Aerosol Jet Printing and Interconnection Technologies on Additive Manufactured Substrates

Abstract

Nowadays, digital printing technologies such as inkjet and aerosol jet printing are gaining more importance since they have proven to be suitable for the assembly of complex microsystems. This also applies to medical technology applications like hearing aids where patient-specific solutions are required. However, assembly is more challenging than with conventional printed circuit boards in terms of material compatibility between substrate, interconnect material and printed ink. This paper describes how aerosol jet printing of nano metal inks and subsequent assembly processes are utilized to connect electrical components on 3D substrates fabricated by Digital Light Processing (DLP). Conventional assembly technologies such as soldering and conductive adhesive bonding were investigated and characterized. For this purpose, curing methods and substrate pretreatments for different inks were optimized. Furthermore, the usage of electroless plating on printed metal tracks for improved solderability was investigated. Finally, a 3D ear mold substrate was used to build up a technology demonstrator by means of conductive adhesives.

A Comprehensive Review on Printed Electronics: A Technology Drift towards a Sustainable Future

“…Furthermore, the printing efficiency of aerosol jet printing can be improved by controlling the focusing ratio of the aerosol jet printer tuned for modulating the line width of the printed line [ 67 ]. The aerosol jet printing technology is a promising alternative technology for the fabrication of metal interconnects via semiconductor ICs [ 73 ]. …”