Low-Cost, Efficient, Photolithography-Free Fabrication of Stretchable Electronics Systems on a Vinyl Cutter

We present a new way for the fabrication of stretchable electronics systems without photolithography procedures by exploiting the through-cut, tunnel-cut, and blind-cut modes of a commercial desktop-size vinyl cutter. Compared to previous studies involving photolithography, our method produces a batch of representative devices in significantly reduced time (by ~69%) and cost (by ~73%) with similar feature sizes (100-1000μm). Our inclusion of blind-cut and tunnel-cut modes facilitates the fabrication of complex stretchable electronics systems, rather than only electrodes and interconnects. Finally, we demonstrate the capacities of our photolithography-free fabrication via a stretchable temperature-mapping patch and flexible functional electronic components.