Fast and Efficient Fabrication of Functional Electronic Devices Through Grayscale Digital Light Processing 3D Printing

Fabricating polymeric composites with desirable characteristics for electronic applications is a complex and costly process. Digital light processing (DLP) 3D printing emerges as a promising technique for manufacturing intricate structures. In this study, polymeric samples are fabricated with a conductivity difference exceeding three orders of magnitude in various portions of a part by employing grayscale DLP (g-DLP) single-vat single-cure 3D printing deliberate resin design. This is realized through the manipulation of light intensity during the curing process. Specifically, the rational resin design with added lithium ions results in the polymer cured under the maximum UV-light intensity exhibiting higher electrical resistance. Conversely, sections that are only partially cured retains uncured monomers, serving as a medium that facilitates ion mobility, consequently leading to higher conductivity. The versatility of g-DLP allows precise control of light intensity in different regions during the printing process. This characteristic opens up possibilities for applications, notably the low-cost, facile, and rapid production of complex electrical circuits and sensors. The utilization of this technique makes it feasible to fabricate materials with tailored conductivity and functionality, providing an innovative pathway to advance the accelerated and facile creation of sophisticated electronic devices.