A cold spray-based novel manufacturing route for flexible electronics

Akin, Semih; Jo, Seunghwan; Jun, Martin Byung‐Guk

doi:10.1016/j.jmapro.2022.12.035

Cited by 6 publications

(3 citation statements)

References 35 publications

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“…Next, the surface of the 3D-printed PLA part is metallized by using CS particle deposition technology. In the present study, the feedstock Tin (Sn) particles with a size range of 10-45 µm [20] were cold deposited on the 3D printed PLA surface through a CS system (Rus Sonic Inc., Model K205/407R, Russia), in which the deposition nozzle was mounted on a programmable robot arm (Kuka KR Agilus). The CS experimental setup is shown in Figure 2a, and further details regarding the experimental setup can be found in the authors' previous works [21][22][23].…”

Section: Methodsmentioning

confidence: 99%

Fully Additively Manufactured Counter Electrodes for Dye-Sensitized Solar Cells

Akin,

Kim,

Song

et al. 2024

Micromachines

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In dye-sensitized solar cells (DSSCs), the counter electrode (CE) plays a crucial role as an electron transfer agent and regenerator of the redox couple. Unlike conventional CEs that are generally made of glass-based substrates (e.g., FTO/glass), polymer substrates appear to be emerging candidates, owing to their intrinsic properties of lightweight, high durability, and low cost. Despite great promise, current manufacturing methods of CEs on polymeric substrates suffer from serious limitations, including low conductivity, scalability, process complexity, and the need for dedicated vacuum equipment. In the present study, we employ and evaluate a fully additive manufacturing route that can enable the fabrication of CEs for DSSCs in a high-throughput and eco-friendly manner with improved performance. The proposed approach sequentially comprises: (1) material extrusion 3-D printing of polymer substrate; (2) conductive surface metallization through cold spray particle deposition; and (3) over-coating of a thin-layer catalyzer with a graphite pencil. The fabricated electrodes are characterized in terms of microstructure, electrical conductivity, and photo-conversion efficiency. Owing to its promising electrical conductivity (8.5 × 104 S·m−1) and micro-rough surface structure (Ra ≈ 6.32 µm), the DSSCs with the additively manufactured CEs led to ≈2.5-times-higher photo-conversion efficiency than that of traditional CEs made of FTO/glass. The results of the study suggest that the proposed additive manufacturing approach can advance the field of DSSCs by addressing the limitations of conventional CE manufacturing platforms.

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Section: Methodsmentioning

confidence: 99%

Fully Additively Manufactured Counter Electrodes for Dye-Sensitized Solar Cells

Akin,

Kim,

Song

et al. 2024

Micromachines

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“…Cold spray (CS) particle deposition, also known as cold gas dynamic spray or cold spray additive manufacturing, is an emerging solid-state material consolidation technology for rapid metallization on target surfaces owing to its high deposition rate, strong adhesion strength, and low operating temperatures. ,,, In CS, the particle deposition is performed below the melting point of the sprayed feedstock material so that the process can avoid oxidation, minimize thermal degradation, and consume low energy without a need of high-temperature explosive gases and radiation, thereby making the CS as a green and safe surface deposition technology . Traditionally, in the CS process, as shown in Figure b, the micrometer-scale metal particles (e.g., copper, tin, zinc, etc.)…”

Section: Methodsmentioning

confidence: 99%

Selective Surface Metallization of 3D-Printed Polymers by Cold-Spray-Assisted Electroless Deposition

Akin,

Nath,

Jun

2023

ACS Appl. Electron. Mater.

