Production of Flexible Transparent Conducting Films of Self‐Fused Nanowires via One‐Step Supersonic Spraying

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Scalable and economical manufacturing of flexible transparent conducting films (TCF) is a key barrier to widespread adoption of low‐cost flexible electronics. Here, a simple, robust, and scalable method of flexible TCF formation using supersonic kinetic spraying is demonstrated. Silver nanowire (AgNW) suspensions are sprayed at supersonic speed to produce self‐sintered films of AgNWs on flexible substrates. These films display remarkably low sheet resistance, <10 Ω sq−1, combined with high transmittance, >90%. These electrically conducting, transparent, and flexible coatings can be deposited over a 100 cm2 area in ≈30 s. Theoretical analysis reveals the underlying physical mechanism behind self‐sintering, showing that self‐sintering is enabled by the high velocity of impact in supersonic spraying.