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Article

In Situ 3D Printing of Conformal Bioflexible Electronics via Annealing PEDOT:PSS/PVA Composite Bio-Ink

1
School of Physics and Optoelectronics, Xiangtan University, Xiangtan 411105, China
2
Agricultural Genomics Institute at Shenzhen, Chinese Academy of Agricultural Sciences, Shenzhen 518120, China
3
Institute of Bast Fiber Crops and Center of Southern Economic Crops, Chinese Academy of Agricultural Sciences, Changsha 410205, China
4
State Key Laboratory of Molecular Engineering of Polymers, Department of Macromolecular Science, Fudan University, Shanghai 200438, China
*
Authors to whom correspondence should be addressed.
Polymers 2025, 17(11), 1479; https://doi.org/10.3390/polym17111479
Submission received: 22 April 2025 / Revised: 13 May 2025 / Accepted: 23 May 2025 / Published: 26 May 2025
(This article belongs to the Special Issue Advances in Biomimetic Smart Hydrogels)

Abstract

High-performance flexible sensors capable of direct integration with biological tissues are essential for personalized health monitoring, assistive rehabilitation, and human–machine interaction. However, conventional devices face significant challenges in achieving conformal integration with biological surfaces, along with sufficient biomechanical compatibility and biocompatibility. This research presents an in situ 3D biomanufacturing strategy utilizing Direct Ink Writing (DIW) technology to fabricate functional bioelectronic interfaces directly onto human skin, based on a novel annealing PEDOT:PSS/PVA composite bio-ink. Central to this strategy is the utilization of a novel annealing PEDOT:PSS/PVA composite material, subjected to specialized processing involving freeze-drying and subsequent thermal annealing, which is then formulated into a DIW ink exhibiting excellent printability. Owing to the enhanced network structure resulting from this unique fabrication process, films derived from this composite material exhibit favorable electrical conductivity (ca. 6 S/m in the dry state and 2 S/m when swollen) and excellent mechanical stretchability (maximum strain reaching 170%). The material also demonstrates good adhesion to biological interfaces and high-fidelity printability. Devices fabricated using this material achieved good conformal integration onto a finger joint and demonstrated strain-sensitive, repeatable responses during joint flexion and extension, capable of effectively transducing local strain into real-time electrical resistance signals. This study validates the feasibility of using the DIW biomanufacturing technique with this novel material for the direct on-body fabrication of functional sensors. It offers new material and manufacturing paradigms for developing highly customized and seamlessly integrated bioelectronic devices.
Keywords: 3D printing; bioelectronics; bio-ink; flexible sensors; direct ink writing 3D printing; bioelectronics; bio-ink; flexible sensors; direct ink writing

Share and Cite

MDPI and ACS Style

Zhang, X.; Lu, C.; Zhang, Y.; Cai, Z.; He, Y.; Liang, X. In Situ 3D Printing of Conformal Bioflexible Electronics via Annealing PEDOT:PSS/PVA Composite Bio-Ink. Polymers 2025, 17, 1479. https://doi.org/10.3390/polym17111479

AMA Style

Zhang X, Lu C, Zhang Y, Cai Z, He Y, Liang X. In Situ 3D Printing of Conformal Bioflexible Electronics via Annealing PEDOT:PSS/PVA Composite Bio-Ink. Polymers. 2025; 17(11):1479. https://doi.org/10.3390/polym17111479

Chicago/Turabian Style

Zhang, Xuegui, Chengbang Lu, Yunxiang Zhang, Zixi Cai, Yingning He, and Xiangyu Liang. 2025. "In Situ 3D Printing of Conformal Bioflexible Electronics via Annealing PEDOT:PSS/PVA Composite Bio-Ink" Polymers 17, no. 11: 1479. https://doi.org/10.3390/polym17111479

APA Style

Zhang, X., Lu, C., Zhang, Y., Cai, Z., He, Y., & Liang, X. (2025). In Situ 3D Printing of Conformal Bioflexible Electronics via Annealing PEDOT:PSS/PVA Composite Bio-Ink. Polymers, 17(11), 1479. https://doi.org/10.3390/polym17111479

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