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Selective surface metallization of insulating polymers is of particular interest in smart films, energy harvesting, and sensing applications. However, traditional polymer metallization techniques face challenges due to the need for environmentally hazardous pretreatment (e.g., strong acid etching) and costintensive palladium seeding processes, thereby limiting the largescale deployment of metallized polymers. With the advent of rapid prototyping, metallization on additively manufactured polymers drew attention in a variety of technological applications, as it enables the fabrication of low-cost electronic devices. In the current work, we deploy and evaluate a hybrid additive metallization route that can enable the fabrication of functional selective metallization on 3D-printed polymers in a rapid and eco-friendly methodology with improved electrical conductivity. The metallization route sequentially comprises (1) material extrusion 3D printing, (2) cold spray metallization, and (3) electroless deposition. The resulting metal (copper) layers on the polymer surfaces are characterized in terms of the microstructure, surface chemistry, wettability, and electrical conductivity. Notably, selective metallization with promising electrical conductivity (i.e., 6.47 × 10 6 S m −1 for ABS and 5.27 × 10 6 S m −1 for PLA parts) is achieved on both linear and curvilinear polymer surfaces. Moreover, strong adhesion between the metallized layer and the 3Dprinted structures was confirmed by adhesion tests. Detailed evaluation of the proposed hybrid metallization route unlocks great potential to advance the field of conductive surface metallization on 3D-printed polymers.

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“…Based on the above-mentioned points, the CS technique has received special attention as a promising candidate for a surface modification method of various materials as it generates a minimal heat-affected zone in both the as-deposited material and substrate [ 5 ]. Copper (Cu) [ 6 ], Cu-based alloys [ 7 , 8 ], Al [ 9 ], Al-based alloys [ 10 , 11 ], Ni [ 12 ], Ni-based alloys [ 13 , 14 ], Ti-based alloys [ 15 , 16 ], Fe-based alloys [ 8 , 17 ], Sn [ 18 ], high or medium entropy alloys [ 19 , 20 ], and metal-based composites such as Cu-Al 2 O 3 [ 21 ], Al-SiC [ 22 ], Al-TiB 2 [ 23 ], Al-Al 2 O 3 [ 24 ], Ni-WC [ 25 ], etc., in the form of coatings or parts, have been successfully actualized by CS technology so far.…”

Section: Introductionmentioning

confidence: 99%

Comparison of Cold-Sprayed Coatings of Copper-Based Composite Deposited on AZ31B Magnesium Alloy and 6061 T6 Aluminum Alloy Substrates

Xue

Shao

et al. 2023

Materials

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Copper-coated graphite and copper mixture powders were deposited on AZ31B magnesium alloy and 6061 T6 aluminum alloy substrates under different process parameters by a solid-state cold spray technique. The microstructure of the copper-coated graphite and copper composite coatings was visually examined using photographs taken with an optical microscope and a scanning electron microscope. The surface roughness of the coatings was investigated with a 3D profilometer. The thickness of the coatings was determined through the analysis of the microstructure images, while the adhesion of the coatings was characterized using the scratch test method. The results indicate that the surface roughness of the coatings sprayed on the two different substrates gradually decreases as gas temperature and gas pressure increase. Additionally, the thickness and adhesion of the coatings deposited on the two different substrates both increase with an increase in gas temperature and gas pressure. Comparing the surface roughness, thickness, and adhesion of the coatings deposited on the two different substrates, the surface roughness and adhesion of the coatings on the soft substrate are greater than those of the coatings on the hard substrate, while the thickness of the coatings is not obviously affected by the hardness of the substrate. Furthermore, it is noteworthy that the surface roughness, thickness, and adhesion of the copper-coated graphite and copper composite coatings sprayed on the two different substrates exhibit a distinct linear relationship with particle velocity.

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A cold spray-based novel manufacturing route for flexible electronics

Cited by 6 publications

References 35 publications

Fully Additively Manufactured Counter Electrodes for Dye-Sensitized Solar Cells

Fully Additively Manufactured Counter Electrodes for Dye-Sensitized Solar Cells

Selective Surface Metallization of 3D-Printed Polymers by Cold-Spray-Assisted Electroless Deposition

Comparison of Cold-Sprayed Coatings of Copper-Based Composite Deposited on AZ31B Magnesium Alloy and 6061 T6 Aluminum Alloy Substrates

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