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

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.