Wireless electronic devices require small, rechargeable batteries that can be rapidly designed and fabricated in customized form factors for shape conformable integration. Here, we demonstrate an integrated design and manufacturing method for aqueous zinc-ion batteries composed of polyaniline (PANI)-coated carbon fiber (PANI/CF) cathodes, laser micromachined zinc (Zn) anodes, and porous separators that are packaged within three-dimensional printed geometries, including rectangular, cylindrical, H-, and ring-shapes. The PANI/CF cathode possesses high surface area and conductivity giving rise to high rate (∼600 C) performance. Due to outstanding stability of Zn-PANI batteries against oxygen and moisture, they exhibit long cycling stability in an aqueous electrolyte solution. As exemplar, we demonstrated rechargeable battery packs with tunable voltage and capacity using stacked electrodes that are integrated with electronic components in customized wearable devices.

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Recently, various functional devices based on printing technologies have been of paramount interest, owing to their characteristic processing advantages along with excellent device performance. In particular, printable metallic electrodes have drawn attention in a variety of optoelectronic applications; however, research into printable metallic nanoparticles has been limited mainly to the case of an environmentally stable Ag phase. Despite its earth-abundance and highly conductive nature, the Cu phase, to date, has not been exploited as an ambient atmosphere-processable, printable material due to its critical oxidation problem in air. In this study, we demonstrate a facile route for generating highly conductive, flexible Cu electrodes in air by introducing the well-optimized photonic sintering at a time frame of 10(-3) s, at which the photon energy, rather than conventional thermal energy, is instantly provided. It is elucidated here how the surface oxide-free, printed Cu particulate films undergo chemical structural/microstructural evolution depending on the instantly irradiated photon energy, and a successful demonstration is provided of large-area, flexible, printed Cu conductors on various substrates, including polyimide (PI), polyethersulfone (PES), polyethylene terephthalate (PET), and paper. The applicability of the resulting printed Cu electrodes is evaluated via implementation into both flexible capacitor devices and indium-gallium-zinc oxide (IGZO) flexible thin-film transistors.

Highly flexible, rollable, printable Ag conductive features are generated on PET and paper substrates through instant continuous photonic sintering for olate-terminated Ag nanoparticles.