Analytical Investigation of Aerosol Jet Printing

Binder, S.; Glatthaar, Markus; Rädlein, Edda

doi:10.1080/02786826.2014.940439

Cited by 79 publications

(64 citation statements)

References 7 publications

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“…Aerosol‐jet based 3‐D printing, or AJP, has emerged as an important additive manufacturing technique offering several key advantages as compared to other direct writing (DW) printing methods, such as syringe/extrusion and ink‐jet printing. For example, it is possible to conduct AJP with a working distance (i.e., the distance between the printer nozzle exit and the target printing surface) in the range of 1–5 mm, thereby ensuring that the AJP technique is adaptable to complex and delicate surface topologies.…”

Section: Introductionmentioning

confidence: 99%

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The Effect of Droplet Sizes on Overspray in Aerosol‐Jet Printing

Guang¹,

Gu²,

Tsang

et al. 2018

Adv Eng Mater

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One of the most important concerns of aerosol-jet based printing (AJP) is the substantial amount of overspray (OS) that can accompany printed traces. In this study, the authors develop a full, three-dimensional (3-D) computational fluid dynamics (CFD) model of the aerosol carrier gas flow (CGF), that is, confined by an annular sheath gas flow (ShGF) during the AJP process. The authors then use this model to pinpoint the fundamental fluid mechanics principles that control the OS in a standard AJP process as a function of the droplet size distribution and the ShGF rate. In their model, the authors consider the trajectories of various sized, monodisperse droplets in an inkstream in order to unravel the manner in which the OS is dictated by the intricate interplay between drop size and both gas flow (CGF and ShGF) rates. Their results explain several experimental results, namely 1) that there is an abundance of smaller sized drops in the OS region at low ShGF rates; 2) that the OS first reduces and then increases as the ShGF rate increases; and 3) that there is no longer a prevalence of smaller particles in the OS region at larger ShGF rates. The authors also discuss the hitherto unaddressed issues related to how 1) the large impact velocity of the ink droplets at the substrate surface (and the resultant Weber number) and 2) the misalignment between the CGF and the cylindrical axis of the ShGF annulus appear to affect OS. The authors anticipate that their analysis will provide an important understanding in the optimization of operating parameters for AJP with respect to OS that can result in an overall improvement in printing resolution.

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Section: Introductionmentioning

confidence: 99%

“…Aerosol‐jet printing, as a method for the deposition of a DW printed ink stream, has been well documented in the literature . In brief, a volume of ink is aerosolized (typically using pneumatic or ultrasonic methods) and transported through a mist tube by a carrier gas flow (CGF).…”

Section: Introductionmentioning

confidence: 99%

The Effect of Droplet Sizes on Overspray in Aerosol‐Jet Printing

Guang¹,

Gu²,

Tsang

et al. 2018

Adv Eng Mater

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“…Given this mechanism of drop formation, dynamic viscosity and surface tension remain important parameters in determining jettability. While a summary equation of parameters similar to the Z number does not exist for aerosol jet printing, experimental observation indicates that printable aerosol jet inks have viscosities in the range of 1–1000 mPas . One of the requirements on ink particle size is that the particles not clog the atomizer nozzle, generally achieved for particles less than one micron.…”

Section: Introductionmentioning

confidence: 99%

Inkjet and Aerosol Jet Printing of Electrochemical Devices for Energy Conversion and Storage

2017

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Inkjet and aerosol jet printing have recently emerged as promising fabrication techniques for a broad range of devices for electrochemical energy conversion and storagebatteries, fuel cells, and supercapacitors. If fully realized, these printing techniques may enable device performance advantages accruing from precise micron scale patterning, thin layer deposition, and materials grading. Printing may also allow scalable, low materials waste manufacturing, and conformal integration of power elements into structural elements. This article reviews the fundamental capabilities of inkjet and aerosol jet printing relevant to electrochemical devices, surveys current literature, and presents future challenges which must be tackled to achieve high performance, printed electrochemical energy storage, and conversion devices.

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“…Despite these advantages, in extrusion‐printing, composition and rheological behaviors of inks are demanding due to the requirements in clogging prevention, substrate bonding and shape maintenance . Alternatively, aerosol printing processes a wide variety of materials, including polymers, metallic conductors, semiconductors, carbon‐based nanomaterials, and energy materials in laden inks with a wider range of viscosity from 1 to 1000 cP . Aerosol printing utilizes moderately pressurized air to nebulize the active materials into aerosol mist and drive the precise material deposition with smallest feature size down to 10 µm .…”

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confidence: 99%

Customizable Nonplanar Printing of Lithium‐Ion Batteries

Liu

Pham

et al. 2019

Adv Materials Technologies

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widely used in consumer electronics due to the advantages of rechargeability and high energy density. [4][5][6] Commercial LIBs are usually fabricated in fixed geometry such as cylinder, coin, and pouch with scrolled or layered planar sheets for each component. [7] Nevertheless, LIBs with customizable geometry are desired for specialized applications such as wearable electronics [8,9] and on-device power systems [10,11] for automobile and aerospace vehicles, For example, LIBs can be made into a watchband to power an electronic watch, [12] which eliminates the installation and replacement of coin cell. To meet such demands, irregular, customizable LIBs in arbitrary geometry on 3D structures along with the packaging, integrating, and manufacturing approaches need to be developed. So far, the most effective solution to fabricate freeform LIBs is additive manufacturing (AM, popularly known as 3D printing). [13][14][15][16] The on-demand and layer-by-layer manufacturing method has provided the flexibility to accommodate customizable designs of 3D LIBs.Electrodes are the most essential components of LIBs. Currently reported AM processes for electrodes are mostly based on extrusion printing, [17][18][19][20][21][22][23][24] with a few reports on other ink-based printing methods including inkjet printing [25] and aerosol printing. [10] In extrusion printing, active material laden inks are directly deposited and powered by ultra-high air pressure. The materials are extruded into semi-solidified and self-supportive filaments owing to the shear-thinning characteristics of the highly viscous inks. Main advantage of AM processes is the capability of printing electrodes in arbitrary geometry. For example, Lacey et al. and Wang et al. demonstrated 3D printing of mesh and lattice structured electrodes, which effectively introduced macroporosity and facilitated the transportation of lithium-ions under high charging/discharging rate. [18,23] The flexibility in printed geometry also enables the fabrication of electrodes with high aspect ratio and high areal capacity, which are usually not processable by conventional slurry-casting method. Sun et al. first printed high aspect ratio, multilayer, interdigitated electrodes for micro-LIBs with high energy density and power density. [21] Despite these advantages, in extrusion-printing, composition and rheological behaviors of inks are demanding due to the requirements in clogging prevention, substrate bonding and shape maintenance. [19,20] Alternatively, aerosol printing Lithium-ion batteries (LIBs) are widely used in consumer electronics due to their rechargeability and high energy density. Commercial LIBs are fabricated in fixed geometries such as cylinder, coin, and pouch. However, for specialized applications such as wearable electronics and on-device power systems, customizable LIBs with arbitrary geometry on threedimensional (3D) structures need to be developed. For this purpose, aerosol printing is uniquely suitable due to its flexible working distance, allowing deposition on nonp...

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Analytical Investigation of Aerosol Jet Printing

Cited by 79 publications

References 7 publications

The Effect of Droplet Sizes on Overspray in Aerosol‐Jet Printing

The Effect of Droplet Sizes on Overspray in Aerosol‐Jet Printing

Inkjet and Aerosol Jet Printing of Electrochemical Devices for Energy Conversion and Storage

Customizable Nonplanar Printing of Lithium‐Ion Batteries

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