High-Resolution Rapid Prototyping of Liquid Metal Electronics by Direct Writing on Highly Prestretched Substrates

A rapid and inexpensive method to produce high-resolution liquid metal patterns and electronics on stretchable substrates was introduced. Two liquid-phase gallium-indium (GaIn) alloy patterns, conductive lines, and interdigitated electrodes, were directly written or shadow mask-printed on a prestretched elastomeric substrate surface. Then, the prestretched substrate was released to recover its original length, and thus, electronic patterns simultaneously shrank on it. After these patterns were transferred to another prestretched substrate by the stamp printing method, the patterning resolution was demonstrated to increase by totally 50 times for the two successive stretch-release-shrink operations. Additionally, the resistance of the handwritten liquid metal conductive line traces remained nearly unchanged during the stretching process, which is believed to be feasible for electrical connections in stretchable electronics. The rapid prototyping of a serpentine strain sensor was successfully demonstrated to be highly sensitive and repeatable with a stretching ratio ranging from 0 to 200%. The proposed method paves a new way to fabricate stretchable electronic devices with high patterning resolution.