Controlling Droplet Evaporation in Aerosol Jet Printing to Understand and Mitigate Overspray DOI Creative Commons
Bella Guyll,

Brayden L. Sanford,

Cary L. Pint

et al.

Small Science, Journal Year: 2025, Volume and Issue: unknown

Published: March 18, 2025

Aerosol jet printing is an additive manufacturing technique with broad materials compatibility, high resolution, and complex geometric capabilities. Despite these advantages, even optimized prints are susceptible to overspray, in which sparse deposition of material outside the primary pattern limits precision quality for high‐value applications. Herein, a method presented overcome this by loading sheath gas solvent vapor before entering printhead. This reduces droplet drying aerosol phase at periphery stream, improving line edge morphology, pitch, porosity, surface finish. demonstrated reduce overspray extent water‐based polyimide ink up 70 ± 2.3% decrease resistivity solvent‐based silver 34 13%. The ability regulate evaporation flight offers versatile control, facilitating wider range process parameters chemistries. These experimental results backed theoretical analysis numerical modeling, providing more refined generalizable understanding underlying physics. enables tailored outcomes challenges including aspect ratio high‐density patterning improved finish functionality compelling applications printed hybrid electronics.

Language: Английский

Controlling Droplet Evaporation in Aerosol Jet Printing to Understand and Mitigate Overspray DOI Creative Commons
Bella Guyll,

Brayden L. Sanford,

Cary L. Pint

et al.

Small Science, Journal Year: 2025, Volume and Issue: unknown

Published: March 18, 2025

Aerosol jet printing is an additive manufacturing technique with broad materials compatibility, high resolution, and complex geometric capabilities. Despite these advantages, even optimized prints are susceptible to overspray, in which sparse deposition of material outside the primary pattern limits precision quality for high‐value applications. Herein, a method presented overcome this by loading sheath gas solvent vapor before entering printhead. This reduces droplet drying aerosol phase at periphery stream, improving line edge morphology, pitch, porosity, surface finish. demonstrated reduce overspray extent water‐based polyimide ink up 70 ± 2.3% decrease resistivity solvent‐based silver 34 13%. The ability regulate evaporation flight offers versatile control, facilitating wider range process parameters chemistries. These experimental results backed theoretical analysis numerical modeling, providing more refined generalizable understanding underlying physics. enables tailored outcomes challenges including aspect ratio high‐density patterning improved finish functionality compelling applications printed hybrid electronics.

Language: Английский

Citations

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