Integrated Design and Manufacturing Method of Multi-Physics Coupling for Self-Deforming Electronic Systems

Wearable devices often lose signal stability and show delayed response when the body moves. To solve this problem, we developed a flexible circuit surface that can change its shape during use. The surface bends according to motion and temperature input, using a thin polyimide layer with built-in sensors and a heating trace. In a test with 15 users, the shape-changing version reduced perceived response delay by 23%, and lowered actual signal delay from 28 ms to 23 ms. Contact with the skin was more stable, with shape change staying within ±0.3 mm during repeated movement. All samples were made using common materials and simple steps. These results suggest that surface bending can help wearable systems stay close to the body and send more stable signals. The system worked well in short-term use, but further tests are needed to check comfort and function over longer time.