Advancements in Flexible Electronics Fabrication: Film Formation, Patterning, and Interface Optimization for Cutting-Edge Healthcare Monitoring Devices

Flexible electronics can seamlessly adhere to human skin or internal tissues, enabling the collection of physiological data and real-time vital sign monitoring in home settings, which give it the potential to revolutionize chronic disease management and mitigate mortality rates associated with sudden illnesses, thereby transforming current medical practices. However, the development of flexible electronic devices still faces several challenges, including issues pertaining to material selection, limited functionality, and performance instability. Among these challenges, the choice of appropriate materials, as well as their methods for film formation and patterning, lays the groundwork for versatile device development. Establishing stable interfaces, both internally within the device and in human-machine interactions, is essential for ensuring efficient, accurate, and long-term monitoring in health electronics. This review aims to provide an overview of critical fabrication steps and interface optimization strategies in the realm of flexible health electronics. Specifically, we discuss common thin film processing methods, patterning techniques for functional layers, interface challenges, and potential adjustment strategies. The objective is to synthesize recent advancements and serve as a reference for the development of innovative flexible health monitoring devices.

Design and Optimization of NR-Based Stretchable Conductive Composites Filled with MoSi2 Nanoparticles and MWCNTs: Perspectives from Experimental Characterization and Molecular Dynamics Simulations

Stretchable conductive composites play a pivotal role in the development of personalized electronic devices, electronic skins, and artificial implant devices. This article explores the fabrication and characterization of stretchable composites based on natural rubber (NR) filled with molybdenum disilicide (MoSi2) nanoparticles and multi-walled carbon nanotubes (MWCNTs). Experimental characterization and molecular dynamics (MD) simulations are employed to investigate the static and dynamic properties of the composites, including morphology, glass transition temperature (Tg), electrical conductivity, and mechanical behavior. Results show that the addition of MoSi2 nanoparticles enhances the dispersion of MWCNTs within the NR matrix, optimizing the formation of a conductive network. Dynamic mechanical analysis (DMA) confirms the Tg reduction with the addition of MWCNTs and the influence of MoSi2 content on Tg. Mechanical testing reveals that the tensile strength increases with MoSi2 content, with an optimal ratio of 4:1 MoSi2:MWCNTs. Electrical conductivity measurements demonstrate that the MoSi2/MWCNTs/NR composites exhibit enhanced conductivity, reaching optimal values at specific filler ratios. MD simulations further support experimental findings, highlighting the role of MoSi2 in improving dispersion and mechanical properties. Overall, the study elucidates the synergistic effects of nanoparticles and nanotubes in enhancing the properties of stretchable conductive composites.

Progress and prospects in flexible tactile sensors

Flexible tactile sensors have the advantages of large deformation detection, high fault tolerance, and excellent conformability, which enable conformal integration onto the complex surface of human skin for long-term bio-signal monitoring. The breakthrough of flexible tactile sensors rather than conventional tactile sensors greatly expanded application scenarios. Flexible tactile sensors are applied in fields including not only intelligent wearable devices for gaming but also electronic skins, disease diagnosis devices, health monitoring devices, intelligent neck pillows, and intelligent massage devices in the medical field; intelligent bracelets and metaverse gloves in the consumer field; as well as even brain-computer interfaces. Therefore, it is necessary to provide an overview of the current technological level and future development of flexible tactile sensors to ease and expedite their deployment and to make the critical transition from the laboratory to the market. This paper discusses the materials and preparation technologies of flexible tactile sensors, summarizing various applications in human signal monitoring, robotic tactile sensing, and human-machine interaction. Finally, the current challenges on flexible tactile sensors are also briefly discussed, providing some prospects for future directions.

