Researchers Develop New Method for Ultra-Thin Printed Circuits

Research on Printed Electronics Researchers Develop New Method for Ultra-Thin Printed Circuits

2025-12-01 Source: Press release Susanne Braun | Translated by AI 2 min Reading Time

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In the summer of 2025, a Japanese research team introduced a printing technology that produces conductive metal layers in a single step without nanoparticles, without high-temperature sintering, and for the first time in a uniform structure only a few nanometers thick.

Researchers use a single-phase reaction of metal ions and an organic compound to produce conductive, well-organized colloidal coordination nanolayers.(Image: Tokyo University of Science) — Researchers use a single-phase reaction of metal ions and an organic compound to produce conductive, well-organized colloidal coordination nanolayers.
(Image: Tokyo University of Science)

Printed conductive traces have been a standard in electronics manufacturing for years. Typically, silver or copper nanoparticle inks are used, which are printed onto foils or flexible substrates and then heated to allow the particles to "fuse" (sinter) into a conductive layer. This process is complex, energy-intensive, and significantly limits the choice of substrate materials. At the same time, the resulting layers are usually relatively thick, porous, and mechanically limited in their durability.

The sequential synthesis mechanism using colloidal solutions of metal ions such as nickel (Ni), copper (Cu), and zinc (Zn) together with a benzenehexathiol (BHT) solution can selectively produce highly conductive coordination nanolayers, while the overall reaction remains confined to a single phase.(Image: Professor Hiroshi Nishihara from Tokyo University of Science, Japan) — The sequential synthesis mechanism using colloidal solutions of metal ions such as nickel (Ni), copper (Cu), and zinc (Zn) together with a benzenehexathiol (BHT) solution can selectively produce highly conductive coordination nanolayers, while the overall reaction remains confined to a single phase.
(Image: Professor Hiroshi Nishihara from Tokyo University of Science, Japan)

Researchers from the Tokyo University of Science presented an approach in summer 2025 that overcomes these known hurdles. The paper "Rationally Engineered Heterometallic Metalladithiolene Coordination Nanosheets with Defined Atomic Arrangements" was published in a journal from the Small series. Instead of particles, the researchers use a metal-organic liquid that independently forms a cohesive, extremely thin metal layer during printing. The layer is only a few nanometers thick, smooth, uniform, and directly conductive without requiring additional processing steps.

The difference from conventional printed electronics: while traditional inks consist of many small metal particles, this approach creates 2D-like, continuous metal layers, comparable to an atomically thin coating. The approach uses a metal-organic liquid made from so-called metalladithiolene compounds. These molecules arrange themselves into a smooth, nanometer-thin 2D metal film as they dry—without particles or thermal post-processing. This not only enables new geometries but also significantly better electrical quality, especially for high-frequency or sensor applications.

The method is still in the research stage, but the approach clearly shows that printed electronics are evolving from nanoparticle-filled inks to directly printable metal nanosheets. For the industry, this could represent a technological leap, making printed electronics simpler, faster, and more cost-effective. For industrial users, the technology promises fewer process steps, lower energy requirements, and greater design freedom. Even sustainable substrates like paper or bio-based films could benefit, as a high-temperature process is no longer necessary. (sb)

Cross-section: The sectional view shows what the substrates look like inside. Fill materials, such as in Rogers RO4730G3, are adjusted so that they do not alter the properties of the antennas. (Image:Rogers Corporation)

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Date: 08.12.2025

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