Intelligent Field‐Adaptive Electrohydrodynamic Printing for Curved Conformal Electronics

ABSTRACT Curved conformal electronics are increasingly important for wearable devices, biosensing, and advanced communication systems, requiring high‐resolution and high‐precision manufacturing on complex surfaces. Electrohydrodynamic printing is a promising method for fabricating conformal electronics, but its application on curved insulating substrates is hindered by local electric‐field disturbances arising from residual charge accumulation and spatial variations, leading to poor dimensional control. To address this challenge, an intelligent field‐adaptive electrohydrodynamic printing framework is established, in which alternating‐electric‐field modulation reduces the effects of residual charge, the equivalent electrical gap quantitatively characterizes spatially varying electric‐field conditions, and machine learning‐based parameter regulation compensates for local electric‐field variations. Based on this framework, a machine‐learning and alternating‐electric‐field synergistic modulated electrohydrodynamic printing approach is developed to achieve stable printing and precise line‐width control on curved substrates. The approach rapidly optimizes parameters for target line widths, achieving average relative errors around 10% or lower at the initial printing position, and further reduces average relative line‐width errors by up to 7.24 percentage points through adaptive regulation during curved‐substrate printing. Diverse high‐precision patterns are printed, and the conformal frequency‐selective surface and antenna with excellent electromagnetic performance are fabricated, demonstrating the potential of this framework for advancing curved conformal electronics manufacturing.