Predicting Deposition Rate and Closing the Loop on Aerosol Jet Printing with In‐Line Light Scattering Measurements
Abstract
Aerosol jet printing is a compelling noncontact, digital manufacturing technology for flexible, hybrid, and conformal electronics, but batch‐to‐batch variability and process drift inhibit systematic study and translation to production environments. Emerging measurement techniques for the aerosol volume fraction, a key parameter governing deposition rate, have shown promise for real‐time response, including a recent demonstration of human‐in‐the‐loop control. By integrating improved light scattering measurements with custom software, a robust environment for real‐time monitoring is established and fully automated closed‐loop control over the deposition rate during printing is enabled. The physical basis for scattering measurements as a feedback source is examined and the quantitative insight this provides for ink development and fundamental process studies is highlighted. Three candidate process variables for closed‐loop control, namely the atomizer voltage, carrier gas flow rate, and print speed, are then evaluated. The atomizer voltage demonstrates the best extended duration validity because it addresses atomization variability directly, but carrier gas flow rate and print speed provide faster and more deterministic responses. This methodology is then demonstrated for electrical properties using a silver nanoparticle ink, maintaining 98% of printed patterns within 10% of the mean resistance value over 3 h of printing.
- Authors:
-
[1]
- Department of Mechanical Engineering Iowa State University 1071 Black Engineering Ames IA 50011 USA
- Publication Date:
- Sponsoring Org.:
- USDOE
- OSTI Identifier:
- 1968643
- Alternate Identifier(s):
- OSTI ID: 1983453
- Resource Type:
- Published Article
- Journal Name:
- Advanced Engineering Materials
- Additional Journal Information:
- Journal Name: Advanced Engineering Materials Journal Volume: 25 Journal Issue: 12; Journal ID: ISSN 1438-1656
- Publisher:
- Wiley Blackwell (John Wiley & Sons)
- Country of Publication:
- Germany
- Language:
- English
Citation Formats
Rurup, Jeremy D., and Secor, Ethan B. Predicting Deposition Rate and Closing the Loop on Aerosol Jet Printing with In‐Line Light Scattering Measurements. Germany: N. p., 2023.
Web. doi:10.1002/adem.202201919.
Rurup, Jeremy D., & Secor, Ethan B. Predicting Deposition Rate and Closing the Loop on Aerosol Jet Printing with In‐Line Light Scattering Measurements. Germany. https://doi.org/10.1002/adem.202201919
Rurup, Jeremy D., and Secor, Ethan B. Thu .
"Predicting Deposition Rate and Closing the Loop on Aerosol Jet Printing with In‐Line Light Scattering Measurements". Germany. https://doi.org/10.1002/adem.202201919.
@article{osti_1968643,
title = {Predicting Deposition Rate and Closing the Loop on Aerosol Jet Printing with In‐Line Light Scattering Measurements},
author = {Rurup, Jeremy D. and Secor, Ethan B.},
abstractNote = {Aerosol jet printing is a compelling noncontact, digital manufacturing technology for flexible, hybrid, and conformal electronics, but batch‐to‐batch variability and process drift inhibit systematic study and translation to production environments. Emerging measurement techniques for the aerosol volume fraction, a key parameter governing deposition rate, have shown promise for real‐time response, including a recent demonstration of human‐in‐the‐loop control. By integrating improved light scattering measurements with custom software, a robust environment for real‐time monitoring is established and fully automated closed‐loop control over the deposition rate during printing is enabled. The physical basis for scattering measurements as a feedback source is examined and the quantitative insight this provides for ink development and fundamental process studies is highlighted. Three candidate process variables for closed‐loop control, namely the atomizer voltage, carrier gas flow rate, and print speed, are then evaluated. The atomizer voltage demonstrates the best extended duration validity because it addresses atomization variability directly, but carrier gas flow rate and print speed provide faster and more deterministic responses. This methodology is then demonstrated for electrical properties using a silver nanoparticle ink, maintaining 98% of printed patterns within 10% of the mean resistance value over 3 h of printing.},
doi = {10.1002/adem.202201919},
journal = {Advanced Engineering Materials},
number = 12,
volume = 25,
place = {Germany},
year = {Thu Apr 06 00:00:00 EDT 2023},
month = {Thu Apr 06 00:00:00 EDT 2023}
}
Free Publicly Available Full Text
Publisher's Version of Record
https://doi.org/10.1002/adem.202201919
https://doi.org/10.1002/adem.202201919
Other availability
Search WorldCat to find libraries that may hold this journal
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:
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
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
Light scattering measurements to support real-time monitoring and closed-loop control of aerosol jet printing
journal, August 2021
- Secor, Ethan B.
- Additive Manufacturing, Vol. 44
Principles of aerosol jet printing
journal, July 2018
- Secor, Ethan B.
- Flexible and Printed Electronics, Vol. 3, Issue 3
Aerosol jet printed capacitive strain gauge for soft structural materials
journal, November 2020
- Fujimoto, Kiyo T.; Watkins, Jennifer K.; Phero, Timothy
- npj Flexible Electronics, Vol. 4, Issue 1
Guided ink and process design for aerosol jet printing based on annular drying effects
journal, September 2018
- Secor, Ethan B.
