Xuanbo Jiang , Zijun Yan , Yingjie Niu , Xuan Zhang , Teng Ma , Hui Cheng , Kaifu Zhang , Chenglin Yi
{"title":"通过优化不同沉积速率下的打印速度范围,提高了气溶胶喷射打印的形貌和电导率","authors":"Xuanbo Jiang , Zijun Yan , Yingjie Niu , Xuan Zhang , Teng Ma , Hui Cheng , Kaifu Zhang , Chenglin Yi","doi":"10.1016/j.matdes.2025.114745","DOIUrl":null,"url":null,"abstract":"<div><div>Aerosol Jet (AJ) printing is becoming increasingly attractive for printed conformal electronics due to its non-contact capability. However, the impact of deposition rate and print speed on the morphology and electrical properties of printed traces remains unclear. In this study, AJ printed traces with different print speed (0.3–20 mm/s) under commonly used deposition rate values (0.0002, 0.0004 and 0.0006 mm<sup>3</sup>/s) were examined. After evaluating the corresponding morphology and conductivity of the printed traces, the optimal print speed range of each deposition rate was determined as follows: deposition rate of 0.0002 mm<sup>3</sup>/s as 0.3–1.5 mm/s, 0.0004 mm<sup>3</sup>/s as 0.7–4 mm/s, and 0.0006 mm<sup>3</sup>/s as 1–6 mm/s, respectively. A three-dimensional computational fluid dynamics (CFD) model is proposed to elucidate the fundamental aerodynamic behaviors of AJ printed traces under different deposition rate, and its trends align with experimental observations. The mechanism by which print speed influences conductivity was analyzed, revealing that internal porosity is the primary factor reducing conductivity at low print speed. The analysis of morphology, conductivity, and printing efficiency across various print modes revealed that the morphology of printed traces under the respective deposition rate and print speed combination remained consistent in single-layer printing. Notably, printing efficiency is substantially enhanced at elevated deposition rate and high print speed. Compared to multi-layer printing at low deposition rate, high deposition rate single-layer printing emerges as the optimal method for achieving superior efficiency and conductivity. Ultimately, a correlation was established between resistance, print speed, and deposition rate, that enabling the successful printing of 15 resistors with specific resistance values (20 Ω) for different geometries, within an average error of 5.9 %, thereby broadening the applicability of AJ printing in printed electronics.</div></div>","PeriodicalId":383,"journal":{"name":"Materials & Design","volume":"259 ","pages":"Article 114745"},"PeriodicalIF":7.9000,"publicationDate":"2025-09-19","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":"{\"title\":\"Enhanced morphology and conductivity in aerosol jet printing via optimization of print speed range under various deposition rate\",\"authors\":\"Xuanbo Jiang , Zijun Yan , Yingjie Niu , Xuan Zhang , Teng Ma , Hui Cheng , Kaifu Zhang , Chenglin Yi\",\"doi\":\"10.1016/j.matdes.2025.114745\",\"DOIUrl\":null,\"url\":null,\"abstract\":\"<div><div>Aerosol Jet (AJ) printing is becoming increasingly attractive for printed conformal electronics due to its non-contact capability. However, the impact of deposition rate and print speed on the morphology and electrical properties of printed traces remains unclear. In this study, AJ printed traces with different print speed (0.3–20 mm/s) under commonly used deposition rate values (0.0002, 0.0004 and 0.0006 mm<sup>3</sup>/s) were examined. After evaluating the corresponding morphology and conductivity of the printed traces, the optimal print speed range of each deposition rate was determined as follows: deposition rate of 0.0002 mm<sup>3</sup>/s as 0.3–1.5 mm/s, 0.0004 mm<sup>3</sup>/s as 0.7–4 mm/s, and 0.0006 mm<sup>3</sup>/s as 1–6 mm/s, respectively. A three-dimensional computational fluid dynamics (CFD) model is proposed to elucidate the fundamental aerodynamic behaviors of AJ printed traces under different deposition rate, and its trends align with experimental observations. The mechanism by which print speed influences conductivity was analyzed, revealing that internal porosity is the primary factor reducing conductivity at low print speed. The analysis of morphology, conductivity, and printing efficiency across various print modes revealed that the morphology of printed traces under the respective deposition rate and print speed combination remained consistent in single-layer printing. Notably, printing efficiency is substantially enhanced at elevated deposition rate and high print speed. Compared to multi-layer printing at low deposition rate, high deposition rate single-layer printing emerges as the optimal method for achieving superior efficiency and conductivity. Ultimately, a correlation was established between resistance, print speed, and deposition rate, that enabling the successful printing of 15 resistors with specific resistance values (20 Ω) for different geometries, within an average error of 5.9 %, thereby broadening the applicability of AJ printing in printed electronics.