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<p>Bath-assisted three-dimensional printing has emerged as a promising strategy for fabricating stretchable electronic systems with high geometric freedom by enabling mechanically stabilized deposition and integrated encapsulation. However, previously reported bath materials have primarily relied on gel-like media, which limits mechanical robustness of the resulting devices. Here, we present a bath-assisted three-dimensional printing approach for patterning eutectic gallium-indium / polydimethylsiloxane (EGaIn/PDMS) electrodes by employing highly viscous and crosslinkable PDMS as a bath and a subsequent encapsulation medium. The engineered viscosity of the PDMS bath provides Stokesian drag–induced stabilization during printing, enabling the fabrication of versatile electrode geometries, while subsequent thermal curing converts the bath into a soft elastomer that serves as a mechanically reliable encapsulation layer. EGaIn/PDMS electrodes printed within the bath exhibit robust electromechanical stability, maintaining a resistance change of approximately 5% after 5,000 cycles of tensile strain up to 50%. Leveraging this approach, we demonstrate fully embedded stretchable multilayer circuits, including crossover interconnects in a passive-matrix light-emitting diode (LED) array and a wearable system integrating thermal sensors, analog circuitry, and LEDs. These results establish PDMS-compatible bath-assisted three-dimensional printing as a viable route toward mechanically robust, fully integrated stretchable electronic systems.</p>

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A Fully Embedded Stretchable Three-Dimensional Circuit via Highly Viscous Polydimethylsiloxane Bath

  • 期刊论文

  • 发表日期：

    2026年4月28日

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  • Christopher Jiyong Yoo,
  • Jinsu Yoon,
  • Minkyun Kang,
  • Yongtaek Hong

摘要

Bath-assisted three-dimensional printing has emerged as a promising strategy for fabricating stretchable electronic systems with high geometric freedom by enabling mechanically stabilized deposition and integrated encapsulation. However, previously reported bath materials have primarily relied on gel-like media, which limits mechanical robustness of the resulting devices. Here, we present a bath-assisted three-dimensional printing approach for patterning eutectic gallium-indium / polydimethylsiloxane (EGaIn/PDMS) electrodes by employing highly viscous and crosslinkable PDMS as a bath and a subsequent encapsulation medium. The engineered viscosity of the PDMS bath provides Stokesian drag–induced stabilization during printing, enabling the fabrication of versatile electrode geometries, while subsequent thermal curing converts the bath into a soft elastomer that serves as a mechanically reliable encapsulation layer. EGaIn/PDMS electrodes printed within the bath exhibit robust electromechanical stability, maintaining a resistance change of approximately 5% after 5,000 cycles of tensile strain up to 50%. Leveraging this approach, we demonstrate fully embedded stretchable multilayer circuits, including crossover interconnects in a passive-matrix light-emitting diode (LED) array and a wearable system integrating thermal sensors, analog circuitry, and LEDs. These results establish PDMS-compatible bath-assisted three-dimensional printing as a viable route toward mechanically robust, fully integrated stretchable electronic systems.