DOE PAGES title logo U.S. Department of Energy
Office of Scientific and Technical Information

Title: Guided ink and process design for aerosol jet printing based on annular drying effects

Abstract

Aerosol jet printing is a promising microscale additive manufacturing technology for emerging applications in printed and flexible electronics. However, the more widespread adoption of this emerging technique is hindered by a limited fundamental understanding of the process. This work focuses on a critical and underappreciated aspect of the process, the interaction between drying induced by the sheath gas and impaction. Combining focused experiments with support from numerical modeling, it is shown that these effects have a dramatic impact on key outputs of the process, including deposition rate, resolution, and morphology. These effects can amplify minor changes in ink composition or atomization yield, increasing process sensitivity and drift. Moreover, these effects can confound strategies for in-line process monitoring and control based on empirical observables. Strategies to directly manipulate this annular drying phenomenon are presented, providing a viable tool to tailor and study the process. This work clarifies coupled effects of printer design, ink formulation, and print parameters, establishing a more robust theoretical framework for understanding the aerosol jet printing process and advancing the maturity of this promising technology.

Authors:
ORCiD logo [1]
  1. Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
Publication Date:
Research Org.:
Sandia National Lab. (SNL-NM), Albuquerque, NM (United States)
Sponsoring Org.:
USDOE National Nuclear Security Administration (NNSA)
OSTI Identifier:
1477320
Report Number(s):
SAND-2018-10453J
Journal ID: ISSN 2058-8585; 668186
Grant/Contract Number:  
AC04-94AL85000
Resource Type:
Accepted Manuscript
Journal Name:
Flexible and Printed Electronics
Additional Journal Information:
Journal Volume: 3; Journal Issue: 3; Journal ID: ISSN 2058-8585
Publisher:
IOPscience
Country of Publication:
United States
Language:
English
Subject:
42 ENGINEERING

Citation Formats

Secor, Ethan B. Guided ink and process design for aerosol jet printing based on annular drying effects. United States: N. p., 2018. Web. doi:10.1088/2058-8585/aadffd.
Secor, Ethan B. Guided ink and process design for aerosol jet printing based on annular drying effects. United States. https://doi.org/10.1088/2058-8585/aadffd
Secor, Ethan B. Thu . "Guided ink and process design for aerosol jet printing based on annular drying effects". United States. https://doi.org/10.1088/2058-8585/aadffd. https://www.osti.gov/servlets/purl/1477320.
@article{osti_1477320,
title = {Guided ink and process design for aerosol jet printing based on annular drying effects},
author = {Secor, Ethan B.},
abstractNote = {Aerosol jet printing is a promising microscale additive manufacturing technology for emerging applications in printed and flexible electronics. However, the more widespread adoption of this emerging technique is hindered by a limited fundamental understanding of the process. This work focuses on a critical and underappreciated aspect of the process, the interaction between drying induced by the sheath gas and impaction. Combining focused experiments with support from numerical modeling, it is shown that these effects have a dramatic impact on key outputs of the process, including deposition rate, resolution, and morphology. These effects can amplify minor changes in ink composition or atomization yield, increasing process sensitivity and drift. Moreover, these effects can confound strategies for in-line process monitoring and control based on empirical observables. Strategies to directly manipulate this annular drying phenomenon are presented, providing a viable tool to tailor and study the process. This work clarifies coupled effects of printer design, ink formulation, and print parameters, establishing a more robust theoretical framework for understanding the aerosol jet printing process and advancing the maturity of this promising technology.},
doi = {10.1088/2058-8585/aadffd},
journal = {Flexible and Printed Electronics},
number = 3,
volume = 3,
place = {United States},
year = {Thu Sep 27 00:00:00 EDT 2018},
month = {Thu Sep 27 00:00:00 EDT 2018}
}

Journal Article:
Free Publicly Available Full Text
Publisher's Version of Record

Figures / Tables:

Figure 1 Figure 1: Effect of solvent bubblers on aerosol jet printing. (a) Photograph of printer with solvent bubblers installed. (b) Film thickness as a function of aerosol flow rate with and without solvent bubblers. (c) Line resolution as a function of focusing ratio, or sheath:aerosol flow ratio, with and without solventmore » bubblers.« less

