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:
-
- 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}
}
Figures / Tables:
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