing high-performance yarn-based devices with ultrarobustness and great stretchability with a simple, cost-effective, and scalable method remains a great challenge for wearable electronics. Here, a highly stretchable yarn with high performance is fabricated, which comprises a core TPU nanoyarn, successively decorated with a liquid metal (LM) layer, and a protective outer nanofiber layer. The ultrarobust (40 MPa) and high-strain (548%) conducting yarn presents potential applications in assembling strain sensors. Moreover, such a unique conductive yarn can be used as a highly deformable, stretchable conductor to charge a mobile phone or for data transfer, a sensor to monitor human activities, and as an effective control for a hand robot as well as for smart thermal management textile application. This research gives promising applications in the field of flexible and wearable electronics.

Correlated Study of Material Interaction Between Capillary Printed Eutectic Gallium Alloys and Gold Electrodes

Liquid metals (LMs) play a growing role in flexible electronics and connected applications. Here, LMs come into direct contact with metal electrodes thus allowing for corrosion and additional alloying, potentially compromising device stability. Nevertheless, comprehensive studies on the interfacial interaction of the materials are still sparse. Therefore, a correlated material interaction study of capillary-printed Galinstan (eutetic alloy of Ga/In/Sn) with gold surfaces and electrodes is conducted. Comprehensive application of optical microscopy, vertical scanning interferometry, scanning electron microscopy/spectroscopy, x-ray photon spectroscopy, and atomic force microscopy allow for an in depth characterization of the spreading process of LM lines on gold films, revealing the differential spread of the different LM components and the formation of intermetallic nanostructures on the surface of the surrounding gold film. A model for the growth process based on the penetration of LM along the gold film grain boundaries is proposed based on the obtained time-dependent characterization. The distribution of gold, Galinstan, and intermetallic phases in a gold wire dipped into LM is observed using X-ray nano tomography as a complementary view on the internal nanostructure. Finally, resistance measurements on LM lines connecting gold electrodes over time allow to estimate the influence on the material interaction on electronic applications.

A highly stretchable and ultra-sensitive strain sensing fiber based on a porous core-network sheath configuration for wearable human motion detection

Functional fibers have attracted much research attention due to their potential application in developing advanced electronic textiles for wearable devices. However, challenges still exist in preparing high-performance fiber-shaped sensors with superior flexibility and stretchability while achieving a high sensitivity and a wide detection range. Herein, we propose the design and fabrication of an ultra-flexible and super-elastic fiber-shaped strain sensor via a facile combining approach of wet-spinning and dip-coating. The sensor adopts a core-sheath configuration of liquid metal droplets dispersed in porous thermoplastic polyurethane as a substrate core and a carbon nanotube intertwined network embedding silver nanowires as a strain sensitive sheath. By taking advantage of both the composition of multiple functional materials and the design of a microstructured device configuration, the developed fiber-shaped sensor exhibits an ultrahigh sensitivity (maximum gauge factor of 7336.1), an extremely large workable strain range (500%), a low strain detection limit (0.5%), a fast response time (200 ms) and good stability (10 000 cycles). In addition, the sensor is temperature insensitive, inert under harsh solution conditions, degradable and recyclable. Intriguingly, the fiber-shaped sensor can be used to detect various human motions and gestures by directly attaching to skins or elaborately weaving into textiles, demonstrating its great potential in human healthcare monitoring and human-machine interactions.

Superhydrophobic conductive rubber band with synergistic dual conductive layer for wide-range sensitive strain sensor

Wearable electronic devices have received increasing interests because of their excellent flexibility, stretchability, and human friendliness. As the core components, flexible strain sensors integrated with wide working range, high sensitivity, and environment stability, especially in moisture or corrosive environments, remain a huge challenge. Herein, synergistic carbon nanotubes (CNTs)/reduced graphene oxide (rGO) dual conductive layer decorated elastic rubber band (RB) was successfully developed and treated with hydrophobic fumed silica (Hf-SiO₂) for preparing superhydrophobic strain sensor. As expected, stable entangled CNTs layer and ultrasensitive microcracked rGO layer endow the sensor with extremely low detection limit (0.1%), high sensitivity (gauge factor is 685.3 at 482% strain), wide workable strain range (0-482%), fast response/recovery (200 ms/200 ms) and favorable reliability and reproducibility over 1000 cycles. Besides, the constructed Hf-SiO₂ coating also makes the sensor exhibit excellent superhydrophobicity, self-cleaning property, and corrosion-resistance. As a proof of concept, our prepared high-performance strain sensor can realize the full-range monitoring of human motions and physiological signals even in the water environment, including pulse, vocalization, joint bending, running, and gesture recognition. Interestingly, it can also be knitted into a tactile electronic textile for spatial pressure distribution measurement. Thus, this study provides a universal technique for the preparation of high-performance strain sensors with great potential applications in the field of next-generation intelligent wearable electronics.

