Highly Stretchable and Patternable Conductive Elastomer Composites Based on Direct Cut‐Patterning Technique for Stretchable Circuit Board Applications

Abstract

Stretchable interconnects, essential to the versatility of stretchable circuit boards (SCBs) in the emerging field of wearable electronic systems, are commonly made from conductive elastomer composites. However, the simultaneous realization of exceptional performance and a simple and reproducible fabrication has proven to be a challenge. In this study, high‐performance stretchable interconnects are introduced. These interconnects, constructed from highly patternable conductive composites, are produced using a straightforward, reproducible, and potentially scalable method termed as direct cut‐patterning (DCP). The DCP process enables the creation of distinctive conductive composite patterns and SCBs in a customizable manner, achieving a minimum feature size of 200 µm. The unique architecture of the proposed stretchable interconnects, featuring a fully embedded meander‐patterned composite conductor with periodic secondary cuts, enables the device to endure stretches exceeding 300%, while displaying a minimal gauge factor of ≈0.19 at 100% strain. Importantly, it fully reverts to its original form upon release. The proposed DCP‐based SCB approach is successfully applied in designing a highly stretchable and stable single‐layer light‐emitting diode array circuit, showcasing its potential for use in stretchable display panels.