Numerical simulation of electrohydrodynamic jet and printing micro-structures on flexible substrate

Abbas, Zeshan; Wang, Dazhi; Du, Zhiyuan; Qian, Jianghong; Zhao, Kuipeng; Du, Zhaoliang; Wang, Zhu; Cui, Yan; Zhang, Xi; Liang, Junsheng

doi:10.1007/s00542-020-05068-1

Cited by 13 publications

(10 citation statements)

References 37 publications

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“…The experimental setup was established in an existing study based on E-Jet printing technology, which consists of a combined needle system (steel and quartz), an air pump dispensing controller (PHD ULTRATM, Harvard Appsratus, Holliston, MA, USA), a DC pulse power supply, a computer-controlled X-Y-Z movement station and a microscopic vision system [2]. The inner and outer diameters of the steel needle were 365 µm and 700 µm, respectively.…”

Section: Methodsmentioning

confidence: 99%

“…The fabrication of different micro/nano-structures on polymer insulating substrates using E-Jet printing technology has generated widespread interest due to its extensive applications in flexible electronic devices [1,2], the biomedical sector [3], optoelectronic fields [4] and other different disciplines. The use of E-Jet printing technology for micro/nanopatterns have many advantages compared to traditional photolithography and ink-jet printing, i.e., a three-dimensional structuring [5], a high-resolution patterning technique [6], high efficiency of resource dissipation [7], high-speed printing with nano-sized structures [8], and a contactless method [9].…”

Section: Introductionmentioning

confidence: 99%

“…In our previous work, Abbas et al performed a numerical simulation of E-Jet and printing micro-droplets on a flexible substrate. The study calculated the optimized parameters for the development of a DoD E-Jet to print stable micro-structures on a PET substrate [2]. In another study, Abbas et al introduced a numerical simulation of stable cone-jet formation [23] and printed direct writing structures on flexible substrate.…”

Section: Introductionmentioning

confidence: 99%

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Simulation of Cone-Jet and Micro-Drip Regimes and Printing of Micro-Scale Patterns on PET Substrate

Wang

Abbas

et al. 2022

Polymers

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The fabrication of various micro-patterns on polymer insulating substrates is a current requirement in micro-electromechanical system (MEMS) and packaging sectors. In this paper, we use electrohydrodynamic jet (E-Jet) printing to create multifaceted and stable micro-patterns on a polyethylene terephthalate (PET) substrate. Initially, simulation was performed to investigate optimized printing settings in phase field physics for the usage of two distinct functional inks. A series of simulation experiments was conducted, and it was determined that the following parameters are optimised: applied pressure of 40 kPa, high pulse voltage of 1.95 kV, low dc voltage of 1.60 kV, duty cycle of 80%, pulse frequency of 60 Hz, printing height of 0.25 mm, and printing speed of 1 mm/s. Then, experiments showed that adjusting a pressure value of 40 kPa and regulating the SEMICOSIL988/1 K ink to print micro-drops on a polymer substrate with a thickness of 1 mm prevents coffee staining. The smallest measured droplet size was 200 μm. Furthermore, underfill (UF 3808) ink was driven with applied pressure to 50 kPa while other parameters were left constant, and the minimum size of linear patterns was printed to 105 μm on 0.5-mm-thick PET substrate. During the micro-drip and cone-jet regimes, the consistency and diameter of printed micro-structures were accurately regulated at a pulse frequency of 60 Hz and a duty cycle of 80%.

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Section: Methodsmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 1 more Smart Citation

Simulation of Cone-Jet and Micro-Drip Regimes and Printing of Micro-Scale Patterns on PET Substrate

Wang

Abbas

et al. 2022

Polymers

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“…Flexible electronics is a technology that allows the construction of electronic circuits on flexible substrates (i.e., PET and PEN), thus making them flexible and stretchable [ 1 ]. It enables new product paradigms that are not possible to build with conventional semiconductors and glass substrates.…”

Section: Introductionmentioning

confidence: 99%

Simulation and Printing of Microdroplets Using Straight Electrode-Based Electrohydrodynamic Jet for Flexible Substrate

Wang

Abbas

et al. 2022

Micromachines

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Electrohydrodynamic jet (e-jet) printing is a modern and decent fabrication method widely used to print high-resolution versatile microstructures with features down to 10 μm. It is currently difficult to break nanoscale resolution (<100 nm) due to limitations of fluid properties, voltage variations, and needle shapes. This paper presents developments in drop-on-demand e-jet printing based on a phase-field method using a novel combined needle and straight electrode to print on a flexible PET substrate. Initially, the simulation was performed to form a stable cone jet by coupling an innovative straight electrode parallel to a combined needle that directs the generation of droplets at optimized parameters, such as f = 8.6 × 10−10 m3s−1, Vn = 9.0 kV, and Vs = 4.5 kV. Subsequently, printing experiments were performed using optimized processing parameters and all similar simulation conditions. Microdroplets smaller than 13 μm were directly printed on PET substrate. The model is considered unique and powerful for printing versatile microstructures on polymeric substrates. The presented method is useful for MEMS technology to fabricate various devices, such as accelerometers, smartphones, gyroscopes, sensors, and actuators.

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“…Various ways of implementation of DOD technology and related investigations can be found in scientific literature. The development of drop-on-demand electrohydrodynamic jet (DoD E-Jet) printing to enhance print control and to achieve stable micro-structures on a flexible insulating substrate were analyzed by Abbas et al [16]. The theoretical design of the inkjet process to improve delivery efficiency was investigated by comparing numerical investigations and physical experiments by Zhong et al [17].…”

Section: Introductionmentioning

confidence: 99%

Numerical Modeling of the Motion and Interaction of a Droplet of an Inkjet Printing Process with a Flat Surface

et al. 2021

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The numerical simulation and analysis of the ejection of an ink droplet through a nozzle as well its motion through air until its contact with a surface and taking up of a stable form is performed. The fluid flow is modeled by the incompressible Navier–Stokes equations with added surface tension. The presented model can be solved using either a level set or a phase field method to track the fluid interface. Here, the level set method is used to determinate the interface between ink and air. The presented work concentrates on the demonstration how to check the suitability of ink for inkjet printhead nozzles, for instance, for the use in printers. The results such as velocity, change of size, and volume dependence on time of an ink droplet are presented. Recommendations for the use of specific inks are also given.

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Numerical simulation of electrohydrodynamic jet and printing micro-structures on flexible substrate

Cited by 13 publications

References 37 publications

Simulation of Cone-Jet and Micro-Drip Regimes and Printing of Micro-Scale Patterns on PET Substrate

Simulation of Cone-Jet and Micro-Drip Regimes and Printing of Micro-Scale Patterns on PET Substrate

Simulation and Printing of Microdroplets Using Straight Electrode-Based Electrohydrodynamic Jet for Flexible Substrate

Numerical Modeling of the Motion and Interaction of a Droplet of an Inkjet Printing Process with a Flat Surface

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