Save / Share:

Works referenced in this record:

Recent Progress in the Development of Printed Thin-Film Transistors and Circuits with High-Resolution Printing Technology
journal, November 2016


Additive Manufacturing of Hybrid Circuits
journal, July 2016


Paper Electronics
journal, March 2011

  • Tobjörk, Daniel; Österbacka, Ronald
  • Advanced Materials, Vol. 23, Issue 17, p. 1935-1961
  • DOI: 10.1002/adma.201004692

Technologies for Printing Sensors and Electronics Over Large Flexible Substrates: A Review
journal, June 2015

  • Khan, Saleem; Lorenzelli, Leandro; Dahiya, Ravinder S.
  • IEEE Sensors Journal, Vol. 15, Issue 6
  • DOI: 10.1109/JSEN.2014.2375203

Additive Manufacturing Technologies Compared: Morphology of Deposits of Silver Ink Using Inkjet and Aerosol Jet Printing
journal, January 2015

  • Seifert, Tobias; Sowade, Enrico; Roscher, Frank
  • Industrial & Engineering Chemistry Research, Vol. 54, Issue 2
  • DOI: 10.1021/ie503636c

Hybrid 2D patterning using UV laser direct writing and aerosol jet printing of UV curable polydimethylsiloxane
journal, September 2017

  • Obata, Kotaro; Schonewille, Adam; Slobin, Shayna
  • Applied Physics Letters, Vol. 111, Issue 12
  • DOI: 10.1063/1.4996547

Three-dimensional microarchitected materials and devices using nanoparticle assembly by pointwise spatial printing
journal, March 2017

  • Saleh, Mohammad Sadeq; Hu, Chunshan; Panat, Rahul
  • Science Advances, Vol. 3, Issue 3
  • DOI: 10.1126/sciadv.1601986

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
  • DOI: 10.1002/pip.759

Printable ion-gel gate dielectrics for low-voltage polymer thin-film transistors on plastic
journal, October 2008

  • Cho, Jeong Ho; Lee, Jiyoul; Xia, Yu
  • Nature Materials, Vol. 7, Issue 11, p. 900-906
  • DOI: 10.1038/nmat2291

Printed, Sub-3V Digital Circuits on Plastic from Aqueous Carbon Nanotube Inks
journal, June 2010

  • Ha, Mingjing; Xia, Yu; Green, Alexander A.
  • ACS Nano, Vol. 4, Issue 8
  • DOI: 10.1021/nn100966s

Printed, sub-2V ZnO Electrolyte Gated Transistors and Inverters on Plastic
journal, March 2013

  • Hong, Kihyon; Kim, Se Hyun; Lee, Keun Hyung
  • Advanced Materials, Vol. 25, Issue 25
  • DOI: 10.1002/adma.201300211

Aerosol-Jet-Assisted Thin-Film Growth of CH 3 NH 3 PbI 3 Perovskites-A Means to Achieve High Quality, Defect-Free Films for Efficient Solar Cells
journal, July 2017

  • Bag, Santanu; Deneault, James R.; Durstock, Michael F.
  • Advanced Energy Materials, Vol. 7, Issue 20
  • DOI: 10.1002/aenm.201701151

Formation of Copper Zinc Tin Sulfide Thin Films from Colloidal Nanocrystal Dispersions via Aerosol-Jet Printing and Compaction
journal, May 2015

  • Williams, Bryce A.; Mahajan, Ankit; Smeaton, Michelle A.
  • ACS Applied Materials & Interfaces, Vol. 7, Issue 21
  • DOI: 10.1021/acsami.5b02484

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
  • DOI: 10.1088/2058-8585/aa5af9

Femtoliter-Scale Patterning by High-Speed, Highly Scaled Inverse Gravure Printing
journal, November 2012

  • Kitsomboonloha, Rungrot; Morris, S. J. S.; Rong, Xiaoying
  • Langmuir, Vol. 28, Issue 48
  • DOI: 10.1021/la3037132

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
  • DOI: 10.1115/1.4036660

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
  • DOI: 10.1115/1.4034591

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
  • DOI: 10.1115/1.4035586

Aerosol focusing in micro-capillaries: Theory and experiment
journal, August 2008


