Phase-separated porous nanocomposite with ultralow percolation threshold for wireless bioelectronics

Realizing the full potential of stretchable bioelectronics in wearables, biomedical implants and soft robotics necessitates conductive elastic composites that are intrinsically soft, highly conductive and strain resilient. However, existing composites usually compromise electrical durability and performance due to disrupted conductive paths under strain and rely heavily on a high content of conductive filler. Here we present an in situ phase-separation method that facilitates microscale silver nanowire assembly and creates self-organized percolation networks on pore surfaces. The resultant nanocomposites are highly conductive, strain insensitive and fatigue tolerant, while minimizing filler usage. Their resilience is rooted in multiscale porous polymer matrices that dissipate stress and rigid conductive fillers adapting to strain-induced geometry changes. Notably, the presence of porous microstructures reduces the percolation threshold (Vc = 0.00062) by 48-fold and suppresses electrical degradation even under strains exceeding 600%. Theoretical calculations yield results that are quantitatively consistent with experimental findings. By pairing these nanocomposites with near-field communication technologies, we have demonstrated stretchable wireless power and data transmission solutions that are ideal for both skin-interfaced and implanted bioelectronics. The systems enable battery-free wireless powering and sensing of a range of sweat biomarkers—with less than 10% performance variation even at 50% strain. Ultimately, our strategy offers expansive material options for diverse applications. ; © The Author(s), under exclusive licence to Springer Nature Limited 2024. ; Z. Yan acknowledges financial support from the start-up fund of the University of Missouri-Columbia. Z. Yan, P.-Y.C. and J.X. acknowledge the National Institute of Biomedical Imaging and Bioengineering (award number R01EB033371). The human study was supported by Z. Yan’s start-up fund. W.G. acknowledges support from National Institutes of Health ...