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Constructing precise micro-nano metal patterns on complex three-dimensional(3D) plastic parts allows the fabrication of functional devices for advancedapplications. However, this patterning is currently expensive and requirescomplex processes with long manufacturing lead time. The present workdemonstrates a process for the fabrication of micro-nano 3D metal-plasticcomposite structures with arbitrarily complex shapes. In this approach, alight-cured resin is modified to prepare an active precursor capable ofallowing subsequent electroless plating (ELP). A multi-material digital lightprocessing 3D printer was newly developed to enable the fabrication of partscontaining regions made of either standard resin or active precursor resinnested within each other. Selective 3D ELP processing of such parts providedvarious metal-plastic composite parts having complicated hollow micro-nanostructures with specific topological relationships on a size scale as small as40 um. Using this technique, 3D metal topologies that cannot be manufactured bytraditional methods are possible, and metal patterns can be produced insideplastic parts as a means of further miniaturizing electronic devices. Theproposed method can also generate metal coatings exhibiting improved adhesionof metal to plastic substrate. Based on this technique, several sensorscomposed of different functional nonmetallic materials and specific metalpatterns were designed and fabricated. The present results demonstrate theviability of the proposed method and suggest potential applications in thefields of smart 3D micro-nano electronics, 3D wearable devices,micro/nano-sensors, and health care.

New metal-plastic hybrid additive manufacturing strategy: Fabrication of  arbitrary metal-patterns on external and even internal surfaces of 3D plastic  structures