Nozzle heating with internal channel enhanced aerosol-jet printing with ultrahigh aspect ratio and ultrafine resolution for conformal electronics

IF 11.1 1区工程技术 Q1 ENGINEERING, MANUFACTURING

Additive manufacturing Pub Date : 2025-08-05 DOI:10.1016/j.addma.2025.104965

Teng Ma , Yuan Li , Ao Li , Yingjie Niu , Hui Cheng , Chenglin Yi , Kaifu Zhang

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引用次数: 0

Abstract

Aerosol jet (AJ) printing enables conformal feature fabrication but struggles with limiting aspect ratio and resolution due to insufficient focus of aerosol ink particles. Here, we introduce an efficient method for AJ printing called nozzle heating with internal channel (NHIC), which incorporates a spiral flow channel into the nozzle, facilitating a continuous and temperature-controlled water bath through the channel to establish an auxiliary annular thermal field around the aerosolized ink particles (AIPs) flow, thereby modifying the flow field dynamics and enhancing the aerodynamic focusing of AIPs By raising up NHIC temperature to 90℃, a 7 μm wide deposited trace with a thickness of 2.1 μm was achieved. Above all, we increased the maximum aspect ratio of the printed deposits up to approximately 0.3, and improved the conductivity by 25 %. NHIC-enabled AJ printing successfully fabricated high-precision and high-density circuits, resistors, and conformal electrodes, demonstrating superior aspect ratio, resolution, thickness, and conductivity compared to conventional AJ methods for uneven conformal surfaces.

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喷嘴加热与内部通道增强气溶胶喷射打印具有超高纵横比和超细分辨率的保形电子

气溶胶喷射（AJ）打印实现了保形特征制造，但由于气溶胶油墨颗粒聚焦不足，其长宽比和分辨率受到限制。本文介绍了一种高效的AJ打印方法——喷嘴内通道加热（NHIC），该方法在喷嘴内引入螺旋流道，使连续的温控水浴通过该通道，在雾化油墨颗粒（AIPs）流动周围建立辅助的环形热场，从而改变流场动力学，增强AIPs的气动聚焦。得到了宽7 μm、厚度2.1 μm的沉积痕迹。最重要的是，我们将打印沉积层的最大纵横比提高到约0.3，并将电导率提高了25% %。与传统的AJ方法相比，nlic技术成功地制造出高精度高密度电路、电阻器和共形电极，在不均匀的共形表面上表现出优越的长宽比、分辨率、厚度和导电性。

本文章由计算机程序翻译，如有差异，请以英文原文为准。

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来源期刊

Additive manufacturing Materials Science-General Materials Science

CiteScore

19.80

自引率

12.70%

发文量

648

审稿时长

35 days

期刊介绍： Additive Manufacturing stands as a peer-reviewed journal dedicated to delivering high-quality research papers and reviews in the field of additive manufacturing, serving both academia and industry leaders. The journal's objective is to recognize the innovative essence of additive manufacturing and its diverse applications, providing a comprehensive overview of current developments and future prospects. The transformative potential of additive manufacturing technologies in product design and manufacturing is poised to disrupt traditional approaches. In response to this paradigm shift, a distinctive and comprehensive publication outlet was essential. Additive Manufacturing fulfills this need, offering a platform for engineers, materials scientists, and practitioners across academia and various industries to document and share innovations in these evolving technologies.