Multiplexed Gas Sensor: Fabrication Strategies, Recent Progress, and Challenges

Due to miscellaneous toxic gases in the vicinity, there is a burgeoning need for advancement in the existing gas sensing technology not only for the survival of mankind but also for the industries based in various fields such as beverage, forestry, health care, environmental monitoring, agriculture, and military security. A gas sensor must be highly selective toward a specific gas in order to avoid incorrect signals while responding to nontarget gases. This may lead to complex scenarios depicting sensor defects, such as low selectivity and cross-sensitivity. Therefore, a multiplex gas sensor is required to address the problems of cross selectivity by combining different gas sensors, signal processing, and pattern recognition techniques along with the currently employed gas sensing technologies. The different sensing materials used in these sensor arrays will produce a unique response signal for developing a set of identifiers as the input that can be used to recognize a specific gas by its "fingerprint". This review provides a comprehensive review of chemiresistive-based multiplex gas sensors, including various fabrication strategies from expensive to low-cost techniques, advances in sensing materials, and a gist of various pattern recognition techniques used for both rigid and flexible gas sensor applications. Finally, the review assesses the current state-of-the-art in multiplex gas sensor technology and discusses various challenges for future research in this direction.

Electrohydrodynamic Printed Ultra-Micro AgNPs Thin Film Temperature Sensors Array for High-Resolution Sensing

Current methods for thin film sensors preparation include screen printing, inkjet printing, and MEMS (microelectromechanical systems) techniques. However, their limitations in achieving sub-10 μm line widths hinder high-density sensors array fabrication. Electrohydrodynamic (EHD) printing is a promising alternative due to its ability to print multiple materials and multilayer structures with patterned films less than 10 μm width. In this paper, we innovatively proposed a method using only EHD printing to prepare ultra-micro thin film temperature sensors array. The sensitive layer of the four sensors was compactly integrated within an area measuring 450 μm × 450 μm, featuring a line width of less than 10 μm, and a film thickness ranging from 150 nm to 230 nm. The conductive network of silver nanoparticles exhibited a porosity of 0.86%. After a 17 h temperature-resistance test, significant differences in the performance of the four sensors were observed. Sensor 3 showcased relatively superior performance, boasting a fitted linearity of 0.99994 and a TCR of 937.8 ppm/°C within the temperature range of 20 °C to 120 °C. Moreover, after the 17 h test, a resistance change rate of 0.17% was recorded at 20 °C.

Design, Fabrication, and Optimization of a Printed Ag Nanoparticle-Based Flexible Capacitive Sensor for Automotive IVI Bezel Display Applications

Since printed capacitive sensors provide better sensing performance, they can be used in automotive bezel applications. It is necessary to fabricate such sensors and apply an optimization approach for choosing the optimal sensor pattern. In the present work, an effort was made to formulate interdigitated pattern-printed Silver (Ag) electrode flexible sensors and adopt the Taguchi Grey Relational (TGR)-based optimization approach to enhance the flexible sensor's panel for enhanced automobile infotainment applications. The optimization technique was performed to derive better design considerations and analyze the influence of the sensor's parameters on change in capacitance when touched and production cost. The fabricated flexible printed sensors can provide better sensing properties. A design pattern which integrates an overlap of 15 mm, an electrode line width of 0.8 mm, and an electrode gap 0.8 mm can produce a higher change in capacitance and achieve a lower weight. The overlap has a greater influence on sensor performance owing to its optimization of spatial interpolation.

Paradigm Changing Integration Technology for the Production of Flexible Electronics by Transferring Structures, Dies and Electrical Components from Rigid to Flexible Substrates

Emerging trends like the Internet of Things require an increasing number of different sensors, actuators and electronic devices. To enable new applications, such as wearables and electronic skins, flexible sensor technologies are required. However, established technologies for the fabrication of sensors and actuators, as well as the related packaging, are based on rigid substrates, i.e., silicon wafer substrates and printed circuit boards (PCB). Moreover, most of the flexible substrates investigated until now are not compatible with the aforementioned fabrication technologies on wafers due to their lack of chemical inertness and handling issues. In this presented paper, we demonstrate a conceptually new approach to transfer structures, dies, and electronic components to a flexible substrate by lift-off. The structures to be transferred, including the related electrical contacts and packaging, are fabricated on a rigid carrier substrate, coated with the flexible substrate and finally lifted off from the carrier. The benefits of this approach are the combined advantages of using established semiconductor and microsystem fabrication technologies as well as packaging technologies, such as high precision and miniaturization, as well as a variety of available materials and processes together with those of flexible substrates, such as a geometry adaptivity, lightweight structures and low costs.

