Digital Light Processing (DLP) 3D printing is increasingly establishing itself as a key technology for the production of flexible and multifunctional electronic components. In a recent review article published on March 19, 2025 in Microsystems & Nanoengineering, research teams from the University of Macau and the Hong Kong University of Science and Technology (Guangzhou) analyze the use of DLP printing processes for applications in soft robotics, sensor technology and energy conversion.
The authors emphasize that DLP opens up new design freedom for elastic, structured components through high resolution down to the micrometer range, fast exposure times and the possibility of multi-material processing. Grayscale DLP techniques allow locally variable curing, which is used, for example, in the production of pneumatic actuators with differentiated stiffness within a single structure. In addition, the process enables the use of novel materials such as self-healing hydrogel systems, conductive liquid metals and biodegradable elastomers specifically developed for wearable or implantable systems.
A key aspect is the combination of mechanical functionality with electrical conductivity. For example, the researchers describe capacitive ion gel sensors with a high sensitivity of up to 15.1 kPa-¹ or resilient strain sensors based on rotaxane-crosslinked hydrogels. In the energy sector, the study addresses biomimetic triboelectric generators for kinetic energy utilization and supercapacitors with application-specific geometry. These developments show how DLP can act as a manufacturing platform for miniaturized, integrated systems.
According to lead author Dr. Iek Man Lei, “DLP is no longer just a prototyping tool—it’s becoming a foundational platform for next-generation electronics and flexible devices. Its ability to print with both structural precision and material diversity allows us to rethink how devices are designed and deployed.” Co-author Dr Liang Yue adds, “By pushing the boundaries of what’s possible in soft device fabrication, DLP offers an efficient path forward for personalized medical technologies and sustainable smart systems.”
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