Roll-To-Roll Screen-Printed Silver Conductors on a Polydimethyl Siloxane Substrate for Stretchable Electronics

Stretchable electronics has attracted much interest recently because of its potential applications in the area of wearable electronics and healthcare. Highly elastic polydimethyl siloxane (PDMS) has been for decades a widely used material in prototyping purposes. It enables the realization of a variety of mechanical and optical functions besides being a substrate for other processes or applications. As a substrate, PDMS enables high stretchability and easy integration of other parts made of PDMS. In this work, we demonstrated a high-volume production of stretchable electrical interconnections on PDMS substrates. We used roll-to-roll (R2R) rotary screen printing that has been conventionally applied in high-throughput fabrication of electronics on flexible, but not stretchable, substrates. We demonstrated silver interconnects whose conductivity remains sufficient for signal transmission, for example, in sensor structures under repeated 20% strain over 100 cycles. We also demonstrated R2R compatible PDMS encapsulation of electrical interconnections that increased the strain repetition durability by a factor of 2.