- Flexible and Printed Electronics, Vol. 3, Issue 3
Fabrication and characterization of aerosol-jet printed strain sensors for multifunctional composite structures
journal, September 2012
- Zhao, Da; Liu, Tao; Zhang, Mei
- Smart Materials and Structures, Vol. 21, Issue 11
Understanding effects of printhead geometry in aerosol jet printing
journal, July 2020
- Tafoya, Rebecca R.; Secor, Ethan B.
- Flexible and Printed Electronics, Vol. 5, Issue 3
Aerosol-Jet Printed Flexible Organic Photodiodes: Semi-Transparent, Color Neutral, and Highly Efficient
journal, June 2015
- Eckstein, Ralph; Rödlmeier, Tobias; Glaser, Tobias
- Advanced Electronic Materials, Vol. 1, Issue 8
Basic optics, aerosol optics, and the role of scattering for sky radiance
journal, May 2014
- Horvath, Helmuth
- Journal of Quantitative Spectroscopy and Radiative Transfer, Vol. 139
In-Situ Image-Based Monitoring and Closed-Loop Control of Aerosol Jet Printing
conference, June 2018
- Lombardi, Jack P.; Salary, Roozbeh (Ross); Weerawarne, Darshana L.
- Volume 1: Additive Manufacturing; Bio and Sustainable Manufacturing
Completely Printed, Flexible, Stable, and Hysteresis-Free Carbon Nanotube Thin-Film Transistors via Aerosol Jet Printing
journal, April 2017
- Cao, Changyong; Andrews, Joseph B.; Franklin, Aaron D.
- Advanced Electronic Materials, Vol. 3, Issue 5
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
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
High‐Performance Flexible Bismuth Telluride Thin Film from Solution Processed Colloidal Nanoplates
journal, October 2020
- Hollar, Courtney; Lin, Zhaoyang; Kongara, Madhusudan
- Advanced Materials Technologies, Vol. 5, Issue 11
Aerosol Jet Printing of Nano Particle Based Electrical Chip Interconnects
journal, January 2015
- Seifert, Tobias; Baum, Mario; Roscher, Frank
- Materials Today: Proceedings, Vol. 2, Issue 8
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
Aerosol Jet Printed Polymer Composite Electrolytes for Solid‐State Li‐Ion Batteries
journal, October 2019
- Deiner, L. Jay; Jenkins, Thomas; Howell, Thomas
- Advanced Engineering Materials, Vol. 21, Issue 12
Integrated capacitive sensor devices aerosol jet printed on 3D objects
journal, December 2019
- Vella, Sarah; Smithson, Chad; Halfyard, Kurt
- Flexible and Printed Electronics, Vol. 4, Issue 4
Inkwells for on-demand deposition rate measurement in aerosol-jet based 3D printing
journal, August 2017
- Gu, Yuan; Gutierrez, David; Das, Siddhartha
- Journal of Micromechanics and Microengineering, Vol. 27, Issue 9
Direct-Write Printed, Solid-Core Solenoid Inductors with Commercially Relevant Inductances
journal, October 2018
- Gu, Yuan; Park, Donghun; Bowen, David
- Advanced Materials Technologies, Vol. 4, Issue 1
Understanding and mitigating process drift in aerosol jet printing
journal, February 2020
- Tafoya, Rebecca R.; Secor, Ethan B.
- Flexible and Printed Electronics, Vol. 5, Issue 1
Real‐Time Optical Process Monitoring for Structure and Property Control of Aerosol Jet Printed Functional Materials
journal, November 2020
- Tafoya, Rebecca R.; Cook, Adam W.; Kaehr, Bryan
- Advanced Materials Technologies, Vol. 5, Issue 12
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
Microscale additive manufacturing and modeling of interdigitated capacitive touch sensors
journal, September 2016
- Rahman, Md Taibur; Rahimi, Arya; Gupta, Subhanshu
- Sensors and Actuators A: Physical, Vol. 248
3D Conformal Printing and Photonic Sintering of High‐Performance Flexible Thermoelectric Films Using 2D Nanoplates
journal, July 2019
- Saeidi‐Javash, Mortaza; Kuang, Wenzheng; Dun, Chaochao
- Advanced Functional Materials, Vol. 29, Issue 35
High Capacity Rate Capable Aerosol Jet Printed Li‐Ion Battery Cathode
journal, February 2019
- Deiner, L. Jay; Jenkins, Thomas; Powell, Amber
- Advanced Engineering Materials, Vol. 21, Issue 5
Aerosol based direct-write micro-additive fabrication method for sub-mm 3D metal-dielectric structures
journal, September 2015
- Rahman, Taibur; Renaud, Luke; Heo, Deuk
- Journal of Micromechanics and Microengineering, Vol. 25, Issue 10
A Miniaturized Nickel Oxide Thermistor via Aerosol Jet Technology
journal, November 2017
- Wang, Chia; Hong, Guan-Yi; Li, Kuan-Ming
- Sensors, Vol. 17, Issue 11