While modern products increasingly feature complex three‐dimensional (3D) forms, the fabrication of electronics remains confined to planar substrates. The resulting technological disconnect hinders the seamless integration of electronic functionality onto nonplanar surfaces. Structural electronics aims to address these challenges by embedding functionality into structural components; however, conventional methods face limitations in design freedom, material compatibility, and process complexity. Here, we introduce a robotics‐enabled manufacturing platform that overcomes these barriers through conformal 3D printing of viscoelastic functional inks. Our system utilizes a 6‐degree‐of‐freedom (6‐DOF) robotic arm for high‐dexterity direct ink writing, integrated with 3D scanning for surface profiling. We engineered functional inks for the electrodes and light‐emissive layers to ensure structural integrity on nonplanar topographies after conformal printing. The 6‐DOF robotic system expands the printable workspace and enhances printing fidelity compared with conventional 3‐DOF systems, enabling uniform multilayer printing on sidewalls and even underneath volumetric objects by maintaining the nozzle perpendicularity. As a proof of concept, we demonstrated a fully printed, dynamically controllable 7‐segment digital display on the sidewall of a cylindrical structure. This work represents a significant step toward a future where robots can manufacture fully functional free‐form devices, dramatically enhancing design freedom and eliminating the need for complex assembly processes.
Yoo et al. (Tue,) studied this question.
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