Analytical Investigation of Aerosol Jet Printing
journal, August 2014


Sessile drop deformations under an impinging jet
journal, June 2015


A Computational Study of Particle Deposition Patterns from a Circular Laminar Jet
journal, July 2017


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
  • DOI: 10.1021/am400606y

Using ultrasonic atomization to produce an aerosol of micron-scale particles
journal, November 2005

  • Donnelly, T. D.; Hogan, J.; Mugler, A.
  • Review of Scientific Instruments, Vol. 76, Issue 11
  • DOI: 10.1063/1.2130336

Aerodynamic focusing of particles in a carrier gas
journal, October 1988


Generating Particle Beams of Controlled Dimensions and Divergence: I. Theory of Particle Motion in Aerodynamic Lenses and Nozzle Expansions
journal, January 1995

  • Liu, Peng; Ziemann, Paul J.; Kittelson, David B.
  • Aerosol Science and Technology, Vol. 22, Issue 3
  • DOI: 10.1080/02786829408959748

Collimated Aerosol Beam Deposition: Sub-5-$\mu$m Resolution of Printed Actives and Passives
journal, May 2010

  • Schulz, D. L.; Hoey, J. M.; Thompson, D.
  • IEEE Transactions on Advanced Packaging, Vol. 33, Issue 2
  • DOI: 10.1109/TADVP.2009.2038615

Characteristics of laminar jet impactors
journal, July 1974

  • Marple, Virgil A.; Liu, Benjamin Y. H.
  • Environmental Science & Technology, Vol. 8, Issue 7
  • DOI: 10.1021/es60092a003

The adhesion of particles undergoing an elastic-plastic impact with a surface
journal, April 1984


Pulmonary applications and toxicity of engineered nanoparticles
journal, September 2008

  • Card, Jeffrey W.; Zeldin, Darryl C.; Bonner, James C.
  • American Journal of Physiology-Lung Cellular and Molecular Physiology, Vol. 295, Issue 3
  • DOI: 10.1152/ajplung.00041.2008

Environmental and Human Health Risks of Aerosolized Silver Nanoparticles
journal, July 2010

  • Quadros, Marina E.; Marr, Linsey C.
  • Journal of the Air & Waste Management Association, Vol. 60, Issue 7
  • DOI: 10.3155/1047-3289.60.7.770

Aerosol-Jet-Printed, 1 Volt H-Bridge Drive Circuit on Plastic with Integrated Electrochromic Pixel
journal, November 2013

  • Ha, Mingjing; Zhang, Wei; Braga, Daniele
  • ACS Applied Materials & Interfaces, Vol. 5, Issue 24
  • DOI: 10.1021/am404204q

Evaporation of Multicomponent Droplets
journal, January 1997


Evaluation of Particle Bounce in Various Collection Substrates to be Used as Vaporizer in Aerosol Mass Spectrometer
journal, March 2015


Reconsidering Adhesion and Bounce of Submicron Particles Upon High-Velocity Impact
journal, May 2013


Fluid dynamics in conically tapered microneedles
journal, January 2005

  • Martanto, Wijaya; Baisch, Stephen M.; Costner, Elizabeth A.
  • AIChE Journal, Vol. 51, Issue 6
  • DOI: 10.1002/aic.10424

Controlling and assessing the quality of aerosol jet printed features for large area and flexible electronics
text, January 2017

  • Smith, Mike; Choi, Yeonsik; Boughey, Chess
  • Apollo - University of Cambridge Repository
  • DOI: 10.17863/cam.8823

Works referencing / citing this record:

Near-IR sintering of conductive silver nanoparticle ink with in situ resistance measurement
journal, September 2019

  • Keller, David J.; Jochem, Krystopher S.; Suszynski, Wieslaw J.
  • Journal of Coatings Technology and Research, Vol. 16, Issue 6
  • DOI: 10.1007/s11998-019-00268-5

Aerosol Jet® Direct-Write for Microscale Additive Manufacturing
journal, March 2019

  • Feng, James Q.; Renn, Michael J.
  • Journal of Micro and Nano-Manufacturing, Vol. 7, Issue 1
  • DOI: 10.1115/1.4043595