Hybrid Printing of Silver-Based Inks for Application in Flexible Printed Sensors

This study explores the potential benefits of combining different printing techniques to improve the production of flexible printed sensors, which is a relevant application for modern coating and surface design. The demand for cheap, flexible, precise, and scalable sensors for wearable electronics is increasing, and printed electronics techniques have shown great potential in meeting these requirements. To achieve higher performance and synergy, the paper introduces the concept of hybrid printing of electronics by combining aerosol jet printing and screen printing. This multi-process approach allows for large-scale production with high printing precision. The study prepares hybrid connections on a flexible substrate foil for use in flexible printed sensor manufacturing. The research team tests different combinations of printed layers and annealing processes and finds that all prepared samples exhibit high durability during mechanical fatigue tests. Surface morphology, SEM images, and cross-section profiles demonstrate the high quality of printed layers. The lowest resistance among the tested hybrid connections obtained was 1.47 Ω. The study’s findings show that the hybrid printing approach offers a novel and promising solution for the future production of flexible sensors. Overall, this research represents an interdisciplinary approach to modern coating and surface design that addresses the need for improved production of wearable electronics. By combining different printing techniques, the study demonstrates the potential for achieving high-volume production, miniaturization, and high precision, which are essential for the ever-growing market of wearable sensors.