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This paper presents a new hybrid method for constructing thin, rigid and free-form interconnected surfaces via fused deposition modelling (FDM) 3D printing and vacuum-forming that builds on recent advances in thermoforming circuits. 3D printing the sheet material allows for the embedding of conductive traces within thin layers of the substrate, which can be vacuum-formed but remain conductive and insulated. This is an unexplored fabrication technique within the context of designing and manufacturing connected things. In addition to explaining the method, this paper characterizes the behavior of vacuum-formed 3D printed sheets, analyses the electrical performance of printed traces after vacuum-forming, and showcases a range of sample artefacts constructed using the technique. In addition, the paper describes a new design interface for designing conformal interconnects that allows designers to draw conductive patterns in 3D and export pre-distorted sheet models ready to be printed.<\/jats:p>","DOI":"10.1007\/s42979-022-01174-1","type":"journal-article","created":{"date-parts":[[2022,5,6]],"date-time":"2022-05-06T19:33:09Z","timestamp":1651865589000},"update-policy":"https:\/\/doi.org\/10.1007\/springer_crossmark_policy","source":"Crossref","is-referenced-by-count":19,"title":["Vacuum-Formed 3D Printed Electronics: Fabrication of Thin, Rigid and Free-Form Interactive Surfaces"],"prefix":"10.1007","volume":"3","author":[{"ORCID":"https:\/\/orcid.org\/0000-0002-6318-9723","authenticated-orcid":false,"given":"Freddie","family":"Hong","sequence":"first","affiliation":[],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Luca","family":"Tendera","sequence":"additional","affiliation":[],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"Connor","family":"Myant","sequence":"additional","affiliation":[],"role":[{"role":"author","vocabulary":"crossref"}]},{"given":"David","family":"Boyle","sequence":"additional","affiliation":[],"role":[{"role":"author","vocabulary":"crossref"}]}],"member":"297","published-online":{"date-parts":[[2022,5,6]]},"reference":[{"issue":"2009","key":"1174_CR1","doi-asserted-by":"publisher","first-page":"831","DOI":"10.1007\/s00170-008-1660-9","volume":"42","author":"A Islam","year":"2009","unstructured":"Islam A, Hansen HN, Tang PT, Sun J. 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