High resolution, high conductivity components by aerosol jet printing
Highly conductive electrical traces formed over mechanical steps or on non-planar surfaces with linewidths of 10 to 100 μm and a method for forming such electrical traces are disclosed. The method employs two steps, with the first step using an aerosol jet printing (AJP) process to form thin electrical traces that serve as the seed layers for the second step. The first step preferably employs multiple passes with the AJP to create multiple seed sub-layers with improved continuity and conductivity. In the second step, the seed layers are subjected to an electrodeposition process that forms the bulk of the thickness of the electrical traces. The electrodeposition process may include one, two, or three phases at corresponding low or high biases, with low biases providing denser, more highly conductive plating sub-layers, while high biases provide plating sub-layers having better gap bridging properties.
- Research Organization:
- Sandia National Laboratories (SNL-NM), Albuquerque, NM (United States); UNM Rainforest Innovations, Albuquerque, NM (United States)
- Sponsoring Organization:
- USDOE National Nuclear Security Administration (NNSA)
- DOE Contract Number:
- NA0003525
- Assignee:
- National Technology & Engineering Solutions of Sandia, LLC (Albuquerque, NM); UNM RAINFOREST INNOVATIONS (Albuquerque, NM)
- Patent Number(s):
- 11,825,609
- Application Number:
- 17/196,492
- OSTI ID:
- 2293897
- Country of Publication:
- United States
- Language:
- English
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