Mechanical Gradients Enable Highly Stretchable Electronics Based on Nanofiber Substrates

Stretchable electronics play a pivotal role in the age of information and intelligence. Integrated circuit components are an integral part of high-performance and multifunctional stretchable electronic devices. Therefore, it is an ideal design concept for stretchable electronic devices to not only ensure the reliability of the connection between rigid inorganic electronic components and stretchable circuits but also maintain the stretchability of the device. In this work, we constructed a mechanical gradient strategy to fabricate high-performance stretchable electronic devices. Briefly, polyvinyl alcohol glue is used to fix integrated circuits on stretchable circuits, which are fabricated by printing liquid metal on a thermoplastic polyurethane nanofiber membrane. The strategy of integrated circuits (rigid)-polyvinyl alcohol glue (high elastic modulus)-thermoplastic polyurethane nanofiber membrane (low elastic modulus)-liquid metal (liquid) realizes the strain gradient during the stretching process of the device, thus ensuring the stability and reliability. Moreover, we explored the mechanism through experiments and finite element analysis. The flexible electronic devices fabricated by this scheme are not only ultra-stretchable (900%) but also have good stability and comfort. As proof, the application in stretchable sensors, human-computer interaction devices, and displays was realized.

Graphene-Based Polymer Composites for Flexible Electronic Applications

Graphene-based nanomaterials have gained a lot of interest over the last years in flexible electronics due to their exceptional electrical, mechanical, and optoelectronic properties, as well as their potential of surface modification. Their flexibility and processability make them suitable for electronic devices that require bending, folding, and stretching, which cannot be fulfilled by conventional electronics. These nanomaterials can be assembled with various types of organic materials, including polymers, and biomolecules, to generate a variety of nanocomposites with greater stretchability and healability, higher stiffness, electrical conductivity, and exceptional thermal stability for flexible lighting and display technologies. This article summarizes the main characteristics and synthesis methods of graphene, its oxidized form graphene oxide (GO), and reduced GO derivative, as well as their corresponding polymeric composites, and provides a brief overview about some recent examples of these nanocomposites in flexible electronic applications, including electrodes for solar cells and supercapacitors, electronic textiles, and transistors.

Stretchable, breathable, and highly sensitive capacitive and self-powered electronic skin based on core-shell nanofibers

Fiber-based nanostructures are greatly desired for the improvement of wearable/flexible electronics, which are expected to be stretchable, conformable, flexible, and long-term. Herein, an ultra-stretchable, breathable, and highly sensitive flexible capacitive tactile sensor and triboelectric effect core-shell nanofibers are proposed. In particular, core-shell ionic TPU/PVDF-HFP nanofibers are effectively prepared by an electrospinning approach. The core-shell ionic TPU/PVDF-HFP nanofibers exhibit high performance as a capacitive flexible sensor with high sensitivity (0.718 kPa^-1) in a low linear pressure range (0-1.2 kPa), an ultralow detection limit (7 Pa), a rapid response and recovery time, and excellent stability. Moreover, we assembled a self-powered pressure sensor, which has a sensitivity of 0.071 V kPa^-1 in the high linear pressure range of 90 kPa to 400 kPa. The increase in the inductive charges of the nanofiber layer allows it to work as an energy harvester with a high power density (1.6 W m^-2) that can light up 100 LEDs instantly. These remarkable results allow the capacitive flexible devices to be applied in various applications, such as spatial pressure mapping, bending angle detection, soft grabbing, and physiological signal monitoring.