Reverse-Offset Printing for Fabricating E-Textiles

Abstract

Printing electronics directly onto fabric to create e-textiles is a promising technology, but it is currently limited by the achievable printing resolution. The suitability of a bespoke reverse-offset printing system for use in printed e-textile devices has been explored because of the higher resolution it can achieve compared with alternatives such as screen printing, while still being scalable due to its roll-to-roll nature. The process has successfully achieved high-resolution patterns, as fine as 30 microns, on flexible polymer substrates suitable for lamination onto textiles and printing directly onto coated fabrics. The printing system comprises a gantry stage with a PDMS-coated roller and a base section that holds the cliché (patterned plate) and substrate. The system is controlled using LabVIEW software to ensure precise synchronization of the linear-stage movement and roller rotation. The results demonstrated a significant improvement in printing resolution compared to conventional methods such as screen and inkjet printing. This work showcases the potential of reverse-offset printing for fabricating advanced electronic devices on flexible substrates, creating new possibilities in the field of wearable technology.