Printed electronics employ established printing methods to create low-cost, mechanically flexible devices including batteries, supercapacitors, sensors, antennas and RFID tags on plastic, paper and textile substrates. This review focuses on the specific contribution of screen printing to that landscape, examining how ink viscosity, mesh selection and squeegee dynamics govern film uniformity, pattern resolution and ultimately device performance. Recent progress in advanced ink systems is surveyed, highlighting carbon allotropes (graphene, carbon nano-onions, carbon nanotubes, graphite), silver and copper nanostructures, MXene and functional oxides that collectively enhance mechanical robustness, electrical conductivity and radio-frequency behavior. Parallel improvements in substrate engineering such as polyimide, PET, TPU, cellulose and elastomers demonstrate the technique’s capacity to accommodate complex geometries for wearable, medical and industrial applications while supporting environmentally responsible material choices such as water-borne binders and bio-based solvents. By mapping two decades of developments across energy-storage layers and functional electronics, the article identifies the key process elements, recurring challenges and emerging sustainable practices that will guide future optimization of screen-printing materials and protocols for high-performance, customizable and eco-friendly flexible devices.

Inkjet printing enables contactless deposition onto fragile substrates for printed energy-storage devices and supports flexible batteries and supercapacitors with reduced material use. This review examines multilayer and interdigital architectures and analyzes how ink rheology, droplet formation, colloidal interactions, and the printability window govern performance. For batteries, reported inkjet-printed electrodes commonly deliver capacities of ~110–150 mAh g⁻¹ for oxide cathodes at C/2–1 C, with coulombic efficiency ≥98% and stability over 10²–10³ cycles; silicon anodes reach ~1.0–2.0 Ah g⁻¹ with efficiency approaching 99% under stepwise formation. Typical current densities are ~0.5–5 mA cm⁻² depending on areal loading, and multilayer designs with optimized drying and parameter tuning can yield rate and discharge behavior comparable to cast films. For supercapacitors, inkjet-printed microdevices report volumetric capacitances in the mid-hundreds of F cm⁻³, translating to ~9–34 mWh cm⁻³ and ~0.25–0.41 W cm⁻³, with 80–95% retention after 10,000 cycles and coulombic efficiency near 99%. In solid-state configurations, stability is enhanced, although often accompanied by reduced areal capacitance. Although solids loading is lower than in screen printing, precise material placement together with thermal or photonic sintering enables competitive capacity, rate capability, and cycle life while minimizing waste. The review consolidates practical guidance on ink formulation, printability, and defect control and outlines opportunities in greener chemistries, oxidation-resistant metallic systems, and scalable high-throughput printing.

This study presents a multiphysics simulation approach to optimize graphite-buffered bilayer anodes for enhanced energy density in lithium-ion batteries, assessing the electrochemical impact of diverse inner-layer materials, including silicon, hard carbon, lithium titanate (LTO), and metallic lithium, in pure and graphite-composite forms. A coupled finite-element model implemented in COMSOL Multiphysics 6.2 was used to integrate spherical lithium diffusion, charge conservation, and the solid electrolyte interphase (SEI) formation kinetics. The evaluated anode structure consisted of a 60 µm-thick bilayer: a 30 µm graphite surface layer coupled with a 30 µm inner layer of alternative active materials. Simulations were performed using an NMC622 cathode, LiPF₆ in EC:EMC electrolyte, at room temperature, under a charge rate of 1 C, considering realistic particle sizes (graphite: 2.5 µm; Si: 0.1 µm; hard carbon: 2.5 µm; LTO: 0.2 µm; Li metal: 0.5 µm), and evaluated over 2000 cycles. The hard carbon/graphite configuration exhibited a capacity fade of 5.8% compared with 7.1% in pure graphite. Additionally, the SEI thickness decreased to 0.20 µm (from 0.25 µm), the overpotential dropped to −17 mV (from −59 mV), and the electrolyte consumption was reduced to 20.8% (from 42.9%). The analysis highlights hard carbon and LTO inner layers as optimal trade-offs between capacity and cycle stability, whereas silicon and lithium metal significantly increased the initial capacity but accelerated SEI formation and impedance growth. These findings demonstrate the graphite-buffered bilayer’s potential to decouple interfacial degradation from high-capacity materials, providing valuable guidelines for the design of advanced lithium-ion battery anodes.

Flexible printed passive Ultra-High Frequency Radio Frequency Identification (UHF RFID) tag antennas couple electromagnetic design to conductor formation, substrate properties, chip attachment, and the mounting environment. This critical narrative review examines how those dependencies affect manufacturing choices and the strength of device-level evidence. Screen printing, inkjet printing, aerosol jet printing, flexography, and gravure are compared using reported process conditions and explicit gaps in reporting. Passive UHF tags containing an integrated circuit form the principal scope; High-Frequency/Near Field Communication (HF/NFC), chipless, and higher-frequency examples supply supporting process evidence. Given the difficulty of establishing a universal range limit across varying Equivalent Isotropically Radiated Power (EIRP) levels, chip sensitivities, polarizations, and mounting environments, this synthesis carefully categorizes performance metrics into directly measured distances, threshold-based estimates, and simulation-based predictions. Within-study comparisons show that reducing conductor consumption can sacrifice activation margin, while substrate morphology and chip bonding can limit performance even when nominal conductivity is high. Complete-tag scalability requires reproducible inter-connections, post-processing, and durability evidence in addition to successful printing. Environmental conclusions are separated into quantitative life-cycle results and indicators such as lower material use or biodegradability. The resulting framework identifies which design choices are supported by controlled comparisons, and which still require repeated device measurements, application validation, and environmental inventories matched to equivalent service.