Understanding effects of printhead geometry in aerosol jet printing

Tafoya, Rebecca R.; Secor, Ethan B.

doi:10.1088/2058-8585/aba2bb

Understanding effects of printhead geometry in aerosol jet printing

Journal Article · Thu Jul 30 00:00:00 EDT 2020 · Flexible and Printed Electronics

DOI:https://doi.org/10.1088/2058-8585/aba2bb· OSTI ID:1670198

Tafoya, Rebecca R. ^[1]; ^[1]

Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)

Aerosol jet printing offers a versatile, high-resolution digital patterning capability broadly relevant to flexible and printed electronic systems. Despite its promise and numerous demonstrations, the theoretical principles driving process outputs have not been thoroughly explored. In this study, a custom-built, modular printing system is developed to provide a head-to-head comparison of two print nozzle geometries to better understand the technology. Print resolution data from a range of process parameters are analyzed using a support vector machine framework. The linear deposition rate is identified as a key variable, which can confound careful studies of printing performance. Taking this into account, a clear difference is observed between the printheads, corresponding to a difference in resolution of 57% ± 11% under typical conditions. Models to understand differences in aerodynamic and mass transport effects identify enhanced drying within the NanoJet printhead as a likely cause of this difference. Overall, this study provides improved understanding of the aerosol jet printing process, including valuable insight to inform process optimization, robust data analysis, ink formulation, and printer geometric design.

View Accepted Manuscript (DOE)

Research Organization:: Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States)

Sponsoring Organization:: USDOE National Nuclear Security Administration (NNSA); USDOE Laboratory Directed Research and Development (LDRD) Program

Grant/Contract Number:: AC04-94AL85000; NA0003525

OSTI ID:: 1670198

Alternate ID(s):: OSTI ID: 1644221

Report Number(s):: SAND--2020-7066J; 687267

Journal Information:: Flexible and Printed Electronics, Journal Name: Flexible and Printed Electronics Journal Issue: 3 Vol. 5; ISSN 2058-8585

Publisher:: IOPscienceCopyright Statement

Country of Publication:: United States

Language:: English

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Understanding effects of printhead geometry in aerosol jet printing

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