Ultra-Stretchable Interconnects for High-Density Stretchable Electronics

The exciting field of stretchable electronics (SE) promises numerous novel applications, particularly in-body and medical diagnostics devices. However, future advanced SE miniature devices will require high-density, extremely stretchable interconnects with micron-scale footprints, which calls for proven standardized (complementary metal-oxide semiconductor (CMOS)-type) process recipes using bulk integrated circuit (IC) microfabrication tools and fine-pitch photolithography patterning. Here, we address this combined challenge of microfabrication with extreme stretchability for high-density SE devices by introducing CMOS-enabled, free-standing, miniaturized interconnect structures that fully exploit their 3D kinematic freedom through an interplay of buckling, torsion, and bending to maximize stretchability. Integration with standard CMOS-type batch processing is assured by utilizing the Flex-to-Rigid (F2R) post-processing technology to make the back-end-of-line interconnect structures free-standing, thus enabling the routine microfabrication of highly-stretchable interconnects. The performance and reproducibility of these free-standing structures is promising: an elastic stretch beyond 2000% and ultimate (plastic) stretch beyond 3000%, with 10 million cycles at 1000% stretch with <1% resistance change. This generic technology provides a new route to exciting highly-stretchable miniature devices.Comment: 13 pages, 5 figure, journal publicatio

Full-field hygroscopic characterization of paper inter-fiber bonds and the implications on network hygro-expansivity

The state-of-the-art in paper micro-mechanics calls for novel experimental data covering the full-field hygro-expansion of inter-fiber bonds, i.e., the 3D morphological changes and inter-fiber interactions. Therefore, a recently developed full-field single fiber hygro-expansion measurement methodology based on global digital height correlation is extended to orthogonal inter-fiber bonds, to investigate their full-field quasi-3D hygroscopic behavior. A sample holder has been developed which enables the quasi-3D characterization of the initial geometry of individual inter-fiber bonds, including the fiber thickness and width along the length of the fibers as well as the degree of wrap around and contact area of the bond, which are vital for understanding the inter-fiber bond hygro-mechanics. Full-field hygroscopic testing reveals the inter-fiber interactions: (i) the transverse hygro-expansion of each fiber strongly reduces when approaching the bonded area, due to the significantly lower longitudinal hygro-expansion of the other bonded fiber. (ii) The relatively large transverse strain of one fiber stretches the other crossing fiber in its longitudinal direction, thereby significantly contributing to the sheet scale hygro-expansion. (iii) Out-of-plane bending is observed in the bonded region which is driven by the significant difference in transverse and longitudinal hygro-expansion of, respectively, the top and bottom fiber constituting the bond. A bi-layer laminate model is employed to rationalize the bending deformation and an adequate match is found with the experimental data. Under the assumption of zero bending, which represents constrained inter-fiber bonds inside a paper sheet, the model can predict the contribution of the transverse strain in the bonded regions to the sheet-scale hygro-expansion.</p

Effect of restrained versus free drying on hygro-expansion of hardwood and softwood fibers and paper handsheet

Earlier work on the hygro-expansion of paper states that the larger hygro-expansivity of freely compared to restrained dried handsheets is due to structural differences between the fibers inside the handsheet. To study this hypothesis, first, the hygro-expansion of freely and restrained dried, hardwood and softwood handsheets has been characterized. Subsequently, the transient full-field hygro-expansion (longitudinal, transverse, and shear strain) of fibers extracted from these handsheets was measured using global digital height correlation, from which the micro-fibril angle was deduced. The hygro-expansivity of each individual fiber was tested before and after a wetting period, during which the fiber’s moisture content is maximized, to analyze if a restrained dried fiber can “transform” into a freely dried fiber. It was found that the longitudinal hygro-expansion of the freely dried fibers is significantly larger than the restrained dried fibers, consistent with the sheet-scale differences. The difference in micro-fibril angle between the freely and restrained dried fibers is a possible explanation for this difference, but merely for the hardwood fibers, which are able to “transform” to freely dried fibers after being soaked in water. In contrast, this “transformation” does not happen in softwood fibers, even after full immersion in water for a day. Various mechanisms have been studied to explain the observations on freely and restrained dried hardwood and softwood, fiber and handsheets including analysis of the fibers’ lumen and cross-sectional shape. The presented results and discussion deepens the understanding of the differences between freely and restrained dried handsheets.</p

Effect of restrained versus free drying on hygro-expansion of hardwood and softwood fibers and paper handsheet

