Three-dimensional (3D) printing technology enables the rapid manufacturing of complex prototypes and customized soft electronics. However, the integrated manufacturing of multilayer, multimaterial, and multifunctional soft electronics via 3D printing remains challenging due to insufficient synergy between material development and process innovation, as well as inadequate compatibility between stretchable conductors and substrates. Herein, we propose a material-process-performance integrated manufacturing strategy for multilayer soft electronics. Firstly, we develop a novel stretchable conductor with strong interfacial bonding to stretchable substrates. By regulating its rheological properties, the material becomes compatible with 3D printing processes. The stretchable conductor employs 3D clustered silver nanoparticles with large surface area and low aspect ratio as fillers, effectively addressing the inherent trade-off in the performance of stretchable conductors. This design simultaneously achieves high stretchability, conductivity, and low hysteresis. Secondly, we propose a manufacturing strategy combining multi-material 3D printing with sacrificial layer assistance. By leveraging the good thixotropy of the stretchable conductor, the direct formation of 3D stretchable interconnects between layers is enabled, ultimately achieving customized and integrated manufacturing of multilayer soft electronics. Through applications such as multilayer infrared encryption devices and wearable wristbands, we demonstrate the feasibility of the proposed stretchable conductor and integrated manufacturing strategy.
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Open Access
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Flexible transparent antennas (FTAs) are widely used in wireless transmission fields, and their technological iterations are accelerating. However, the high losses caused by materials and structures limit the development of FTAs with both high light transmission and high gain, and the rapid iteration rate demands greater process flexibility, which makes it difficult for existing technologies to achieve both demands. Here, we design a novel shell-core structure composite metal mesh (CMM) FTA to achieve extremely low skin depth loss and ohmic loss using skin effect and report a novel hybrid additive manufacturing method based on electric field oriented deposition to achieve efficient and flexible manufacturing of the unique Ag/Cu core-shell structure CMM FTA. The typical sample has a light transmittance of 80% (including substrate) when the sheet resistance is 0.29 Ω·sq−1, and has excellent bending and torsion resistance. The peak gain in the working band is as high as 5.22 dB, and the efficiency is 80%, which is close to the performance of the opaque Cu patch antenna. It also realizes smooth and stable real-time wireless transmission under bending and long-distance conditions. This method addresses the shortcomings of FTAs, namely their high cost, low manufacturing efficiency, and low performance, especially in the rapid iterative development of antennas.
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