Mechanically programmable substrate enable highly stretchable solar cell arrays for self-powered electronic skin

Development of stretchable solar cells to accommodate large strain without sacrificing the power conversion efficiency is challenging. This study presents a novel approach to manufacture highly stretchable solar cell arrays, which can be integrated into wearable medical devices to operate under challenging environments. Overcoming the limitations of rigid metal wires, liquid metal wires are employed to connect single crystal silicon solar cells, ensuring both high conversion efficiency and exceptional stretchability (up to 100%). The manufacturing process introduces embedding electrospinning films into elastic silicone substrates to create a tight bond between rigid solar cells and stretchable substrates with programmable strain capabilities. Notably, a stretchable interconnect wire is efficiently fabricated using the semi-liquid metal template printing technique and demonstrates remarkable conductivity (up to 6 × 10⁶ S/m). Individual structural unit of solar cell presents an impressive tensile rate of 200%, and endures up to 5000 cycles of tensile testing. The overall solar cell array exhibits outstanding adaptability to extensive bending and twisting, with a mere 0.1% short-circuit current reduction in its maximum stretched state. The stretchable photovoltaic device is successfully employed in creating self-powered electronic skin for continuous real-time monitoring of parameters, showcasing its valuable potential in wearable medical electronic devices and comprehensive sports health monitoring.