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Abstract Resistors are basic yet essential circuit components that must be fabricated with high precision at low cost if they are to be viable for flexible electronic applications. Inkjet printing is one of many additive fabrication techniques utilized to realize this goal. In this work, a process termed self-aligned capillarity-assisted lithography for electronics (SCALE) was used to fabricate inkjet-printed resistors on flexible substrates. Capillary channels and reservoirs imprinted onto flexible substrates enabled precise control of resistor geometry and straightforward alignment of materials. More than 300 devices were fabricated using poly(3,4-ethylene dioxythiophene):poly(styrene sulfonate) (PEDOT:PSS) as the resistive material and silver as the electrode material. By varying PEDOT:PSS ink formulation and resistor geometry, resistances spanning from 170 Ω to 3.8 MΩ were achieved. Over 98% of devices were functional and the relative standard deviation in resistance ranged from 3% to 18% depending on resistor length and ink composition. The resistors showed no significant change in resistance after 10 000 cycles of bend testing at 1.6% surface tensile strain. In summary, this work demonstrated a fully roll-to-roll compatible process for inkjet printing resistors with superior properties. 

Abstract Capillary flow is the spontaneous wicking of liquids in narrow spaces without the assistance of external forces. Examples of capillary flow can be found in numerous applications ranging from controlling and transporting fuel in spacecrafts to printed electronics manufacturing. Open rectangular microchannels often appear in these applications, with the lack of a top resulting in a complex free-surface morphology and evaporation. Here, we present a brief overview of this topic and discuss some recent advances. 

Capillary flow of liquids plays a key role in many applications including lab-on-a-chip devices, heat pipes and printed electronics manufacturing. Open rectangular microchannels often appear in these applications, with the lack of a top resulting in a complex free-surface morphology and evaporation. In this work we develop a theoretical model based on lubrication theory and kinetically limited evaporation to examine capillary flow of evaporating liquid solutions in open rectangular microchannels connected to circular reservoirs. The model accounts for the complex free-surface morphology, solvent evaporation, Marangoni flows due to gradients in solute concentration and temperature and finite-size reservoir effects. Significant differences are predicted in flow behaviour between pure liquids and liquid solutions due to solvent evaporation and solute transport. Marangoni flows are found to promote more uniform solute deposition patterns after solvent evaporation. Model predictions of meniscus position evolution are in good agreement with prior capillary-flow experiments of aqueous poly(vinyl alcohol) solutions in the presence of evaporation. The model reveals that the principal mechanism through which evaporation influences the meniscus position in the experiments is the increase in viscosity with solute concentration.