</div></div>\",\"PeriodicalId\":383,\"journal\":{\"name\":\"Materials & Design\",\"volume\":\"259 \",\"pages\":\"Article 114745\"},\"PeriodicalIF\":7.9000,\"publicationDate\":\"2025-09-19\",\"publicationTypes\":\"Journal Article\",\"fieldsOfStudy\":null,\"isOpenAccess\":false,\"openAccessPdf\":\"\",\"citationCount\":\"0\",\"resultStr\":null,\"platform\":\"Semanticscholar\",\"paperid\":null,\"PeriodicalName\":\"Materials & Design\",\"FirstCategoryId\":\"88\",\"ListUrlMain\":\"https://www.sciencedirect.com/science/article/pii/S0264127525011657\",\"RegionNum\":2,\"RegionCategory\":\"材料科学\",\"ArticlePicture\":[],\"TitleCN\":null,\"AbstractTextCN\":null,\"PMCID\":null,\"EPubDate\":\"\",\"PubModel\":\"\",\"JCR\":\"Q1\",\"JCRName\":\"MATERIALS SCIENCE, MULTIDISCIPLINARY\",\"Score\":null,\"Total\":0}","platform":"Semanticscholar","paperid":null,"PeriodicalName":"Materials & Design","FirstCategoryId":"88","ListUrlMain":"https://www.sciencedirect.com/science/article/pii/S0264127525011657","RegionNum":2,"RegionCategory":"材料科学","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q1","JCRName":"MATERIALS SCIENCE, MULTIDISCIPLINARY","Score":null,"Total":0}
Enhanced morphology and conductivity in aerosol jet printing via optimization of print speed range under various deposition rate
Aerosol Jet (AJ) printing is becoming increasingly attractive for printed conformal electronics due to its non-contact capability. However, the impact of deposition rate and print speed on the morphology and electrical properties of printed traces remains unclear. In this study, AJ printed traces with different print speed (0.3–20 mm/s) under commonly used deposition rate values (0.0002, 0.0004 and 0.0006 mm3/s) were examined. After evaluating the corresponding morphology and conductivity of the printed traces, the optimal print speed range of each deposition rate was determined as follows: deposition rate of 0.0002 mm3/s as 0.3–1.5 mm/s, 0.0004 mm3/s as 0.7–4 mm/s, and 0.0006 mm3/s as 1–6 mm/s, respectively. A three-dimensional computational fluid dynamics (CFD) model is proposed to elucidate the fundamental aerodynamic behaviors of AJ printed traces under different deposition rate, and its trends align with experimental observations. The mechanism by which print speed influences conductivity was analyzed, revealing that internal porosity is the primary factor reducing conductivity at low print speed. The analysis of morphology, conductivity, and printing efficiency across various print modes revealed that the morphology of printed traces under the respective deposition rate and print speed combination remained consistent in single-layer printing. Notably, printing efficiency is substantially enhanced at elevated deposition rate and high print speed. Compared to multi-layer printing at low deposition rate, high deposition rate single-layer printing emerges as the optimal method for achieving superior efficiency and conductivity. Ultimately, a correlation was established between resistance, print speed, and deposition rate, that enabling the successful printing of 15 resistors with specific resistance values (20 Ω) for different geometries, within an average error of 5.9 %, thereby broadening the applicability of AJ printing in printed electronics.
期刊介绍:
Materials and Design is a multi-disciplinary journal that publishes original research reports, review articles, and express communications. The journal focuses on studying the structure and properties of inorganic and organic materials, advancements in synthesis, processing, characterization, and testing, the design of materials and engineering systems, and their applications in technology. It aims to bring together various aspects of materials science, engineering, physics, and chemistry.
The journal explores themes ranging from materials to design and aims to reveal the connections between natural and artificial materials, as well as experiment and modeling. Manuscripts submitted to Materials and Design should contain elements of discovery and surprise, as they often contribute new insights into the architecture and function of matter.