multi-axial super-stretchable interconnects with active electronics

We report on the fabrication and characterization of stretchable interconnects using room temperature liquid alloy filled PDMS microchannels. Several novel fabrication techniques are presented to increase the functionality and manufacturing yield. These include selective deposition of a gold wetting layer at the bottom of the channels, microfluidic injection of room temperature liquid alloy, and reservoirs for accommodation of surface mount components. Achieved maximum stretchability of a bi-axial diamond-shaped structure is 100% with a 0.24 Omega resistance variation. Active electronics is also integrated onto the PDMS substrate with stretchable interconnects and tested for functionality.