Stretchable thin-film metal structures on a stimuli-responsive polymer nanocomposite for mechanically-dynamic microsystems

Long-term reliability of mechanically-flexible microsystems requires that all components of the device subjected to flexing, twisting, and stretching can withstand this motion. A pre-straining method has been developed to use the dynamic mechanical behavior and shape memory-like characteristics of a stimuli-responsive polymer nanocomposite to form stretchable thin-film metal traces on the material surface. Samples recovered up to 23% of the applied pre-strain after exposure to temperatures above the glass transition temperature of the polymer nanocomposite. This fabrication technique produced metal structures with metal traces that could be strained up to 21% without losing continuity.