Phase-change metal ink with pH-controlled chemical sintering for versatile and scalable fabrication of variable stiffness electronics

Authors: Simok Lee, Gun-Hee Lee, Inho Kang, Woojin Jeon, Semin Kim, Yejin Ahn, Choong Yeon Kim, Do A Kwon, Michael D. Dickey, Steve Park, Seongjun Park, Jae-Woong Jeong

Published: 2025-05-30

DOI: 10.1126/sciadv.adv4921

Source: Full article


Abstract

Variable stiffness electronics represent the forefront of adaptive technology, integrating rigid and soft electronics in a single system through dynamic mechanical modulation. While gallium’s high modulus tuning ratio and rapid phase transitions make it ideal for transformative electronic systems (TES), its liquid-state instability, high surface tension, and unintended phase transitions during processing pose substantial challenges. Here, we introduce STiffness-Adjustable temperature-Responsive ink (STAR ink), a chemically sinterable gallium composite electronic ink designed to overcome these obstacles. STAR ink enables high-resolution (~50 micrometers) circuit patterning, large-scale batch fabrication, and three-dimensional structure coating at room temperature. Through pH-controlled chemical sintering, STAR ink–based TES exhibits exceptional mechanical tunability (tuning ratio: 1465) and electrical conductivity (2.27 × 10