Printed flexible mechanical sensors

Flexible mechanical sensors (e.g., strain, pressure, and force) fabricated primarily by printing technologies have emerged and evolved promptly in the past several years. 2D and 3D printing approaches enabled rapid prototyping of various flexible mechanical sensors that have demonstrated their unique applications in fields including robotics, human-machine interfaces, and biomedicine. Research efforts have primarily been focused on experimenting with different materials, device configurations, and sensing mechanisms to achieve better sensing performance. While great progress has been made, this field is still in its infancy where most research is exploratory; and even the performance standards and long-term objective/vision of these sensors are not clear. In this review, the state-of-the-art of three types of printed flexible mechanical sensors will be discussed and analyzed in terms of their fabrication methods, types of sensing materials and mechanisms, and challenges for future development.

Garage-Fabricated, Ultrasensitive Capacitive Humidity Sensor Based on Tissue Paper

The role of humidity sensors in different industries and field applications, such as agriculture, food monitoring, biomedical equipment, heating, and ventilation, is well known. However, most commercially available humidity sensors are based on polymers or electronic materials that are not degradable and thus contribute to electronic waste. Here, we report a low-cost, flexible, easy-to-fabricate, and eco-friendly parallel-plate capacitive humidity sensor for field applications. The sensor is fabricated from copper tape and tissue paper, where copper tape is used to create the plates of the capacitor, and tissue paper is used as a dielectric sensing layer. Along with the low cost, the high sensitivity, better response and recovery times, stability, and repeatability make this sensor unique. The sensor was tested for relative humidity (RH), ranging from 40% to 99%, and the capacitance varied linearly with RH from 240 pF to 720 pF, as measured by an Arduino. The response time of the sensor is ~1.5 s, and the recovery time is ~2.2 s. The experiment was performed 4-5 times on the same sensor, and repeatable results were achieved with an accuracy of ±0.1%. Furthermore, the sensor exhibits a stable response when tested at different temperatures. Due to the above advantages, the presented sensor can find ready applications in different areas.

Luminescence Nanomaterials for Biosensing Applications

Due to their capabilities of immobilizing more bioreceptor parts with reduced volumes, nanomaterials have emerged as potential tools for increasing sensitivity to specific molecules. Furthermore, carbon nanotube, gold nanoparticles, polymer nanoparticles, semiconductor quantum dots, graphene, nano-diamonds and graphene are among the nanomaterials that are under investigation. Due to the fast development of such a field of research, review summarises the classification of biosensors using main receptors, and designing biosensors. Numerous studies have concentrated on the manipulation of Persistent luminescence nanoparticles (PLNPs) in biosensing, cell tracking, bioimaging, and cancer therapy due to the effective removal of the autofluorescence interferences from tissues and the ultra-long near-infrared afterglow emission. As luminescence has a unique optical property, it can be detected without constant external illumination, preventing autofluorescence and light dispersion through tissues. These successes sparked an increasing curiosity in creating novel PLNP kinds with desired superior properties and multiple purposes. In this review, we emphasize the most recent developments in biosensing, imaging, and image-guided therapy while summarizing the research on synthesis methods, bio applications, bio membrane modification and bio-safety of PLNPs. Finally, the remaining issues and difficulties are examined together with prospective future developments in the field of biomedical applications.

Fabrication and Performance Analysis of 3D Inkjet Flexible Printed Touch Sensor Based on AgNP Electrode for Infotainment Display

It is possible to employ printed capacitive sensors in car bezel applications because of its lower cost and higher detecting capabilities. In this paper, a flexible sensor for automotive entertainment applications has been developed using an electrode flexible sensor with an interdigitated pattern printed on it using screen printing and 3D printing fabrication processes. Design concerns such as electrode overlap, electrode gap and width on capacitance changes, and production costs were studied. In addition, a new generation of flexible printed sensors has been developed that can outperform conventional human–machine interface (HMI) sensors. The capacitance of the design pattern may be optimized by using a 15mm overlap and 0.5mm electrode line width. Due to the precision of interpolation, overlap has a larger effect on sensor performance than it would have without it.

