No abstract
Direct writing of hierarchical micro/nanofibers have recently gained popularity in flexible/stretchable electronics due to its low cost, simple process and high throughput. A kinetically controlled mechanoelectrospinning (MES) is developed to directly write diversified hierarchical micro/nanofibers in a continuous and programmable manner. Unlike conventional near-field electrospinning, our MES method introduces a mechanical drawing force, to simultaneously enhance the positioning accuracy and morphology controllability. The MES is predominantly controlled by the substrate speed, the nozzle-to-substrate distance, and the applied voltage. As a demonstration, smooth straight, serpentine, self-similar, and bead-on-string structures are direct-written on silicon/elastomer substrates with a resolution of 200 nm. It is believed that MES can promote the low-cost, high precision fabrication of flexible/stretchable electronics or enable the direct writing of the sacrificial structures for nanoscale lithography.
Droplet generation process can directly affect process regulation and output performance of electrohydrodynamic jet (E-jet) printing in fabricating micro-to-nano scale functional structures. This paper proposes a numerical simulation model for whole process of droplet generation of E-jet printing based on the Taylor-Melcher leaky-dielectric model. The whole process of droplet generation is successfully simulated in one whole cycle, including Taylor cone generation, jet onset, jet break, and jet retraction. The feasibility and accuracy of the numerical simulation model is validated by a 30G stainless nozzle with inner diameter ~160 μm by E-jet printing experiments. Comparing numerical simulations and experimental results, period, velocity magnitude, four steps in an injection cycle, and shape of jet in each step are in good agreement. Further simulations are performed to reveal three design constraints against applied voltage, flow rate, and nozzle diameter, respectively. The established cone-jet numerical simulation model paves the way to investigate influences of process parameters and guide design of printheads for E-jet printing system with high performance in the future.
It is critical and challenging to achieve the individual jetting ability and high consistency in multi-nozzle electrohydrodynamic jet printing (E-jet printing). We proposed multi-level voltage method (MVM) to implement the addressable E-jet printing using multiple parallel nozzles with high consistency. The fabricated multi-nozzle printhead for MVM consists of three parts: PMMA holder, stainless steel capillaries (27G, outer diameter 400 μm) and FR-4 extractor layer. The key of MVM is to control the maximum meniscus electric field on each nozzle. The individual jetting control can be implemented when the rings under the jetting nozzles are 0 kV and the other rings are 0.5 kV. The onset electric field for each nozzle is ∼3.4 kV/mm by numerical simulation. Furthermore, a series of printing experiments are performed to show the advantage of MVM in printing consistency than the “one-voltage method” and “improved E-jet method”, by combination with finite element analyses. The good dimension consistency (274μm, 276μm, 280μm) and position consistency of the droplet array on the hydrophobic Si substrate verified the enhancements. It shows that MVM is an effective technique to implement the addressable E-jet printing with multiple parallel nozzles in high consistency.
A printhead that is compatible with Si-based processes and able to generate homogeneous micro- and nano-scale droplets plays an important role in electrohydrodynamic jet printing (E-jet printing) for the large-scale manufacturing. This paper proposes the design, fabrication and evaluation of a novel protruding Si-based printhead for E-jet printing. The protruding nozzle can concentrate the electrical field and restrain the lateral wetting so as to improve the jetting stability. However, it is a challenge to have both the protruding structure and a stable solution/voltage supply. Accordingly, a set of micro-manufacturing processes, as well as methods of adopting hydrophobic and insulation treatments, are also presented to stabilize the solution/voltage supply. The diameter and height of the protruding nozzle are 50 µm and 60 µm, respectively. Printing tests are performed using both quantum dots solution (CdSe/CdS/ZnS) and a mixed solution of glycerol, ethylene glycol and water. Feasibility of the protruding nozzle is proved by experiments that a stable meniscus with Taylor cone could form on the nozzle orifice, and fine dots (⩽30 µm) could be printed successfully and continuously. The protruding design and micro-fabrication processes of the protruding Si-based printhead pave the way for the multi-nozzle E-jet printing with high efficiency and resolution.
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