Cold spray-based rapid and scalable production of printed flexible electronics

Akin, Semih; Lee, Seungjun; Jo, Seunghwan; Ruzgar, Duygu Gazioglu; Subramaniam, Karthick; Tsai, Jung-Ting; Jun, Martin Byung‐Guk

doi:10.1016/j.addma.2022.103244

Cited by 6 publications

(5 citation statements)

References 65 publications

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“…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]. Air was used as the compressed propellant gas at a gauge pressure of 0.7 MPa.…”

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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“…Traditionally, in the CS process, as shown in Figure b, the micrometer-scale metal particles (e.g., copper, tin, zinc, etc.) are accelerated at higher velocities (i.e., 300–1200 m s –1 ) through a supersonic gas stream. , When the particle stream impacts the target, the kinetic energy of particles is absorbed by the substrate surface, leading to high-strength material consolidation due to the metallurgical bonding and/or mechanical interlocking of the particles at particle–substrate interface . Unlike the metal substrates, mechanical interlocking (i.e., rigidly embedding of particles into the polymer) is mainly responsible for CS metallization on thermoplastic polymers such as ABS and PLA …”

Section: Methodsmentioning

confidence: 99%

“…22,25,34,35 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. 36 Traditionally, in the CS process, as shown in Figure 2b, the micrometer-scale metal particles (e.g., copper, tin, zinc, etc.) are accelerated at higher velocities (i.e., 300−1200 m s −1 ) through a supersonic gas stream.…”

Section: ■ Experimental Sectionmentioning

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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“…Integration of AM with the cold spray process—cold spray additive manufacturing (CSAM) is the solid-state supersonic deposition method that can build 3D components for mass production and remanufacturing [ 187 ]. Generalized AM techniques are presented in contrast to traditional AM methods, as shown in Figure 21 a [ 188 ].…”

Section: Intelligence In State-of-the-art Manufacturing Technology: M...mentioning

confidence: 99%

Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

et al. 2023

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Additive manufacturing (AM), an enabler of Industry 4.0, recently opened limitless possibilities in various sectors covering personal, industrial, medical, aviation and even extra-terrestrial applications. Although significant research thrust is prevalent on this topic, a detailed review covering the impact, status, and prospects of artificial intelligence (AI) in the manufacturing sector has been ignored in the literature. Therefore, this review provides comprehensive information on smart mechanisms and systems emphasizing additive, subtractive and/or hybrid manufacturing processes in a collaborative, predictive, decisive, and intelligent environment. Relevant electronic databases were searched, and 248 articles were selected for qualitative synthesis. Our review suggests that significant improvements are required in connectivity, data sensing, and collection to enhance both subtractive and additive technologies, though the pervasive use of AI by machines and software helps to automate processes. An intelligent system is highly recommended in both conventional and non-conventional subtractive manufacturing (SM) methods to monitor and inspect the workpiece conditions for defect detection and to control the machining strategies in response to instantaneous output. Similarly, AM product quality can be improved through the online monitoring of melt pool and defect formation using suitable sensing devices followed by process control using machine learning (ML) algorithms. Challenges in implementing intelligent additive and subtractive manufacturing systems are also discussed in the article. The challenges comprise difficulty in self-optimizing CNC systems considering real-time material property and tool condition, defect detections by in-situ AM process monitoring, issues of overfitting and underfitting data in ML models and expensive and complicated set-ups in hybrid manufacturing processes.

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Cold spray-based rapid and scalable production of printed flexible electronics

Cited by 6 publications

References 65 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

Review of Intelligence for Additive and Subtractive Manufacturing: Current Status and Future Prospects

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