The future of DLP-printed flexible devices

Flexible devices play a central role in next-generation technologies, from health monitoring to soft robotics. However, conventional manufacturing methods such as casting and lithography often fall short—they are costly, time-consuming, and struggle with design complexity and multifunctionality. Moreover, traditional materials like rigid polymers and non-stretchable conductors compromise both comfort and durability.

As demands rise for smarter, adaptable electronics, the need for a more scalable and environmentally responsible fabrication method becomes urgent. In response, researchers are increasingly turning to advanced 3D printing technologies like digital light processing (DLP), which offer high precision, material versatility, and speed, making them ideal for producing flexible, high-performance devices tailored for dynamic applications.

In a compelling review featured in Microsystems & Nanoengineering, scientists from the University of Macau and Hong Kong University of Science and Technology (Guangzhou) explore the cutting-edge role of DLP 3D printing in the field of flexible devices.

Highlighting innovations in soft actuators, sensors, and energy systems, the study delves into how this technology—enabled by grayscale control, multi-material printing, and new printable materials—allows engineers to fine-tune the mechanical and conductive properties of printed devices. Their findings underscore DLP’s transformative potential for wearables, implants, and sustainable smart systems.

The review outlines how DLP 3D printing achieves unprecedented capabilities in flexible devices by addressing core challenges in resolution, speed, and material integration. With printing resolutions reaching down to 1 μm, DLP enables intricate geometries such as porous sensor arrays and compact energy-harvesting structures—faster and more precisely than traditional methods.

Material breakthroughs include self-healing hydrogels, conductive liquid metals, and biodegradable elastomers, dramatically enhancing flexibility and environmental compatibility.

The integration of DLP with other techniques has led to the creation of complex devices like liquid crystal elastomer actuators, capable of programmable deformation and load-bearing functions. Grayscale DLP printing further allows for spatially tunable stiffness within a single structure, enabling pneumatic actuators that twist or bend as needed.

In sensing, the review features dome-shaped ionogel capacitive sensors with ultra-high sensitivity (15.1 kPa⁻¹) and fatigue-resistant rotaxane hydrogel-based strain sensors. For energy applications, innovations include biomimetic triboelectric nanogenerators that harvest kinetic energy with improved efficiency and supercapacitors with 3D-customized internal architectures for better storage.

Collectively, these advances showcase DLP’s ability to seamlessly integrate materials science and structural engineering, offering a new design paradigm for multifunctional, miniaturized electronics.

According to senior 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.”

Looking ahead, DLP-printed flexible devices are expected to revolutionize sectors from health care to robotics. In medicine, they could enable skin-conforming sensors for continuous health tracking or soft actuators for delicate surgical interventions. Robotics will benefit from integrated sensor-actuator systems that mimic biological movements and respond intelligently to stimuli.

Energy innovations, like personalized supercapacitors or motion-powered generators, promise to enhance mobile and wearable tech. Importantly, the use of recyclable hydrogels and biodegradable materials supports greener electronics and reduces waste.

While scaling up production and material standardization remain ongoing challenges, DLP’s flexibility and accessibility make it a vital tool for accelerating innovation in both academic and industrial R&D environments.