Understanding effects of printhead geometry in aerosol jet printing
Abstract
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.
- Publication Date:
- Research Org.:
- Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
- Sponsoring Org.:
- USDOE National Nuclear Security Administration (NNSA); USDOE Laboratory Directed Research and Development (LDRD) Program
- OSTI Identifier:
- 1670198
- Alternate Identifier(s):
- OSTI ID: 1644221
- Report Number(s):
- SAND-2020-7066J
Journal ID: ISSN 2058-8585; 687267
- Grant/Contract Number:
- AC04-94AL85000; NA-0003525
- Resource Type:
- Accepted Manuscript
- Journal Name:
- Flexible and Printed Electronics
- Additional Journal Information:
- Journal Volume: 5; Journal Issue: 3; Journal ID: ISSN 2058-8585
- Publisher:
- IOPscience
- Country of Publication:
- United States
- Language:
- English
- Subject:
- 42 ENGINEERING; flexible electronics; printed electronics; additive manufacturing; aerosol jet printing
Citation Formats
Tafoya, Rebecca R., and Secor, Ethan B. Understanding effects of printhead geometry in aerosol jet printing. United States: N. p., 2020.
Web. doi:10.1088/2058-8585/aba2bb.
Tafoya, Rebecca R., & Secor, Ethan B. Understanding effects of printhead geometry in aerosol jet printing. United States. https://doi.org/10.1088/2058-8585/aba2bb
Tafoya, Rebecca R., and Secor, Ethan B. Thu .
"Understanding effects of printhead geometry in aerosol jet printing". United States. https://doi.org/10.1088/2058-8585/aba2bb. https://www.osti.gov/servlets/purl/1670198.
@article{osti_1670198,
title = {Understanding effects of printhead geometry in aerosol jet printing},
author = {Tafoya, Rebecca R. and Secor, Ethan B.},
abstractNote = {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.},
doi = {10.1088/2058-8585/aba2bb},
journal = {Flexible and Printed Electronics},
number = 3,
volume = 5,
place = {United States},
year = {Thu Jul 30 00:00:00 EDT 2020},
month = {Thu Jul 30 00:00:00 EDT 2020}
}
Free Publicly Available Full Text
Publisher's Version of Record
Other availability
Search WorldCat to find libraries that may hold this journal
Cited by: 11 works
Citation information provided by
Web of Science
Web of Science
Save to My Library
You must Sign In or Create an Account in order to save documents to your library.
Works referenced in this record:
Aerosol focusing in micro-capillaries: Theory and experiment
journal, August 2008
- Akhatov, I. S.; Hoey, J. M.; Swenson, O. F.
- Journal of Aerosol Science, Vol. 39, Issue 8
Aerosol-Jet-Printed Preferentially Aligned Carbon Nanotube Twin-Lines for Printed Electronics
journal, October 2019
- Goh, Guo Liang; Agarwala, Shweta; Yeong, Wai Yee
- ACS Applied Materials & Interfaces, Vol. 11, Issue 46
Analytical Investigation of Aerosol Jet Printing
journal, August 2014
- Binder, Sebastian; Glatthaar, Markus; Rädlein, Edda
- Aerosol Science and Technology, Vol. 48, Issue 9
Computational Fluid Dynamics Modeling and Online Monitoring of Aerosol Jet Printing Process
journal, October 2016
- Salary, Roozbeh (Ross); Lombardi, Jack P.; Samie Tootooni, M.
- Journal of Manufacturing Science and Engineering, Vol. 139, Issue 2
Online Monitoring of Functional Electrical Properties in Aerosol Jet Printing Additive Manufacturing Process Using Shape-From-Shading Image Analysis
journal, August 2017
- Salary, Roozbeh (Ross); Lombardi, Jack P.; Rao, Prahalad K.
