Self-Limiting Electrospray Deposition for the Surface Modification of Additively Manufactured Parts

Abstract

Electrospray deposition (ESD) is a spray coating process that utilizes a high voltage to atomize a flowing solution into charged microdroplets. These self-repulsive droplets evaporate as they travel to a target substrate, depositing the solution solids. Our previous research investigated the conditions necessary to minimize charge dissipation and deposit a thickness-limited film that grows in area over time through self-limiting electrospray deposition (SLED). Such sprays possess the ability to conformally coat complex three-dimensional objects without changing the location of the spray needle or orientation of the object. This makes them ideally suited for the post-processing of materials fabricated through additive manufacturing (AM), opening a paradigm of independent bulk and surface functionality. Having demonstrated three-dimensional coating with film thickness in the range of 1-50 µm on a variety of conductive objects, in this study we employed model substrates to quantitatively study the technique's limits with regard to geometry and scale. Specifically, we examined the effectiveness of thickness-limited ESD for coating recessed features with gaps ranging from 50 µm to 1 cm, as well as the ability to coat surfaces hidden from the line-of-sight of the spray needle. This was then extended to the coating of hydrogel structures printed by AM, demonstrating that coating could be conducted even into the body of the structures as a means to create hydrophobic surfaces without affecting the absorption-driven humidity response. File list (6) download file view on ChemRxiv Manuscript.pdf (810.15 KiB) download file view on ChemRxiv SupportingInformation.pdf (354.12 KiB) download file view on ChemRxiv SupplementaryVideo1.mp4 (20.99 MiB) download file view on ChemRxiv SupplementaryVideo2.mp4 (60.98 MiB) download file view on ChemRxiv SupplementaryVideo3.MOV (3.59 MiB) download file view on ChemRxiv SupplementaryVideo4.MOV (3.65 MiB)

Self-limiting electrospray deposition on polymer templates

“…Recently, we have demonstrated self-limiting electrospray deposition (SLED) as a means to create microcoatings on complex 3-dimensional (3D) surfaces 18,21 . When an insulating glassy material in a volatile solvent is sprayed below its glass transition temperature (T g ) onto a conductive surface, charges accumulate on the deposited porous, insulating thin film.…”

Electrospray: More than just an ionization source

“…If the deposited aerosol does not dissipate its charge, the accumulated charge becomes so strong that it influences the trajectories of incoming droplets (so-called focusing effect). This phenomenon was exploited by Kovacevich et al to demonstrate that the electrospray can be used to conformally coat complex nonconductive 3D objects [89]. At the beginning of the deposition, the closest part of the target is covered with a sprayed material.…”

Determining the Self-Limiting Electrospray Deposition Compositional Limits for Mechanically Tunable Polymer Composites

“…An extension of ESD, coined self-limiting electrospray deposition (SLED) has been demonstrated by only spraying glassy insulating materials below their glass transition temperature (Tg) and mixed with a volatile solvent onto a sufficiently conducting substrate [18][19][20][21][22] . A limited thickness will be achieved as charges accumulate with increased spray time and spray is redirected to uncoated parts of the target.…”