Sustainable bioplastics as durable cast film substrates for printed electronics, digital printing, and biosensor applications

The increasing integration of digital printing technologies in printed electronics and biosensor fabrication has intensified the demand for sustainable polymer substrates that combine environmental compatibility with high mechanical durability, dimensional stability, and printability. Poly(lactic acid) (PLA), as a renewable, compostable, and non-toxic biopolymer, represents an attractive alternative to conventional fossil-based substrates commonly used in printed electronic systems. However, the limited resistance to thermo-mechanical stresses of PLA significantly restricts its applicability in digitally printed electronics and disposable biosensor platforms, where repeated handling, deformation, and processing stability are critical.

In this study, neat PLA and PLA-based copolyester cast film sheets was developed and subsequently biaxially stretched to induce molecular orientation via strain-induced crystallization. This approach was employed to enhance the mechanical toughness, dimensional stability, and durability of the films under conditions relevant to digital printing and biosensor integration. The results demonstrated that biaxial orientation improved the durability of PLA-based cast films, enabling their use as sustainable substrates for digitally printed conductive patterns, electronic components, and biosensing platforms. Thus, this work provides a viable pathway toward environmentally friendly substrates suitable for next-generation printed electronics and disposable biosensors, specifically for cost-effective glucose biosensors.

Acknowledgements

Funded by the European Union under the GA no 101070556. Views and opinions expressed are however those of the author(s) only and do not necessarily reflect those of the European Union or RIA. Neither the European Union nor the granting authority can be held responsible for them.