3D-Printed Arch-Structured Tribolayer with Conducting Polymer Coating for Enhanced Triboelectric Energy Harvesting

Three-dimensional printed (3DP) triboelectric nanogenerators (TENGs) provide a versatile approach for complex and customizable microstructures tailored for efficient energy harvesting and sensing. Here, we demonstrate the fabrication of flexible microstructured TENGs produced via stereolithography 3D printing and subsequently coated with a conducting polymer, PEDOT:PSS (P:P). Three geometries are investigated: pillars, pyramids, and arches, with the arch configuration emerging as a new design combining enhanced mechanical adaptability and improved triboelectric performance. The arch-shaped TENGs exhibit superior flexibility, structural stability, and a high active surface area, which collectively facilitate efficient energy conversion under repetitive deformation. Furthermore, the incorporation of P:P coating substantially enhances performance, resulting in a more than twentyfold increase in voltage output compared to uncoated counterparts. Among the 3DP structures, the arch geometry consistently delivers better performance, confirming the geometry-driven performance of 3DP-TENGs. The optimized arch configuration is found to yield a peak voltage output of ∼101 V, corresponding to a maximum power output of ∼193.6 mW/m². By exploiting the spring-like behavior of the arch-shaped tribolayer, a “zero-gap” TENG architecture is presented, offering a compact and adaptable energy-harvesting platform as well as pressure-sensing capabilities. Finally, a wireless pressure-sensing platform configured as a vehicle parking counter is demonstrated, showcasing the potential of this development for integration into smart infrastructure and environmental monitoring systems.