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In the last decades, the demand for electronics and, therefore, electronic waste, has increased. To reduce this electronic waste and the impact of this sector on the environment, it is necessary to develop biodegradable systems using naturally produced materials with low impact on the environment or systems that can degrade in a certain period. One way to manufacture these types of systems is by using printed electronics because the inks and the substrates used are sustainable. Printed electronics involve different methods of deposition, such as screen printing or inkjet printing. Depending on the method of deposition selected, the developed inks should have different properties, such as viscosity or solid content. To produce sustainable inks, it is necessary to ensure that most of the materials used in the formulation are biobased, biodegradable, or not considered critical raw materials. In this review, different inks for inkjet printing or screen printing that are considered sustainable, and the materials that can be used to formulate them, are collected. Printed electronics need inks with different functionalities, which can be mainly classified into three groups: conductive, dielectric, or piezoelectric inks. Materials need to be selected depending on the ink’s final purpose. For example, functional materials such as carbon or biobased silver should be used to secure the conductivity of an ink, a material with dielectric properties could be used to develop a dielectric ink, or materials that present piezoelectric properties could be mixed with different binders to develop a piezoelectric ink. A good combination of all the components selected must be achieved to ensure the proper features of each ink.

Highly conductive ink with low sintering temperature is important for printed electronics on paper substrate. Silver nanoparticles (Ag NPs) of different average radii ranging from 48 to 176 nm were synthesized by adjusting the Ag + concentration in the reaction process. The electric resistivity of the Ag NP-based ink film in relation to Ag NP size, sintering temperature, amount of PVP capping agent on Ag NP surface, and morphology evolution of the film during heating process was investigated. It was found that the resistivity of the films reduced very rapidly with increasing particle size due above all to reduced amount of protective agent capping on the Ag NPs. A semi-empirical relationship between the resistivity and the particle size was proposed. With the help of this mathematical expression, one gains both systematic and detailed insight to the resistivity evaluation with regard to the Ag particle size. The optimal electric resistivity of 4.6 μΩ cm was achieved at 140 °C for 10 min which was very close to the resistivity value of bulk Ag (1.58 μΩ cm). Mechanical flexibility of the printed electronics with the Ag NP-based ink on paper substrates was investigated. The prints on the art coated paper exhibited better flexibility compared to that on the photopaper. This might be attributed to the surface coating composition, surface morphology of the paper, and their corresponding ink absorption property.

The newly developed research area of inkjet-printed radio frequency (RF) electronics on cellulose-based and synthetic paper substrates is introduced in this paper. This review paper presents the electrical properties of the paper substrates, the printed silver nanoparticle-based thin films, the dielectric layers, and the catalyst-based metallization process. Numerous inkjet-printed microwave passive/ative systems on paper, such as a printed radio frequency identification (RFID) tag, an RFID-enabled sensor utilizing carbon nanotubes (CNTs), a substrate-integrated waveguide (SIW), fully printed vias, an autonomous solar-powered beacon oscillator (active antenna), and artificial magnetic conductors (AMC), are discussed. The reported technology could potentially act as the foundation for true “green” low-cost scalable wireless topologies for autonomous Internet-of-Things (IoT), bio-monitoring, and “smart skin” applications.

Roll-to-roll (R2R) printing methods are well known as additive, cost-effective, and ecologically friendly mass-production methods for processing functional materials and fabricating devices. However, implementing R2R printing to fabricate sophisticated devices is challenging because of the efficiency of material processing, the alignment, and the vulnerability of the polymeric substrate during printing. Therefore, this study proposes the fabrication process of a hybrid device to solve the problems. The device was created so that four layers, composed of polymer insulating layers and conductive circuit layers, are entirely screen-printed layer by layer onto a roll of polyethylene terephthalate (PET) film to produce the circuit. Registration control methods were presented to deal with the PET substrate during printing, and then solid-state components and sensors were assembled and soldered to the printed circuits of the completed devices. In this way, the quality of the devices could be ensured, and the devices could be massively used for specific purposes. Specifically, a hybrid device for personal environmental monitoring was fabricated in this study. The importance of environmental challenges to human welfare and sustainable development is growing. As a result, environmental monitoring is essential to protect public health and serve as a basis for policymaking. In addition to the fabrication of the monitoring devices, a whole monitoring system was also developed to collect and process the data. Here, the monitored data from the fabricated device were personally collected via a mobile phone and uploaded to a cloud server for additional processing. The information could then be utilized for local or global monitoring purposes, moving one step toward creating tools for big data analysis and forecasting. The successful deployment of this system could be a foundation for creating and developing systems for other prospective uses.

Different conductive bonding strategies for the hybrid integration of flexible, inkjet-printed electronics are investigated. The focus of the present work lies on providing a practical guide comprising standard techniques that are inexpensive, easily implementable and frequently used. A sample set consisting of identical conductive test structures on different paper and plastic substrates was prepared using silver (Ag) nanoparticle ink. The sintered specimens were electrically contacted using soldering, adhesive bonding and crimping. Electrical and mechanical characterization before and after exposing the samples to harsh environmental conditions was performed to evaluate the reliability of the bonding methods. Resistance measurements were done before and after connecting the specimens. Afterwards, 85 °C/85% damp-heat tests and tensile tests were applied. Adhesive bonding appears to be the most suitable and versatile method, as it shows adequate stability on all specimen substrates, especially after exposure to a 85 °C/85% damp-heat test. During exposure to mechanical tensile testing, adhesive bonding proved to be the most stable, and forces up to 12 N could be exerted until breakage of the connection. As a drawback, adhesive bonding showed the highest increase in electrical resistance among the different bonding strategies.

