A Multilayer Template Stripping Transfer Printing Method for Engineered Stretchable Electronics

Stretchable electronics require sophisticated fabrication strategies to achieve both high electrical performance and mechanical compliance. While various approaches exist, from geometric designs to composite materials, most face challenges in balancing fabrication complexity with device performance. Here, we present a multilayer template stripping approach for fabricating stretchable conductors. This method combines the precision and scalability of template based fabrication with the simplicity of transfer printing to create engineered microwire networks. Through systematic investigation of geometric parameters, we establish design rules for optimizing mechanical resilience of microwire arrays. We demonstrate both high-performance designs achieving 100% stretchability and robust architectures tolerant to fabrication variations, while maintaining low electrical resistance. The process is compatible with various metals and enables rapid, large area fabrication, offering a practical route toward scalable manufacturing of stretchable conductors.