Rethinking the need for ultra-high stretchability in stretchable electronics

Abstract

Stretchable electronics have progressed rapidly, with many academic prototypes frequently demonstrating elongations exceeding 100%. However, in practical applications such as healthcare and industry, mechanical strains are typically far lower. In medical wearables, skin and internal tissues experience only modest deformations during normal activity, while industrial systems ranging from manufacturing sensors to automotive components and Soft robotics operate under mild bending, vibration, or thermal expansion with strain requirements usually below 50%. While some studies report ultra-high stretch ratios, these often exceed the strain demands of real-world use and may introduce trade-offs in electronic performance, durability, signal stability, and fabrication complexity. In this review, we analyze the disparity between laboratory benchmarks and real-world strain demands in both biomedical and industrial contexts, highlight the hidden costs of ultra-stretchable designs at the material and system levels, and propose a refocused, application-driven design philosophy. By targeting sufficient mechanical compliance rather than maximal elongation, combined with enhanced conformability, environmental resilience, and integration strategies, the future of stretchable electronics can achieve practical impact.