Versatile Patterning of Liquid Metal via Multiphase 3D Printing

Traditional electronics and sensors often fail under mechanical stress due to structural fatigue, limited flexibility, and an inability to stretch, which restricts their use in advanced applications. Liquid metals (LMs), such as gallium alloys, like EGaIn, and gallium indium tin, have emerged as significant materials in the realm of stretchable electronics, soft robotics and human-interface devices. With a fluidic nature at nearly room temperature and physiological compatibility, they maintain their electrical properties even under mechanical deformation. Yet, achieving precise, ordered patterns of LMs within composites or hybrid materials remains a significant challenge.

 

Researchers at Arizona State University have developed a scalable, multiphase 3D printing method and custom nozzles to co-print two distinct feedstocks, liquid metal (EGaIn) and polyvinyl alcohol (PVA), forming intricate periodic. The combination of tailored nozzle geometry and optimized rheologic feedstock properties enables the generation of precise structures with enhanced dielectric properties, leading to improved capacitance in flexible, wearable pressure sensors and motion detectors. Further, this approach leverages the self-passivating oxide layer of liquid metal in an oxidative environment to ensure a robust interface with the polymer matrix.

 

This novel multiphase 3D printing technique and nozzles offers a transformative, high-potential pathway for improved capacitive sensor performance in advanced wearable sensors and human-interface devices.

 

 

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