This research delves into the burgeoning realm of 3D printing for flexible electronics, seeking a robust method to establish both electrical and mechanical connections between metals and conductive polymers. The investigation focuses on mechanical interlocking, employing perforated copper tape embedded during the 3D-printing process to create durable connections with molten Thermoplastic Poly-Urethane (ETPU).
The study involves modelling and fabricating physical samples, optimizing contact design, and employing an experimental setup for tensile tests, simulating real-world applications. Results indicate that perforated tapes outperform conventional wires, displaying mechanically resilient contacts with low, stabilized contact resistance under varying loads. The research contributes to advancing additive manufacturing for flexible electronics, addressing critical challenges in bonding electrical components to 3D-printed structures and standardizing contact methods.
The implications extend to potential applications in soft robotics and biomedical devices, including wearable sensors, robotic prostheses, and integrated displays.