Lab Electrospinning System| Adaptive Printing of Conductive Microfibersfor Seamless Functional EnhancementAcross Diverse Surfaces and Shapes
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Author: Nanofiberlabs
Publish Time: 2025-06-10
Origin: Adaptive printing
Advanced Fiber Materials: Adaptive Fiber-of-Things (FoT) Transforms Daily Objects into Smart Devices
Have you ever imagined a regular pencil, face mask, or even a pair of pliers could instantly become smart devices? A research team from the Hong Kong University of Science and Technology (Guangzhou), the University of Cambridge, and Queen Mary University of London recently published a breakthrough in Advanced Fiber Materials—adaptive printing of conductive microfibers to add electronic functionalities to everyday objects, turning them into smart sensors effortlessly while preserving their original appearance and usability!
Attaching conductive material layers to existing objects is an effective way to expand their functions, but traditional methods have significant limitations. While 3D printing can create customized conductive tracks, its precision is greatly affected by surface textures. Spraying functional inks is simple but alters the object’s appearance and relies heavily on surface wettability. In contrast, conductive microfibers offer unique advantages due to their microscale diameter, flexibility, and breathability. However, existing microfiber technologies typically require additional transfer and adhesion steps after deposition, limiting practical applications.To address this, this study developed a one-step fiber printing strategy using innovative adaptive printing technology to directly print microfibers onto objects of various shapes and materials without modeling or transfer.
The team first prepared two fiber solutions: PEDOT:PSS and silver nanoparticle (AgNP) inks. The critical microfiber printing process was achieved using a self-developed adaptive fiber printing system, which relies on mechanical shearing and stretching for in-situ fiber formation and direct deposition. The entire process takes only 1–2 seconds, with fibers tightly adhering to the target surface in a semi-wet state.
Detailed characterization of the microfibers showed high conductivities of ~2×10³ S/m for PEDOT:PSS and ~1×10⁵ S/m for AgNP fibers. Their microscale diameters (1.5–3 μm) and sparse arrangement (spacing ~100 μm) enable 90% visible light transmittance. Notably, this open-network structure exhibits excellent electromagnetic wave transmittance in the GHz range, causing almost no signal attenuation between 1–40 GHz. This makes it ideal for smart devices requiring wireless communication, such as smartwatches and NFC tags, where the conductive fibers do not interfere with interface characteristics.
Figure 1: Adaptive fiber printing applicable to objects of diverse shapes and materials.
In practical applications, the team demonstrated the technology’s versatility. Depositing PEDOT:PSS microfibers on a mask’s exhalation valve enabled real-time monitoring of breathing frequency. Microfiber arrays printed directly on a smartwatch detected humidity changes without affecting touchscreen operations or wireless communications. Innovatively, a "Lego-like" assembly strategy quickly constructed 3D structures from pre-printed microfiber modules to monitor multi-point airflow distributions.
Figure 2: Fiber sensors integrated with masks and smartwatches for breath sensing.
In biomedicine, temporary printing of PEDOT:PSS microfibers on robotic fingers significantly reduced skin contact impedance, enabling stable ECG signal acquisition. Similarly, microfiber arrays wrapped around tool handles accurately recorded EMG signal changes during use. These applications highlight the microfiber functional layer’s "invisible" nature—providing sensing capabilities without compromising the object’s primary functions.
Figure 3: Fibers adaptively integrated with daily objects for electrophysiological sensing.
In energy applications, AgNP microfiber arrays served as transparent heating elements, reaching local temperatures of 110°C at 10V, while their open structure ensured no interference with wireless communications like NFC. PEDOT:PSS microfibers wrapped around coasters generated continuous electricity from temperature differences when holding an 80°C hot water cup. Most notably, the team integrated porous graphene aerogels using a two-layer microfiber "sandwich" structure, achieving highly sensitive formaldehyde gas detection while fully preserving aerogel porosity, with response values over three times higher than traditional electrode structures.
Figure 4: Substrate-less fibers as electrode materials for porous graphene, enabling efficient gas sensing.
This adaptive microfiber printing technology overcomes limitations of conventional functionalization methods, enabling seamless integration of sensing interfaces with various substrates through one-step deposition. The ultra-fine diameter and controllable arrangement of microfibers add functionalities without altering an object’s appearance or usability. This "invisible enhancement" strategy opens new technical pathways for smart devices, health monitoring, and environmental sensing. Future expansion of material systems (e.g., novel thermoelectric materials) and deposition process optimization could position this technology as pivotal in building a "Fiber-of-Things (FoT)" ecosystem. Notably, its low energy consumption (<50W) and high material efficiency (0.01–0.4 mg/device) align with sustainability goals, offering new ideas for green manufacturing of electronic devices.
