Finite Element Analysis of Liquid Droplet Stamp Contact Mechanics for Thin-Film Integration
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Transfer printing technology is a cornerstone for enabling the heterogeneous integration of thin films onto flexible substrates in advanced flexible electronics. Liquid-phase stamps have garnered attention as a viable alternative, addressing the inherent limitations of conventional elastomeric stamps, which often induce significant mechanical damage to delicate thin-film devices due to excessive contact forces. Nevertheless, the intrinsic fluidity of liquid droplets introduces substantial complexity to the interfacial mechanics during the contact process. While numerous theoretical models exist to describe the adhesion mechanisms of various interfaces, finite element analysis (FEA) with fluid–structure interaction (FSI) modeling offers significant advantages for analyzing complex contact mechanics scenarios. In this study, based on fluid structure interaction (FSI) theory, FEA was employed to simulate the contact process of thin-film devices in liquid stamp transfer printing. The simulated transverse and longitudinal stress-strain responses of the thin-film devices under applied strains were analysed, confirming that the process does not cause device rupture or damage. Additionally, key parameters such as surface tension, categories of materials, and radius were varied in the simulations, providing direct theoretical insights and a scientific foundation for the optimization of liquid stamps. Furthermore, a comparison with elastomer stamps demonstrated that liquid stamps exhibit superior resistance to the destruction of thin-film devices during the contacting process.
