Sequential-Photocuring-Assisted Transformation of Planar Multilayer Structures into Curved Geometries

Abstract

The integration of functional electronic structures into curved geometries remains challenging, as conventional approaches rely on post-shaping or adhesive-assisted assembly that separate structure formation from shape definition. Here, we present a sequential-photocuring-assisted fabrication strategy that transforms planar multilayer structures into curved forms within a single material system. A wavelength-selective acrylate–epoxy resin is designed to create a deformable intermediate state under visible light, followed by a fixation-enabled final state through UV-triggered curing. A gradient-like curing strategy, involving time-dependent evolution of conversion during sequential irradiation, allows controlled partial epoxy conversion and provides both processability and subsequent reactivity. The second curing step induces simultaneous interfacial bonding and structural stiffening, enabling adhesive-free integration and fixation of the mold-imposed geometry. A multilayer patch antenna operating at 28 GHz is fabricated and transformed from planar to curved geometry while maintaining its performance. This approach provides a material-based framework for integrating planar-fabricated structures into three-dimensional form factors without thermoforming or adhesives.