The status and perspectives of nanostructured materials and fabrication processes for wearable piezoresistive sensors

The wearable sensors have attracted a growing interest in different markets, including health, fitness, gaming, and entertainment, due to their outstanding characteristics of convenience, simplicity, accuracy, speed, and competitive price. The development of different types of wearable sensors was only possible due to advances in smart nanostructured materials with properties to detect changes in temperature, touch, pressure, movement, and humidity. Among the various sensing nanomaterials used in wearable sensors, the piezoresistive type has been extensively investigated and their potential have been demonstrated for different applications. In this review article, the current status and challenges of nanomaterials and fabrication processes for wearable piezoresistive sensors are presented in three parts. The first part focuses on the different types of sensing nanomaterials, namely, zero-dimensional (0D), one-dimensional (1D), two-dimensional (2D), and three-dimensional (3D) piezoresistive nanomaterials. Then, in second part, their fabrication processes and integration are discussed. Finally, the last part presents examples of wearable piezoresistive sensors and their applications.

Fabrication and Performance Evolution of AgNP Interdigitated Electrode Touch Sensor for Automotive Infotainment

In the present scenario, a considerable assiduity is provided to develop novel human-machine interface technologies that rapidly outpace the capabilities of display technology in automotive industries. It is necessary to use a new cockpit design in conjunction with a fully automated driving environment in order to enhance the driving experience. It can create a seamless and futuristic dashboard for automotive infotainment application. In the present study, an endeavor was made to equip the In-vehicle bezels with printed capacitive sensors for providing superior sensing capabilities. Silver Nanoparticles based interdigitated pattern electrodes were formed over polycarbonate substrates to make printed capacitive sensors using screen printing process. The developed sensor was investigated to evaluate the qualitative and quantitative measures using direct and in-direct contact of touch. The proposed approach for sensors pattern and fabrication can highly impact on sensor performance in automotive infotainment application due to the excellent spatial interpolation with lower cost, light weight, and mechanical flexibility.

Review of Materials and Fabrication Methods for Flexible Nano and Micro-Scale Physical and Chemical Property Sensors

The use of flexible sensors has tripled over the last decade due to the increased demand in various fields including health monitoring, food packaging, electronic skins and soft robotics. Flexible sensors have the ability to be bent and stretched during use and can still maintain their electrical and mechanical properties. This gives them an advantage over rigid sensors that lose their sensitivity when subject to bending. Advancements in 3D printing have enabled the development of tailored flexible sensors. Various additive manufacturing methods are being used to develop these sensors including inkjet printing, aerosol jet printing, fused deposition modelling, direct ink writing, selective laser melting and others. Hydrogels have gained much attention in the literature due to their self-healing and shape transforming. Self-healing enables the sensor to recover from damages such as cracks and cuts incurred during use, and this enables the sensor to have a longer operating life and stability. Various polymers are used as substrates on which the sensing material is placed. Polymers including polydimethylsiloxane, Poly(N-isopropylacrylamide) and polyvinyl acetate are extensively used in flexible sensors. The most widely used nanomaterials in flexible sensors are carbon and silver due to their excellent electrical properties. This review gives an overview of various types of flexible sensors (including temperature, pressure and chemical sensors), paying particular attention to the application areas and the corresponding characteristics/properties of interest required for such. Current advances/trends in the field including 3D printing, novel nanomaterials and responsive polymers, and self-healable sensors and wearables will also be discussed in more detail.

Recent Progress in Development of Wearable Pressure Sensors Derived from Biological Materials

This review summarizes recent progress in the use of biological materials (biomaterials) in wearable pressure sensors. Biomaterials are abundant, sustainable, biocompatible, and biodegradable. Especially, many have sophisticated hierarchical structure and biological characteristics, which are attractive candidates for facile and ecologically-benign fabrication of wearable pressure sensors that are biocompatible, biodegradable, and highly sensitivity. The biomaterials and structures that use them in wearable pressure sensors that exploit sensing mechanisms such as piezoelectric, triboelectric, piezoresistive and capacitive effects are present. Finally, remaining impediments are discussed to use of biomaterials in wearable pressure sensors.

Flexible Electronics and Healthcare Applications

Flexible electronics has attracted tremendous attention in recent years. The essential requirements for flexible electronics include excellent electrical properties, flexibility and stretchability. By introducing special structures or using flexible materials, electronic devices can be given excellent flexibility and stretchability. In this paper we review the realization of flexible electronics from the perspective of structural design strategies and materials; then, healthcare application of flexible electronic systems was introduced. Finally, a brief summary and outlook are presented.

