Emerging Patterning Strategies for Intrinsically Stretchable Conductors: Materials, Architectures, and Device-level Performance

Intrinsically stretchable electronics enable seamless integration with dynamic biological tissues and curved surfaces, making them vital for next-generation wearables, biointerfaces, and intelligent robotics. Yet, precise, high-resolution patterning of stretchable electrodes and circuits remains challenging, limiting practical applications. Traditional lithography offers excellent resolution but is hindered by thermal and chemical incompatibilities with soft substrates. Consequently, alternative approaches such as soft lithography, laser-based patterning, printing methods, and electrospray deposition have gained importance. Soft lithography provides an economical, low-temperature option suitable for delicate materials like liquid metals. Laser-based techniques deliver high resolution and design flexibility but require careful parameter tuning for specific substrates. Mask-free printing methods, including direct ink writing and inkjet printing, enable versatile patterning of complex geometries, while electrospray deposition supports precise, non-contact patterning on stretchable surfaces. Collectively, these techniques advance the fabrication of robust stretchable displays, wireless antennas, and bioelectronic interfaces for accurate physiological monitoring. Despite progress, challenges persist, particularly in achieving large-area uniformity, multilayer stability, and sustainable processing. Addressing these issues demands interdisciplinary collaboration across materials science, fluid dynamics, interfacial engineering, and digital manufacturing. This review highlights recent progress and remaining hurdles, offering guidance for future research in stretchable electronics.