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Abstract The electronics industry is rapidly advancing toward the development of highly miniaturized sensors and circuits, driving an increasing demand for precise, localized manufacturing techniques. Extrusion-based additive manufacturing—particularly direct ink writing—has emerged as a promising method for fabricating microscale electronic components. Recent efforts have focused on producing fine-resolution structures capable of conformal deposition on complex or uneven surfaces. While prior studies have established theoretical models for the trajectory of non-conductive material jets under electric fields—demonstrating feasibility in printing high-resolution features—a theoretical framework for conductive ink behavior under similar conditions remains lacking. This study introduces a theoretical model to describe the behavior of conductive jet extrusion under varying electrostatic forces. The model is validated through high-speed physical and manufacturing experiments using poly(3,4-ethylene-dioxythiophene)-based ink. The results demonstrate that the application of an external electric field significantly broadens the printable window, enabling: (i) high-speed printing up to 1.7 m/s with successful deposition on rough textile substrates (average surface roughness Ra = 8 µm), and (ii) the formation of micro-sized lines with widths as small as ∼60% of the nozzle's inner diameter (e.g., 300 µm-wide lines printed using a 500 µm diameter nozzle). 

Abstract This work investigates the application of poly(3,4‐ethylenedioxythiophene) polystyrenesulfonate (PEDOT:PSS) with polyethylene oxide (PEO) in lithium batteries (LIBs). This composite film comprising PEDOT:PSS and PEO was 3D printed onto a carbon nanofiber (CNF) substrate to serve as a layer between the polypropylene (PP) separator and the lithium anode in LIBs. The resulting CNF‐PEDOT:PSS‐PEO film exhibited superior mechanical and thermal properties compared to conventional PP separators. Mechanical tests revealed a high Young's modulus and puncture strength for the composite film. Thermal stability tests indicated that the CNF‐PEDOT:PSS‐PEO film remained stable at higher temperatures compared to the commercial PP separator, and combustion tests confirmed its superior fire‐resistance properties. In terms of conductivity, the composite film maintained comparable ionic conductivity to the commercial PP separator. Electrochemical tests demonstrated that LIBs incorporating the CNF‐PEDOT:PSS‐PEO film exhibited slight improvement in cycling performance, with a 7.9 % increase in long‐term cycling capacity compared to LIBs using only the commercial PP separator. These findings indicate that the developed CNF‐PEDOT:PSS‐PEO composite film holds promise to improve safety, while maintaining the electrochemical performance of LIBs by reducing dendrite formation and enhancing thermal stability.