- Journal of Manufacturing Science and Engineering, Vol. 139, Issue 10
Digital Aerosol Jet Printing for the Fabrication of Terahertz Metamaterials
journal, December 2017
- Jahn, David; Eckstein, Ralph; Schneider, Lorenz Maximilian
- Advanced Materials Technologies, Vol. 3, Issue 2
Controlling and assessing the quality of aerosol jet printed features for large area and flexible electronics
journal, February 2017
- Smith, Michael; Choi, Yeon Sik; Boughey, Chess
- Flexible and Printed Electronics, Vol. 2, Issue 1
Quality Modeling of Printed Electronics in Aerosol Jet Printing Based on Microscopic Images
journal, April 2017
- Sun, Hongyue; Wang, Kan; Li, Yifu
- Journal of Manufacturing Science and Engineering, Vol. 139, Issue 7
Aerosol-Jet-Printed Graphene Immunosensor for Label-Free Cytokine Monitoring in Serum
journal, January 2020
- Parate, Kshama; Rangnekar, Sonal V.; Jing, Dapeng
- ACS Applied Materials & Interfaces, Vol. 12, Issue 7
A New Frontier of Printed Electronics: Flexible Hybrid Electronics
journal, April 2020
- Khan, Yasser; Thielens, Arno; Muin, Sifat
- Advanced Materials, Vol. 32, Issue 15
Micro-scale aerosol-jet printing of graphene interconnects
journal, September 2015
- Jabari, Elahe; Toyserkani, Ehsan
- Carbon, Vol. 91
Compositionally Graded Organic–Inorganic Nanocomposites for Enhanced Thermoelectric Performance
journal, October 2019
- Ou, Canlin; Zhang, Lu; Jing, Qingshen
- Advanced Electronic Materials, Vol. 6, Issue 1
Mist flow visualization for round jets in Aerosol Jet ® printing
journal, October 2018
- Feng, James Q.
- Aerosol Science and Technology, Vol. 53, Issue 1
Low-Loss 3-D Multilayer Transmission Lines and Interconnects Fabricated by Additive Manufacturing Technologies
journal, October 2016
- Cai, Fan; Chang, Yung-Hang; Wang, Kan
- IEEE Transactions on Microwave Theory and Techniques, Vol. 64, Issue 10
Optimization of Aerosol Jet Printing for High-Resolution, High-Aspect Ratio Silver Lines
journal, May 2013
- Mahajan, Ankit; Frisbie, C. Daniel; Francis, Lorraine F.
- ACS Applied Materials & Interfaces, Vol. 5, Issue 11
Sessile drop deformations under an impinging jet
journal, June 2015
- Feng, James Q.
- Theoretical and Computational Fluid Dynamics, Vol. 29, Issue 4
Printable Materials for the Realization of High Performance RF Components: Challenges and Opportunities
journal, January 2018
- Rosker, Eva S.; Sandhu, Rajinder; Hester, Jimmy
- International Journal of Antennas and Propagation, Vol. 2018
Printing Flexible and Hybrid Electronics for Human Skin and Eye‐Interfaced Health Monitoring Systems
journal, July 2019
- Kim, Kyunghun; Kim, Bongjoong; Lee, Chi Hwan
- Advanced Materials
A review of aerosol jet printing—a non-traditional hybrid process for micro-manufacturing
journal, May 2019
- Wilkinson, N. J.; Smith, M. A. A.; Kay, R. W.
- The International Journal of Advanced Manufacturing Technology, Vol. 105, Issue 11
Recent Progress in Materials and Devices toward Printable and Flexible Sensors
journal, February 2016
- Rim, You Seung; Bae, Sang-Hoon; Chen, Huajun
- Advanced Materials, Vol. 28, Issue 22
Metal aerosol jet printing for solar cell metallization
journal, January 2007
- Mette, A.; Richter, P. L.; Hörteis, M.
- Progress in Photovoltaics: Research and Applications, Vol. 15, Issue 7
The Effect of Droplet Sizes on Overspray in Aerosol-Jet Printing
journal, April 2018
- Chen, Guang; Gu, Yuan; Tsang, Harvey
- Advanced Engineering Materials, Vol. 20, Issue 8
Aerosol jet printing of biological inks by ultrasonic delivery
journal, February 2020
- Williams, Nicholas X.; Watson, Nathan; Joh, Daniel Y.
- Biofabrication, Vol. 12, Issue 2
Flexible, Print-in-Place 1D–2D Thin-Film Transistors Using Aerosol Jet Printing
journal, September 2019
- Lu, Shiheng; Cardenas, Jorge A.; Worsley, Robyn
- ACS Nano, Vol. 13, Issue 10