Multimaterial bathless stereolithography using aerosol jet printing and UV           laser based polymerization

Ceramic multilayer technologies such as LTCC (low temperature cofired ceramics) or HTCC (high temperature cofired ceramics) are applied for the fabrication of highly integrated ceramic microelectronic packages. Furthermore, ceramic multilayer technologies offer the possibility of additionally integrating 3D structures for multilayer-based microsystems. This paper presents a new machine for tape/multilayer structuring that combines micro punching tools and micro UV-laser ablation/cutting. The application for the production of different multilayer-based components is described (e.g., LTCC-based PEM fuel cell system, LTCC-based pressure sensors). Aerosol jet printing is a new technology, for example, for rapid prototyping for LTCC multilayer and 3D deposition of functional layers on LTCC. Advantages and limitations of the technology are discussed.

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A knowledge transfer framework to support rapid process modeling in aerosol jet printing

Advanced Engineering Informatics ◽

10.1016/j.aei.2021.101264 ◽

2021 ◽

Vol 48 ◽

pp. 101264

Author(s):

Haining Zhang ◽

Joon Phil Choi ◽

Seung Ki Moon ◽

Teck Hui Ngo

Keyword(s):

Knowledge Transfer ◽

Process Modeling ◽

Rapid Process ◽

Jet Printing ◽

Aerosol Jet Printing

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Light Scattering Measurements to Support Real-Time Monitoring and Closed-Loop Control of Aerosol Jet Printing

Additive Manufacturing ◽

10.1016/j.addma.2021.102028 ◽

2021 ◽

pp. 102028

Author(s):

Ethan B. Secor

Keyword(s):

Light Scattering ◽

Real Time ◽

Closed Loop ◽

Closed Loop Control ◽

Real Time Monitoring ◽

Loop Control ◽

Scattering Measurements ◽

Jet Printing ◽

Aerosol Jet Printing

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Synthesis of Printable Polyvinyl Alcohol for Aerosol Jet and Inkjet Printing Technology

Micromachines ◽

10.3390/mi12020220 ◽

2021 ◽

Vol 12 (2) ◽

pp. 220

Author(s):

Mahmuda Akter Monne ◽

Chandan Qumar Howlader ◽

Bhagyashree Mishra ◽

Maggie Yihong Chen

Keyword(s):

Polyvinyl Alcohol ◽

Inkjet Printing ◽

Micro Electro Mechanical System ◽

Device Fabrication ◽

Silicon Substrates ◽

Excellent Candidate ◽

Jet Printing ◽

Inkjet Printing Technology ◽

Transistor Fabrication ◽

Aerosol Jet Printing

Polyvinyl Alcohol (PVA) is a promising polymer due to its high solubility with water, availability in low molecular weight, having short polymer chain, and cost-effectiveness in processing. Printed technology is gaining popularity to utilize processible solution materials at low/room temperature. This work demonstrates the synthesis of PVA solution for 2.5% w/w, 4.5% w/w, 6.5% w/w, 8.5% w/w and 10.5% w/w aqueous solution was formulated. Then the properties of the ink, such as viscosity, contact angle, surface tension, and printability by inkjet and aerosol jet printing, were investigated. The wettability of the ink was investigated on flexible (Kapton) and non-flexible (Silicon) substrates. Both were identified as suitable substrates for all concentrations of PVA. Additionally, we have shown aerosol jet printing (AJP) and inkjet printing (IJP) can produce multi-layer PVA structures. Finally, we have demonstrated the use of PVA as sacrificial material for micro-electro-mechanical-system (MEMS) device fabrication. The dielectric constant of printed PVA is 168 at 100 kHz, which shows an excellent candidate material for printed or traditional transistor fabrication.

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Considerations of Aerosol-Jet Printing for the Fabrication of Printed Hybrid Electronic Circuits

Additive Manufacturing ◽

10.1016/j.addma.2021.102325 ◽

2021 ◽

pp. 102325

Author(s):

D.R. Hines ◽

Y. Gu ◽

A.A. Martin ◽

P. Li ◽

J. Fleischer ◽

...

Keyword(s):

Electronic Circuits ◽

Jet Printing ◽

Aerosol Jet Printing

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Online Monitoring of Functional Electrical Properties in Aerosol Jet Printing Additive Manufacturing Process Using Shape-From-Shading Image Analysis

Journal of Manufacturing Science and Engineering ◽

10.1115/1.4036660 ◽

2017 ◽

Vol 139 (10) ◽

Cited By ~ 17

Author(s):

Roozbeh (Ross) Salary ◽

Jack P. Lombardi ◽

Prahalad K. Rao ◽

Mark D. Poliks

Keyword(s):

Cross Section ◽

Electrical Resistance ◽

Online Monitoring ◽

Shape From Shading ◽

Sectional Area ◽

Cross Sectional ◽

Jet Printing ◽

The Cross ◽

Aerosol Jet Printing ◽

Line Resistance

The goal of this research is online monitoring of functional electrical properties, e.g., resistance, of electronic devices made using aerosol jet printing (AJP) additive manufacturing (AM) process. In pursuit of this goal, the objective is to recover the cross-sectional profile of AJP-deposited electronic traces (called lines) through shape-from-shading (SfS) analysis of their online images. The aim is to use the SfS-derived cross-sectional profiles to predict the electrical resistance of the lines. An accurate characterization of the cross section is essential for monitoring the device resistance and other functional properties. For instance, as per Ohm’s law, the electrical resistance of a conductor is inversely proportional to its cross-sectional area (CSA). The central hypothesis is that the electrical resistance of an AJP-deposited line estimated online and in situ from its SfS-derived cross-sectional area is within 20% of its offline measurement. To test this hypothesis, silver nanoparticle lines were deposited using an Optomec AJ-300 printer at varying sheath gas flow rate (ShGFR) conditions. The four-point probes method, known as Kelvin sensing, was used to measure the resistance of the printed structures offline. Images of the lines were acquired online using a charge-coupled device (CCD) camera mounted coaxial to the deposition nozzle of the printer. To recover the cross-sectional profiles from the online images, three different SfS techniques were tested: Horn’s method, Pentland’s method, and Shah’s method. Optical profilometry was used to validate the SfS cross section estimates. Shah’s method was found to have the highest fidelity among the three SfS approaches tested. Line resistance was predicted as a function of ShGFR based on the SfS-estimates of line cross section using Shah’s method. The online SfS-derived line resistance was found to be within 20% of offline resistance measurements done using the Kelvin sensing technique.

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