Ultra-thin high-resolution transfer-printed breathable electronics for conformal wearable devices

Abstract

Nanomesh electronics offer remarkable potential for biomedical and human–machine interface applications due to their conformability to nonplanar surfaces, versatile functionality, and long-term reliability. However, existing materials face significant challenges related to surface structure and chemical resistance, resulting in high electrical resistance and complex fabrication requirements. To address these challenges, we present transfer-printed nanomesh electrodes (NEs) produced by integrating fine-patterned 2D electrodes with porous nanomesh. Electrospun thermoplastic-polyurethane nanofibers provide strong adhesion to the electrodes, which generate sufficient force (95.1 mN∙cm−1) to maintain structural integrity and electrical performance. Unlike direct deposition, which requires a minimum thickness of 100nm to achieve 14.12±2 mS, transfer-printed NEs reach 16.91±8.7 mS only with 20nm. Furthermore, our electrodes demonstrate excellent durability under deformation, maintaining stable electrical performance with only a 0.53% change at a bending radius of 1mm. To validate their practical application, we demonstrate a NE-based tactile sensor, which exhibits a conductance change from 0 mS in the normal state to 130 mS upon touch. These results highlight the potential of transfer-printed NEs for next-generation e-skin with fine patterning, high conductivity, and long-term reliability. In addition, our novel method addresses the challenges of manufacturing breathable devices with functionalities extending beyond simple electrodes.