Robotized Fabrication Strategy for Large-Scale 3D Conformal Electronics

Conformal electronics are distinguished by their unique characteristics, such as the integration of structure and function and their conformability with complex geometries. These features unlock a broad spectrum of applications, including structural health monitoring and the creation of metasurfaces. However, the current landscape of large-scale curved electronic fabrication is characterized by a significant gap in specialized equipment and standardized strategies. In this context, we introduce a pioneering strategy that leverages robotized electrohydrodynamic (EHD) printing for the conformal fabrication of large-scale curved electronics on 3D surfaces. This comprehensive multi-robot EHD conformal printing strategy integrates several critical components, including plasma surface treatment, EHD conformal printing, and near-infrared (NIR) sintering processes. These are supported by enabling technologies such as 3D surface reconstruction and precise hybrid positioning. Notably, our strategy achieves 5 µm printing resolution via EHD lithography and 35 µm repeatable positioning accuracy. After plasma treatment, conductive patterns on FR4 substrates reach 5B-level adhesion strength. NIR sintering enables high-efficiency sintering within only 125 s. Seamless integration of these processes into multi-robot collaborative equipment enables the fabrication of large-area conformal electronics, such as 400 mm × 1000 mm unmanned aerial vehicle wings and 650 mm × 350 mm satellite shells, and supports multi-layer systems including wires, LED arrays, antennas, and sensors. This strategy possesses substantial potential to transcend the limitations inherent in traditional fabrication methods, paving the way for new frontiers in conformal electronics across a variety of applications, including smart wings and satellite surfaces.