Earlier work on the hygro-expansion of paper states that the larger hygro-expansivity of freely compared to restrained dried handsheets is due to structural differences between the fibers inside the handsheet. To study this hypothesis, first, the hygro-expansion of freely and restrained dried, hardwood and softwood handsheets has been characterized. Subsequently, the transient full-field hygro-expansion (longitudinal, transverse, and shear strain) of fibers extracted from these handsheets was measured using global digital height correlation, from which the micro-fibril angle was deduced. The hygro-expansivity of each individual fiber was tested before and after a wetting period, during which the fiber’s moisture content is maximized, to analyze if a restrained dried fiber can “transform” into a freely dried fiber. It was found that the longitudinal hygro-expansion of the freely dried fibers is significantly larger than the restrained dried fibers, consistent with the sheet-scale differences. The difference in micro-fibril angle between the freely and restrained dried fibers is a possible explanation for this difference, but merely for the hardwood fibers, which are able to “transform” to freely dried fibers after being soaked in water. In contrast, this “transformation” does not happen in softwood fibers, even after full immersion in water for a day. Various mechanisms have been studied to explain the observations on freely and restrained dried hardwood and softwood, fiber and handsheets including analysis of the fibers’ lumen and cross-sectional shape. The presented results and discussion deepens the understanding of the differences between freely and restrained dried handsheets.</p

An adaptive wavelet-based collocation method for solving multiscale problems in continuum mechanics

Computational multiscale methods are highly sophisticated numerical approaches to predict the constitutive response of heterogeneous materials from their underlying microstructures. However, the quality of the prediction intrinsically relies on an accurate representation of the microscale morphology and its individual constituents, which makes these formulations computationally demanding. Against this background, the applicability of an adaptive wavelet-based collocation approach is studied in this contribution. It is shown that the Hill–Mandel energy equivalence condition can naturally be accounted for in the wavelet basis, (discrete) wavelet-based scale-bridging relations are derived, and a wavelet-based mapping algorithm for internal variables is proposed. The characteristic properties of the formulation are then discussed by an in-depth analysis of elementary one-dimensional problems in multiscale mechanics. In particular, the microscale fields and their macroscopic analogues are studied for microstructures that feature material interfaces and material interphases. Analytical solutions are provided to assess the accuracy of the simulation results.</p

An adaptive wavelet-based collocation method for solving multiscale problems in continuum mechanics

Computational multiscale methods are highly sophisticated numerical approaches to predict the constitutive response of heterogeneous materials from their underlying microstructures. However, the quality of the prediction intrinsically relies on an accurate representation of the microscale morphology and its individual constituents, which makes these formulations computationally demanding. Against this background, the applicability of an adaptive wavelet-based collocation approach is studied in this contribution. It is shown that the Hill–Mandel energy equivalence condition can naturally be accounted for in the wavelet basis, (discrete) wavelet-based scale-bridging relations are derived, and a wavelet-based mapping algorithm for internal variables is proposed. The characteristic properties of the formulation are then discussed by an in-depth analysis of elementary one-dimensional problems in multiscale mechanics. In particular, the microscale fields and their macroscopic analogues are studied for microstructures that feature material interfaces and material interphases. Analytical solutions are provided to assess the accuracy of the simulation results.</p

An efficient ray tracing methodology for the numerical analysis of powder bed additive manufacturing processes

This paper presents a ray tracing model to simulate the laser-powder bed interaction for additive manufacturing processes. Ray tracing is a technique that is able to accurately and efficiently capture the interaction of light with multiple objects with complex geometries made of different materials. In the proposed methodology the laser energy distribution is modelled by a finite number of rays which are traced through the powder bed that is modelled as stacked spherical particles. The proposed ray tracing methodology addresses the reflection and refraction of light using the Fresnel equations and its absorption using a Beer–Lambert law. Simulations of a stationary laser on a powder bed show that for metallic materials the effect of polarisation of the light on the energy distribution in the powder bed is negligible. In addition, it is demonstrated that the refracted rays are fully absorbed by single powder particles. The illumination results of a stationary polarised laser under a range of incident angles indicate a significant absorption difference at high angles. In order to increase computational efficiency, a closed form relation for an equivalent homogenised volumetric laser heat source has been derived, whereby the shape and power profile of the laser matches the ray tracing results. Simulating single scan lines by varying power, spot size and speed demonstrates that the model accurately captures a moving laser in a DEM simulation, revealing the relations between single scan line dimensions and printer settings.</p