A review on scalable printing techniques for conductive and composite polymer nanoinks

Abstract Emerging research in conductive and composite polymer nanoinks (CCPNIs) demonstrate remarkable advantages in electrical, thermal, and mechanical properties which are highly desired for printable applications. The development of suitable scalable production techniques can address the demand for wearable, printable, and flexible nanoink-based electronic applications. In this review we present a comparative analysis for contact based techniques such as screen printing (SP), nano imprint lithography (NIL) and non-contact printing techniques such as inkjet printing (IJP), aerosol jet printing (AIP) and 3D printing with a focus on CCPNIs. We discuss the application of these techniques across various electronic domains such as wearable electronics, flexible sensors and robotics which rely on scalable printing technologies. Among the techniques reviewed, SP stands out as particularly suitable and sustainable, primarily due to its scalability and efficiency. It is capable of producing between 1,000 and 5,000 parts per hour, while maintaining a practical resolution range of 1000 μm (±5–10%). SP is suitable for applications in printed electronics, where cost-effectiveness, simplicity, and scalability are of focus. In contrast, for complex and multidimensional printing, 3D printing shows promise with an excellent resolution which are crucial for industrial-scaled production.