Inkjet printing has been used to produce a range of printed electronic devices, such as solar panels, sensors, and transistors. This article discusses inkjet printing and its employment in the field of printed electronics. First, printing as a field is introduced before focusing on inkjet printing. The materials that can be employed as inks are then introduced, leading to an overview of wetting, which explains the influences that determine print morphology. The article considers how the printing parameters can affect device performance and how one can account for these influences. The article concludes with a discussion on adhesion. The aim is to illustrate that the factors chosen in the fabrication process, such as dot spacing and sintering conditions, will influence the performance of the device.

Inkjet-printing technology enables the contactless deposition of functional materials such as conductive inks on surfaces, hence reducing contamination and the risk of substrate damage. In printed electronics, inkjet technology offers the significant advantage of controlling the volume of material deposited, and therefore the fine-tuning of the printed geometry, which is crucial for the performance of the final printed electronics. Inkjet printing of functional inks can be used to produce sensors to detect failure of mechanical structures such as carbon fiber reinforced composite (CFRC) components, instead of using attached sensors, which are subject to delamination. Here, silver nanoparticle-based strain sensors were embedded directly in an insulated carbon-fiber laminate by using inkjet printing to achieve an optimized conductive and adhesive geometry, forming a piezoresistive strain sensor. Following the inkjet-printing optimization process, the sensor conductivity and adhesion performance were evaluated. Finally, the sensor was quantified by using a bending rig which applied a pre-determined strain, with the response indicating an accurate sensitivity as the resistance increased with an increased strain. The ability to embed the sensor directly on the CFRC prevents the use of interfacial adhesives which is the main source of failure due to delamination.

Structural health monitoring (SHM) represents the next generation of carbon fiber‐reinforced composite nondestructive testing. One challenge facing the application of magnetostrictive SHM is the lightweighting and ease of installation of actuators and sensors. Inkjet printing (IJP) technology is well suited to produce miniaturized electronic induction sensors that can be paired with magnetostrictive actuators to detect strain. These sensors have several advantages: their thicknesses can be minimized, the surface area can be maximized to increase sensitivity, and complex multifilar coil configurations can be fabricated. A parametric study of the efficacy of IJP induction coils with different parameters (number of coils, monofilar/bifilar, size) tested on a number of actuator‐functionalized composite coupons (FeSiB ribbon and impregnated epoxy sensors) is conducted. The samples are characterized by measuring their inductance response through induced strains. Increased sensitivity and accuracy of the 10‐turn monofilar IJP sensor are shown with respect to 1) 70‐turn hand‐wound coils, 2) a three‐axis AMR sensor, and 3) other IJP actuators with <10 turns. This is attributed to increased contact area to the composite surface and the requirement of minimum sensitivity (i.e., the number of turns and surface area) for strain detection.