Roll-to-roll production for stretchable electronics
Researchers in Japan have developed a roll to roll process for mass production of stretchable electronics.
The team at Yokohama National University in Japan enable continuous production of patterned and multilayered elastic substrates with liquid metal wiring for stretchable electronics using a roll to roll (R2R) process.
There is a growing demand for stretchable technology, but the current methods are not easily scalable for mass production to make these devices available to the public. However, mass development may be possible using the R2R process, which prints various layers on a flexible rolled substrate and cuts out the manual nature of the process.
Conventional methods can make complex, multilayered patterned substrates, but it does not have the high production capacity to extend that capacity to large-scale production. Other techniques use R2R for microLEDs, sensors and perovskite solar cells.
“In this study, we conducted research and development for the mass production of stretchable devices based on the R2R production process. These technologies are important to promote market introduction in order to further develop the field of stretchable electronics, which is still in the research phase,” said Hiroki Ota, associate professor at Yokohama National University and author of the paper.
The R2R production process uses elastic substrates that are multilayered with different material layers and embedded electronics. This allows the addition of elastic materials like hydro-gels or silicone, and liquid metal wiring. The process also involves a coating step and a step to prepare the material for wiring. The result is a single material that is flexible, elastic and functional.
In the study, 15 stretchable devices with light detection were produced and tested the ability to respond to light levels while being stretched. These materials were shown to maintain functionality even when being stretched by 70% of the substrate’s maximum.
Devices equipped with thermistors also appeared accurate when comparing the temperature of each compartment given by the device against the actual set temperature.
“The stretchable wiring technology has not been realized by the R2R process technology, and in the future, by linking the R2R production process technology for liquid metal wiring and substrates, the R2R process can realize the continuous and mass production of the stretchable device itself,” said Ota.
So far, R2R processing on the elastic materials has achieved accuracy and continued performance when stretched. Researchers hope to see further developments in micropattern fabrication for higher resolution and improve the overall functionality of the process and its outcomes.
onlinelibrary.wiley.com/doi/10.1002/admt.202400487
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