Recent Progress in Manufacturing Techniques of Printed and Flexible Sensors: A Review

This review provides an outlook on some of the significant research work done on printed and flexible sensors. Printed sensors fabricated on flexible platforms such as paper, plastic and textiles have been implemented for wearable applications in the biomedical, defense, food, and environmental industries. This review discusses the materials, characterization methods, and fabrication methods implemented for the development of the printed and flexible sensors. The applications, challenges faced and future opportunities for the printed and flexible sensors are also presented in this review.

Gold/Polyimide-Based Resistive Strain Sensors

This paper presents the fabrication and implementation of novel resistive sensors that were implemented for strain-sensing applications. Some of the critical factors for the development of resistive sensors are addressed in this paper, such as the cost of fabrication, the steps of the fabrication process which make it time-consuming to complete each prototype, and the inability to achieve optimised electrical and mechanical characteristics. The sensors were fabricated via magnetron sputtering of thin-film chromium and gold layer on the thin-film substrates at defined thicknesses. Sticky copper tapes were attached on the two sides of the sensor patches to form the electrodes. The operating principle of the fabricated sensors was based on the change in their responses with respect to the corresponding changes in their relative resistance as a function of the applied strain. The strain-induced characteristics of the patches were studied with different kinds of experiments, such as consecutive bending and pressure application. The sensors with 400 nm thickness of gold layer obtained a sensitivity of 0.0086 Ω/ppm for the pressure ranging between 0 and 400 kPa. The gauge factor of these sensors was between 4.9–6.6 for temperatures ranging between 25 °C and 55 °C. They were also used for tactile sensing to determine their potential as thin-film sensors for industrial applications, like in robotic and pressure-mapping applications. The results were promising in regards to the sensors’ controllable film thickness, easy operation, purity of the films and mechanically sound nature. These sensors can provide a podium to enhance the usage of resistive sensors on a higher scale to develop thin-film sensors for industrial applications.

3D Printed Sensors for Biomedical Applications: A Review

This paper showcases a substantial review on some of the significant work done on 3D printing of sensors for biomedical applications. The importance of 3D printing techniques has bloomed in the sensing world due to their essential advantages of quick fabrication, easy accessibility, processing of varied materials and sustainability. Along with the introduction of the necessity and influence of 3D printing techniques for the fabrication of sensors for different healthcare applications, the paper explains the individual methodologies used to develop sensing prototypes. Six different 3D printing techniques have been explained in the manuscript, followed by drawing a comparison between them in terms of their advantages, disadvantages, materials being processed, resolution, repeatability, accuracy and applications. Finally, a conclusion of the paper is provided with some of the challenges of the current 3D printing techniques about the developed sensing prototypes, their corresponding remedial solutions and a market survey determining the expenditure on 3D printing for biomedical sensing prototypes.

An Overview of the Development of Flexible Sensors

Flexible sensors that efficiently detect various stimuli relevant to specific environmental or biological species have been extensively studied due to their great potential for the Internet of Things and wearable electronics applications. The application of flexible and stretchable electronics to device-engineering technologies has enabled the fabrication of slender, lightweight, stretchable, and foldable sensors. Here, recent studies on flexible sensors for biological analytes, ions, light, and pH are outlined. In addition, contemporary studies on device structure, materials, and fabrication methods for flexible sensors are discussed, and a market overview is provided. The conclusion presents challenges and perspectives in this field.

Laser-induced forward transfer of high-viscosity silver precursor ink for non-contact printed electronics

Non-contact printing of high-viscosity silver precursor inks was achieved to provide highly conductive lines by a laser-induced forward transfer technique.

