Topology Optimization of Stretchable Conductive Structures for High‐Performance Flexible Electronics

ABSTRACT Stretchable conductive structures are essential components to provide compliance with deformation in flexible electronics. They are conventionally designed using empirical methods that adopt serpentine, meander, or fractal shapes, which enable quick prototyping but have limitations in mechanical and electrical performance under strict layout and boundary constraints. In µLED testing, topology optimization (TO) is a target‐oriented design approach that determines the optimal material distribution within the design domain and can better adapt to boundary conditions and objectives. Here, we propose a TO method for designing stretchable conductive structures. TO generates a structure with at least 15% stretchability in an 80 µm square area, meeting additional design constraints. The topology‐optimized structure exhibits an internal average stress of 134.32 MPa at 30% deformation and maintains fatigue performance for more than 5000 cycles, significantly outperforming empirically designed counterparts. These results demonstrate the great potential of TO to assist or replace empirical design in flexible electronics. filling a vital technical gap in high‐density and 3D terrain compatibility is simultaneously limited.