Deconvoluting sources of variability in aerosol jet printing using light scattering measurements

Rurup, Jeremy D.; Bui, Duy L.; Secor, Ethan B.

doi:10.1088/2058-8585/ae0049

Deconvoluting sources of variability in aerosol jet printing using light scattering measurements

Journal Article · Wed Sep 10 00:00:00 EDT 2025 · Flexible and Printed Electronics

DOI:https://doi.org/10.1088/2058-8585/ae0049· OSTI ID:2998396

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Iowa State Univ., Ames, IA (United States)

Aerosol jet printing (AJP) is a digital additive manufacturing technique for hybrid and conformal electronics, where its contactless deposition readily enables patterning over 3D surface topography. However, the complexity of aerosol transport physics makes deposition rate sensitive to process variability, hindering widespread industry adoption. Light scattering measurements have recently been demonstrated as a capable tool for measuring deposition rate in real time, enabling closed-loop control and in-situ qualification frameworks. These inline optical measurements present further opportunity as a diagnostic tool to understand the effects of secondary process parameters affecting vapor–liquid equilibrium and heat and mass transport during deposition. Downstream of the optical measurement cell, changing the sheath gas flow rate, increasing temperature via an inline heater, and adding solvent vapor via a sheath gas bubbler were observed to alter drying physics during sheath-collimation, and thereby impaction efficiency. Further upstream, the introduction of solvent vapor via a carrier gas bubbler and liquid build-up in the printhead were seen to affect the quantitative relationship between the light scattering data and the true deposition rate. Using this information, tightened controls of meaningful secondary parameters were implemented to improve the batch-to-batch consistency for printing a dielectric ink. In addition to advancing AJP process reliability for production, this work demonstrates the capability of inline optical measurements to provide insight into process physics and deconvolute competing mechanisms that underly variability.

View Accepted Manuscript (DOE)

Research Organization:: Kansas City Plant (KCP), Kansas City, MO (United States)

Sponsoring Organization:: National Science Foundation (NSF); US Air Force Office of Scientific Research (AFOSR); USDOE National Nuclear Security Administration (NNSA)

Grant/Contract Number:: NA0002839

OSTI ID:: 2998396

Journal Information:: Flexible and Printed Electronics, Journal Name: Flexible and Printed Electronics Journal Issue: 3 Vol. 10; ISSN 2058-8585

Publisher:: IOP PublishingCopyright Statement

Country of Publication:: United States

Language:: English

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Deconvoluting sources of variability in aerosol jet printing using light scattering measurements

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