Transfer printing and patterning of stretchable electrospun film

• Stretchable nonwoven film with small-scale wavy fibers is fabricated.
• The film is transferred and patterned by thermal detachment lithography.
• The patterned film is validated with high stretchability.

Electrospinning is an effective method for nanofiber production, but seldom used in the fabrication of patterned structures directly due to the whipping instability of the electrospinning jet. The whipping instability of electrospinning is adopted to fabricate stretchable patterned film by combination with an improved thermal transfer printing. The electrospun film is composed of small-scale wavy/coiled fibers, which make the patterned film highly stretchable. The optimal process parameters of whipping-based electrospinning are investigated to fabricate electrospun film with uniform and compact wavy/coiled fiber. Then the transfer printing and thermal detachment lithography are studied to generate patterned film, including the pressure, temperature, and peeling-off speed. Finally, the stretchability of the patterned electrospun film is studied through experiment and finite element analysis. It may open a cost-effective and high-throughput way for flexible/stretchable electronics fabrication.