25th anniversary article: The evolution of electronic skin (e-skin): a brief history, design considerations, and recent progress

Human skin is a remarkable organ. It consists of an integrated, stretchable network of sensors that relay information about tactile and thermal stimuli to the brain, allowing us to maneuver within our environment safely and effectively. Interest in large-area networks of electronic devices inspired by human skin is motivated by the promise of creating autonomous intelligent robots and biomimetic prosthetics, among other applications. The development of electronic networks comprised of flexible, stretchable, and robust devices that are compatible with large-area implementation and integrated with multiple functionalities is a testament to the progress in developing an electronic skin (e-skin) akin to human skin. E-skins are already capable of providing augmented performance over their organic counterpart, both in superior spatial resolution and thermal sensitivity. They could be further improved through the incorporation of additional functionalities (e.g., chemical and biological sensing) and desired properties (e.g., biodegradability and self-powering). Continued rapid progress in this area is promising for the development of a fully integrated e-skin in the near future.

P(VDF-TrFE) polymer-based thin films deposited on stainless steel substrates treated using water dissociation for flexible tactile sensor development

In this work, deionized (DI) water dissociation was used to treat and change the contact angle of the surface of stainless steel substrates followed by the spin coating of P(VDF-TrFE) material for the fabrication of tactile sensors. The contact angle of the stainless steel surface decreased 14° at −30 V treatment; thus, the adhesion strength between the P(VDF-TrFE) thin film and the stainless steel substrate increased by 90%. Although the adhesion strength was increased at negative voltage treatment, it is observed that the crystallinity value of the P(VDF-TrFE) thin film declined to 37% at −60 V. In addition, the remanent polarization value of the P(VDF-TrFE) thin film declined from 5.6 μC/cm² to 4.61 μC/cm² for treatment voltages between −5 V and −60 V. A maximum value of approximately 1000 KV/cm of the coercive field value was obtained with the treatment at −15 V. The d33 value was approximately −10.7 pC/N for the substrate treated at 0 V and reached a minimum of −5 pC/N for treatment at −60 V. By using the P(VDF-TrFE) thin-film as the sensing material for tactile sensors, human pulse measurements were obtained from areas including the carotid, brachial, ankle, radial artery, and apical regions. In addition, the tactile sensor is suitable for monitoring the Cun, Guan, and Chi acupoints located at the radial artery region in Traditional Chinese Medicine (TCM). Waveform measurements of the Cun, Guan, and Chi acupoints are crucial because, in TCM, the various waveforms provided information regarding the health conditions of organs.

Flexible PZT thin film tactile sensor for biomedical monitoring

This paper presents the development of tactile sensors using the sol-gel process to deposit a PZT thin-film from 250 nm to 1 μm on a flexible stainless steel substrate. The PZT thin-film tactile sensor can be used to measure human pulses from several areas, including carotid, brachial, finger, ankle, radial artery, and the apical region. Flexible PZT tactile sensors can overcome the diverse topology of various human regions and sense the corresponding signals from human bodies. The measured arterial pulse waveform can be used to diagnose hypertension and cardiac failure in patients. The proposed sensors have several advantages, such as flexibility, reliability, high strain, low cost, simple fabrication, and low temperature processing. The PZT thin-film deposition process includes a pyrolysis process at 150 °C/500 °C for 10/5 min, followed by an annealing process at 650 °C for 10 min. Finally, the consistent pulse wave velocity (PWV) was demonstrated based on human pulse measurements from apical to radial, brachial to radial, and radial to ankle. It is characterized that the sensitivity of our PZT-based tactile sensor was approximately 0.798 mV/g.

Optical panel with full multitouch using patterned indium tin oxide

This study proposes an optical panel with full multitouch using the patterned indium tin oxide (ITO) and an algorithm matrix to avoid ghost points. The patterned ITOs include the virtual high and low impedances. The algorithm matrix with two configurations of equivalent circuits for array scanning is derived using the voltage divider rule. The fabrication process of the multitouch panel is carried out using microelectromechanical systems technology. The optical characteristics of the multitouch panel in the UV, visible, and IR regions are measured using photometric analysis. The multitouch panel, containing sensing pixels of 30×30 arrays, has a pixel size of 2×2 mm2 and a pitch distance of 2 mm. The average values of high and low impedances are 53.23 and 9.3 k Ω, respectively. The maximum transmittance is about 74.2% at the wavelength of 692 nm. The multitouch panel based on high and low impedance patterns has been specifically designed to offer good adjacent touch resolution and sensitivity for reality multitouch applications. In addition, the patterned design and the algorithm matrix provide unlimited multitouch points and avoid ghost points.