Considerations of aerosol-jet printing for the fabrication of printed hybrid electronic circuits

Hines, D. R.; Gu, Yuan; Martin, Andrew; Li, P.; Fleischer, Jason W.; Clough-Paez, Aaron; Stackhouse, George; Dasgupta, Abhijit; Das, Siddhartha

doi:10.1016/j.addma.2021.102325

Cited by 32 publications

(31 citation statements)

References 76 publications

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“…(4) in eqs 3 and 4, subscripts 1 and 2, respectively, denote the liquid phase and the air phase, and α varies from 0 (representing the pure air phase or phase-2) to 1 (representing the pure liquid phase or phase-1). Also, in eqs 1 and 2, I̅ is the identity tensor, g is the acceleration due to gravity, and F σ is the surface tension force that is modeled implicitly using the continuum surface force model described by Brackbill et al 44 = F (5) In eq 5, σ is the liquid−air surface tension, which remains constant throughout the polymerization process and κ is the local curvature of the drop at the liquid−air interface, which is defined in terms of the normal vector (n) at the liquid−air interface as…”

Section: ■ Theory and Simulation Methodsmentioning

confidence: 99%

Coalescence of 3D Polymeric Drops in the Presence of In Situ Photopolymerization

et al. 2023

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We develop a combined numerical (using direct numerical simulation) and scaling model to study the dynamics of two identical photocurable, shear-thinning polymeric drops undergoing spreading and coalescence (on a substrate) in the presence of in situ curing. We only consider the shear-thinning nature of the drops but do not account for any changes in the drop elasticity during the in situ photocuring process. Two separate cases are studied: (1) τs ≪ τp (case 1) and (2) τs ∼ τp (case 2) (τs and τp represent the spreading and photocuring timescales, respectively). Photopolymerization-driven increase in the drop viscosity significantly delays the spreading and the coalescence events for case 2. Furthermore, for case 2, at any given time during the coalescence process, both the height and the width of the “bridge” that forms due to coalescence are always smaller than those for case 1. Our scaling analysis establishes three distinct regimes characterizing the bridge growth for both cases 1 and 2: the initial regime (viscous and capillary forces balance each other, and the bridge growth rate is weak), the intermediate regime (inertia and capillary forces balance each other, and the bridge growth rate is enhanced), and the late regime (viscous and capillary forces balance each other, and the bridge growth rate is weak). Also, in regimes where viscous forces play a role (initial and late regimes), the bridge growth is weaker for case 2, while in the intermediate regime, the rate of bridge growth is similar between cases 1 and 2. We also provide the temperature variation and the evolution of the curing front inside the coalescing drops for cases 1 and 2: the significantly rapid rate of polymerization for case 2 manifests in a noticeable temperature drop, fast propagation of the curing front, and the fluid flow (associated with coalescence) affecting the migration of the curing front inside the coalescing drops. We anticipate that our study will be crucial in designing polymeric droplet-based additive manufacturing systems and understanding the behavior of polymeric blends and polymeric emulsions.

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Section: ■ Theory and Simulation Methodsmentioning

confidence: 99%

Coalescence of 3D Polymeric Drops in the Presence of In Situ Photopolymerization

et al. 2023

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“…The two main governing parameters for achieving optimal ink performance are the viscosity of the ink formulation and the particle size of the dispersed conductive material. The viscosity of ink formulations suitable for the various printing methods is as follows: inkjet printing (1–30 × 10 –3 Pa·s), − aerosol-jet (1–2500 × 10 –3 Pa·s), − gravure printing (50–500 × 10 –3 Pa·s), , screen printing (1–50 Pa·s), , and direct ink writing (DIW, 0.1–1000 Pa·s). − Mismatching the printer with the viscosity of the ink generally leads to intermittent printing when the ink is too viscous or smudging and dripping if the viscosity is too low. The particle size of the conductive material limits the use of printhead (“applicator”) due to possible clogging risk.…”

Section: Introductionmentioning

confidence: 99%

Fabrication Approaches of Soft Electronics

Tan

Farraj

Kamyshny

et al. 2023

ACS Appl. Electron. Mater.

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The use of conductive materials to be printed/embedded onto/within a polymeric matrix has gained increasing attention in the fabrication of next-generation soft electronics. In this review, we provide a comprehensive overview of the materials and approaches for the fabrication of 2D and 3D conductive structures while focusing on the importance of the compatibility between the particles' shape, the polymeric matrix type, and the deposition method, along with the target application. The review presents a summary of the main conductive materials and the type of polymeric materials which were utilized for fabricating soft electronic devices that are bendable/twistable and stretchable. It is divided into two sections: Introduction section, which presents briefly conductive materials, polymeric matrix, and fabrication methods, and Fabrication section, presenting the main 6 approaches of fabrication. Each of the fabrication subsections presents the main recent reports in a detailed table. The review is concluded with an Outlook section, describing the current challenges in this field. Despite the progress in the fabrication of 2D bendable/twistable electronic devices toward industrial integration, there is still a need for tailoring and improving the durability and robustness of 3D stretchable electronic devices.

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“…Aerosol jet printing (AJP) is emerging as a transformative three-dimensional (3D) printing technology to fabricate high-resolution and flexible micro-electronic devices 1 , 2 . Compared with conventional fabrication techniques, such as etching, photolithographic and electroplating 3 , AJP can significantly reduce chemical waste and simplify manufacturing process 4 , while lowering fabrication costs 5 .…”

Section: Introductionmentioning

confidence: 99%

A hybrid multi-objective optimization of functional ink composition for aerosol jet 3D printing via mixture design and response surface methodology

Zhang

Liu²,

Yin³

et al. 2023

Sci Rep

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The limited electrical performance of microelectronic devices caused by low inter-particle connectivity and inferior printing quality is still the greatest hurdle to overcome for Aerosol jet printing (AJP) technology. Despite the incorporation of carbon nanotubes (CNTs) and specified solvents into functional inks can improve inter-particle connectivity and ink printability respectively, it is still challenging to consider multiple conflicting properties in mixture design simultaneously. This research proposes a novel hybrid multi-objective optimization method to determine the optimal functional ink composition to achieve low electrical resistivity and high printed line quality. In the proposed approach, silver ink, CNTs ink and ethanol are blended according to mixture design, and two response surface models (ReSMs) are developed based on the Analysis of Variance. Then a desirability function method is employed to identify a 2D optimal operating material window to balance the conflicting responses. Following that, the conflicting objectives are optimized in a more robust manner in the 3D mixture design space through the integration of a non-dominated sorting genetic algorithm III (NSGA-III) with the developed ReSMs and the corresponding statistical uncertainty. Experiments are conducted to validate the effectiveness of the proposed approach, which extends the methodology of designing materials with multi-component and multi-property in AJP technology.

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Considerations of aerosol-jet printing for the fabrication of printed hybrid electronic circuits

Cited by 32 publications

References 76 publications

Coalescence of 3D Polymeric Drops in the Presence of In Situ Photopolymerization

Coalescence of 3D Polymeric Drops in the Presence of In Situ Photopolymerization

Fabrication Approaches of Soft Electronics

A hybrid multi-objective optimization of functional ink composition for aerosol jet 3D printing via mixture design and response surface methodology

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