Optimization of process parameters in micro-scale pneumatic aerosol jet printing for high-yield precise electrodes

Abstract

Aerosol jet printing (AJP) is a new non-contact direct writing technique designed to achieve precise and intricate patterns on various substrates. Specifically, the pneumatic AJP process breaks down the ink into fine particles, significantly reducing the risk of nozzle clogging and rendering it highly advantageous for industrial applications. This paper focuses on the optimization of the line electrode formation process using soluble silver clusters as the conductive ink, along with the aerosol formation procedure. The main parameters of the AJP process, namely sheath flow rate, atomizer flow rate, and dispensing speed, were identified and examined for their influence on line width and resistivity. Through this analysis, an operability window, including optimized conditions for printing high-quality lines using the AJP process, was established, along with a regression equation enabling the statistical estimation of line width. In summary, the outcomes of this investigation underscore the feasibility of an integrated printing system capable of precision control over line width, achieved through the optimization of AJP process parameters. Furthermore, it was established that pneumatic AJP offers robust process stability. The practical applicability of the proposed optimization techniques was assessed, highlighting their potential utilization in electrode formation processes within the electronic and display industry.

A review of hierarchical porous carbon derived from various 3D printing techniques

“…Aerosol jet printing (AJP), a novel non-contact direct writing technique, is specifically designed to achieve precise and intricate patterns on a variety of substrates. 73 Parate et al 74 reported on an innovative aerosol-jet-printed (AJP) graphene-based immunosensor, which is capable of monitoring two distinct cytokines: interferon gamma (IFN-γ) and interleukin 10 (IL-10). To construct this sophisticated device, interdigitated electrodes (IDEs) were printed with a 40 μm finger width using graphene-nitrocellulose ink on a durable polyimide substrate.…”

Machine learning enables electrical resistivity modeling of printed lines in aerosol jet 3D printing

“…While AJP technology presents numerous advantages, intricate interactions among the machine, process, and materials result in low controllability over the electrical performance of printed lines. This significantly affects the functionality of printed components, thereby limiting the broad applications of AJP 16 , 17 . As the AJP process exerts an indirect yet impactful influence on the electrical resistivity of printed lines via their effect on printed line morphology, researchers tend to optimize AJP process parameters, aiming to enhance the overall electrical performance of printed lines and broaden the applications of AJP.…”