Printed electronics are a set of additive manufacturing methods for creating future flexible electronics on thin polymeric sheets. We proposed the toner-type, dry, page-printing of Ag–Ni composite conductive particles on flexible plastic sheets without pre-treatment. No chemical solvents are necessary to compose the inks of the electronic materials used for the toner-type printing, and no chemical treatment is required for the plastic film substrate surface. In addition, multilayer printing is simple when using toner printing because previously printed materials do not need to be resolved; furthermore, composing the thick films of the electronic materials is relatively simple. In this study, we fabricated an Ag–Ni composite toner to improve the fluidity of the toner particles compared to bare Ag particles. We successfully printed IC peripheral circuits at a resolution of 0.20 mm and demonstrated that the actual electrical circuit pattern can be formed using our method.

We fabricate a wearable blood leakage sensor on a cotton textile by combining two newly developed techniques. First, we employ a screen-offset printing technique that avoids blurring, short circuiting between adjacent conductive patterns, and electrode fracturing to form an interdigitated electrode structure for the sensor on a textile. Furthermore, we develop a scheme to distinguish blood from other substances by utilizing the specific dielectric dispersion of blood observed in the sub-megahertz frequency range. The sensor can detect blood volumes as low as 15 μL, which is significantly lower than those of commercially available products (which can detect approximately 1 mL of blood) and comparable to a recently reported value of approximately 10 μL. In this study, we merge two technologies to develop a more practical skin-friendly sensor that can be applied for safe, stress-free blood leakage monitoring during hemodialysis.

The ability to fabricate an entire smart sensor patch with read‐out electronics using commercial printing techniques may have a wide range of potential applications. Although solution‐processed oxide thin film transistors (TFTs) are capable of providing high mobility electron transport, resulting in large ON‐state current and power output, there is hardly any literature report that uses the printed oxide TFTs at the sensor interfaces. Here, printed amorphous indium‐gallium‐zinc oxide (a‐IGZO)‐based deep‐subthreshold operated TFTs that comprise signal amplifiers and analog‐to‐digital converters (ADCs) that can successfully digitalize the analog sensor signals up to a frequency range of 1 kHz are reported. In addition, exploiting the high current oxide TFTs, a current drive circuit placed after the ADC unit has been found useful in producing easy‐to‐detect visual recognition of the sensor signal at a predefined threshold crossover. Notably, the entire smart sensor patch is demonstrated to operate at a low supply voltage of ≤2 V, thereby ensuring that it can be an on‐chip energy source compatible and standalone detection unit. The readout circuit based on inkjet‐printed deep‐subthreshold operated thin film transistors (TFTs) based on amorphous indium‐gallium‐zinc oxide (a‐IGZO) successfully digitalizes analog sensor data and provides easy‐to‐detect visual identification of the sensor signal at a preset threshold crossover using high‐current oxide TFTs. Notably, the complete smart sensor patch is shown to operate at a low voltage of ≤2 V, assuring that the on‐chip power source is compatible.

Organic thin-film transistors using small-molecule semiconductor materials such as 6,13-bis(triisopropylsilylethynyl)pentacene (TIPS-P) have been recently studied for the production of flexible and printed electronic devices. Blending a semiconductor with an insulating polymer, such as polystyrene, is known to improve the device performance; however, its molecular-level structure remains unknown. In this study, we performed molecular dynamics (MD) simulations on a mixed system of TIPS-P and atactic polystyrene (aPS) with fully atomistic models to understand the structure of the mixed thin film at the molecular level and the influence on the device properties. To reproduce the deposition from the solution, we gradually reduced the number of toluene molecules in the simulation. The dynamic characteristics of the system, mean squared displacement, diffusion coefficient, density profile, and P2 order parameter were analyzed. Some of the simulated systems reached the equilibrium state. In these systems, the simulated structures suggested the presence of more TIPS-P molecules on the surface than inside the bulk, even at the low molecular weight of aPS, where phase separation was not observed experimentally. The results of the fully atomistic MD simulations are also a basis for the coarse-grained model to increase the speed of the MD simulation.

Wearable biosensors attract significant interest for their capabilities in real-time monitoring of wearers’ health status, as well as the surrounding environment. Sensor patches are embedded onto the human epidermis accompanied by data readout and signal conditioning circuits with wireless communication modules for transmitting data to the computing devices. Wearable sensors designed for recognition of various biomarkers in human epidermis fluids, such as glucose, lactate, pH, cholesterol, etc., as well as physiological indicators, i.e., pulse rate, temperature, breath rate, respiration, alcohol, activity monitoring, etc., have potential applications both in medical diagnostics and fitness monitoring. The rapid developments in solution-based nanomaterials offered a promising perspective to the field of wearable sensors by enabling their cost-efficient manufacturing through printing on a wide range of flexible polymeric substrates. This review highlights the latest key developments made in the field of wearable sensors involving advanced nanomaterials, manufacturing processes, substrates, sensor type, sensing mechanism, and readout circuits, and ends with challenges in the future scope of the field. Sensors are categorized as biological and fluidic, mounted directly on the human body, or physiological, integrated onto wearable substrates/gadgets separately for monitoring of human-body-related analytes, as well as external stimuli. Special focus is given to printable materials and sensors, which are key enablers for wearable electronics.