Printability assessment and modelling for process optimization of 3D Aerosol Jet® printed high aspect ratio microstructures

The printability assessment of high-aspect-ratio structures in additive manufacturing is critical for ensuring dimensional accuracy and functional properties. This study proposes a method to evaluate print quality by quantifying metrics, including accuracy, shape fidelity and line edge quality, using advanced imaging and predictive analysis. A printability index is developed to relate these metrics to process parameters, here applied to Aerosol Jet® Printing. By validating structures’ quality and optimizing parameters, the index effectively improves process stability, reduces defects, and enhances structural precision. This approach provides a robust tool for process optimization, ensuring consistent results in complex high-aspect-ratio designs, further advancing printing scalability and reproducibility.