Synthesis of disc-shaped copper flakes by mechanical milling: Green laser-sintered, highly conductive printed Cu features

•Disc-shaped Cu flakes were synthesized by successive chemical/mechanical reactions.•The printed Cu particulate layers were transformed into highly conductive metallic films by the green-laser sintering process.•Highly conductive printed metallic Cu features were generated with the value in resistance of 1.9 Ω/cm.