Flexible and wearable electronics, which require stable operation under mechanical deformation, are increasingly utilizing Eutectic Gallium-Indium (EGaIn) for their conductive components. This study presents a systematic approach to fabricating highly reliable, deformable electrodes via a direct-ink-writing (DIW) 3D printing process using EGaIn as the functional ink. We conducted a thorough optimization of key printing parameters, specifically the extrusion pressure and printing speed, to achieve stable and uniform conductive lines. Through this optimization, we successfully established an optimal process window, achieving a stable line width of approximately 130 μm at an extrusion pressure of 300 kPa and a printing speed of 16 mm/s. The fabricated flexible electrodes exhibited exceptional electromechanical stability, maintaining negligible resistance change (< 0.82%) both under severe bending (3 mm radius) and after 100 repetitive bending cycles. This work demonstrates that the 3D printing of EGaIn is a viable and effective method for creating robust, high-performance electrodes for the next generation of deformable and wearable electronic devices.

Micro light-emitting diodes (μLEDs) have been utilized in various fields such as displays, and smart devices, due to their superior stabilities. Since the applications of the μLEDs have been extended to medical devices and wearable sensors, excellent optical properties and uniformity of the μLEDs are important. Hence, several researchers have investigated to enhance the optical efficiency of the μLEDs through micro/nano lens. However, the reported methods for realizing the micro/nano lens have some drawbacks such as complex and high-cost manufacturing processes. Herein, we developed μLEDs with 3D-printed hydrogel microlenses. The printed hydrogel had high transparency and excellent adhesive strength, allowing it to attach onto top surface of the μLEDs without any additional adhesives. Microscale printing technology using a 3D printer achieved quick and fine printing in desired shapes and arrangements, showing the possibility of mass production. The 3D-printed microlens can be applied to improve not only the optical properties of μLEDs but also other optical devices.