scholarly journals Printed Strain Gauge on 3D and Low-Melting Point Plastic Surface by Aerosol Jet Printing and Photonic Curing

Sensors ◽  
2019 ◽  
Vol 19 (19) ◽  
pp. 4220 ◽  
Author(s):  
Michela Borghetti ◽  
Mauro Serpelloni ◽  
Emilio Sardini
Keyword(s):  
Manufacturing Process ◽  
Printed Electronics ◽  
Volume Resistivity ◽  
Smart Devices ◽  
Gauge Factor ◽  
Temperature Sensitive ◽  
Thermal Coefficient ◽  
Plastic Surface ◽  
Jet Printing ◽  
Aerosol Jet Printing

Printing sensors and electronics directly on the objects is very attractive for producing smart devices, but it is still a challenge. Indeed, in some applications, the substrate that supports the printed electronics could be non-planar or the thermal curing of the functional inks could damage temperature-sensitive substrates such as plastics, fabric or paper. In this paper, we propose a new method for manufacturing silver-based strain sensors with arbitrary and custom geometries directly on plastic objects with curvilinear surfaces: (1) the silver lines are deposited by aerosol jet printing, which can print on non-planar or 3D surfaces; (2) photonic sintering quickly cures the deposited layer, avoiding the overheating of the substrate. To validate the manufacturing process, we printed strain gauges with conventional geometry on polyvinyl chloride (PVC) conduits. The entire manufacturing process, included sensor wiring and optional encapsulation, is performed at room temperature, compatible with the plastic surface. At the end of the process, the measured thickness of the printed sensor was 8.72 μm on average, the volume resistivity was evaluated 40 μΩ∙cm, and the thermal coefficient resistance was measured 0.150 %/°C. The average resistance was (71 ± 7) Ω and the gauge factor was found to be 2.42 on average.

scholarly journals Printed Smart Devices on Cellulose-Based Materials by means of Aerosol-Jet Printing and Photonic Curing

Sensors ◽  
2020 ◽  
Vol 20 (3) ◽  
pp. 841 ◽  
Author(s):  
Mauro Serpelloni ◽  
Edoardo Cantù ◽  
Michela Borghetti ◽  
Emilio Sardini
Keyword(s):  
Printed Electronics ◽  
Optical Microscope ◽  
Research Field ◽  
Smart Devices ◽  
Chromatographic Paper ◽  
Cellulose Substrates ◽  
Photonic Curing ◽  
Jet Printing ◽  
High Flexibility ◽  
Aerosol Jet Printing

Printed electronics is an expanding research field that can reach the goal of reducing the environmental impact on electronics exploiting renewable and biodegradable materials, like paper. In our work, we designed and tested a new method for fabricating hybrid smart devices on cellulose substrates by aerosol jet printing (AJP) and photonic curing, also known as flash lamp annealing (FLA), capable to cure low temperature materials without any damage. Three different cellulose-based materials (chromatographic paper, photopaper, cardboard) were tested. Multilayer capability and SMDs (surface mount devices) interconnections are possible permitting high flexibility in the fabrication process. Electrical and geometrical tests were performed to analyze the behavior of printed samples. Resulted resistivities are 26.3 × 10−8 Ω⋅m on chromatographic paper, 22.3 × 10−8 Ω⋅m on photopaper and 13.1 × 10−8 Ω⋅m on cardboard. Profilometer and optical microscope evaluations were performed to state deposition quality and penetration of the ink in cellulose materials (thicknesses equal to 24.9, 28.5, and 51 μm respectively for chromatographic paper, photopaper, and cardboard). Furthermore, bending (only chromatographic paper did not reach the break-up) and damp environment tests (no significant variations in resistance) where performed. A final prototype of a complete functioning multilayer smart devices on cellulose 3D-substrate is shown, characterized by multilayers, capacitive sensors, SMDs interconnections.

scholarly journals Future Sensors for Smart Objects by Printing Technologies in Industry 4.0 Scenario

Energies ◽  
2020 ◽  
Vol 13 (22) ◽  
pp. 5916
Author(s):  
Michela Borghetti ◽  
Edoardo Cantù ◽  
Emilio Sardini ◽  
Mauro Serpelloni
Keyword(s):  
Industry 4.0 ◽  
Printed Electronics ◽  
Spare Parts ◽  
Smart Devices ◽  
Smart Objects ◽  
Photonic Curing ◽  
Jet Printing ◽  
Manufacturing Technologies ◽  
Aerosol Jet Printing ◽  
Physical Quantities

Industry 4.0 has radically been transforming the production processes and systems with the adoption of enabling technologies, such as Internet of things (IoT), big data, additive manufacturing (AM), and cloud computing. In this context, sensors are essential to extract information about production, spare parts, equipment health, and environmental conditions necessary for improving many aspects of industrial processes (flexibility, efficiency, costs, etc.). Sensors should be placed everywhere (on machines, smart devices, objects, and tools) inside the factory to monitor in real-time physical quantities such as temperature, vibrations, deformations that could affect the production. Printed electronics (PE) offers techniques to produce unconventional sensor and systems or to make conventional objects “smart”. This work aims to analyze innovative PE technologies—inkjet printing and aerosol jet printing in combination with photonic curing—as manufacturing technologies for electronics and sensors to be integrated into objects, showing a series of sensors fabricated by PE as applications that will be adopted for smart objects and Industry 4.0.

Quality Modeling of Printed Electronics in Aerosol Jet Printing Based on Microscopic Images

2017 ◽  
Vol 139 (7) ◽  
Author(s):  
Hongyue Sun ◽  
Kan Wang ◽  
Yifu Li ◽  
Chuck Zhang ◽  
Ran Jin
Keyword(s):  
Printed Circuit Boards ◽  
Printed Electronics ◽  
Model Performance ◽  
Image Features ◽  
Direct Write ◽  
Microscopic Images ◽  
Jet Printing ◽  
Manufacturing Techniques ◽  
Input Variables ◽  
Aerosol Jet Printing

Aerosol jet printing (AJP) is a direct write technology that enables fabrication of flexible, fine scale printed electronics on conformal substrates. AJP does not require the time consuming mask and postpatterning processes compared with traditional electronics manufacturing techniques. Thus, the cycle time can be dramatically reduced, and highly personalized designs of electronics can be realized. AJP has been successfully applied to a variety of industries, with different combinations of inks and substrates. However, the quality of the printed electronics, such as resistance, is not able to be measured online. On the other hand, the microscopic image sensors are widely used for printed circuit boards (PCBs) quality quantification and inspection. In this paper, two widely used quality variables of printed electronics, resistance and overspray, will be jointly modeled based on microscopic images for fast quality assessment. Augmented quantitative and qualitative (AUGQQ) models are proposed to use features of microscopic images taken at different locations on the printed electronics as input variables, and resistance and overspray as output variables. The association of resistance and overspray can be investigated through the AUGQQ models formulation. A case study for fabricating silver lines with Optomec® aerosol jet system is used to evaluate the model performance. The proposed AUGQQ models can help assess the printed electronics quality and identify important image features in a timely manner.

scholarly journals Platinum Based Nanoparticles Produced by a Pulsed Spark Discharge as a Promising Material for Gas Sensors

2021 ◽  
Vol 11 (2) ◽  
pp. 526
Author(s):  
Ivan A. Volkov ◽  
Nikolay P. Simonenko ◽  
Alexey A. Efimov ◽  
Tatiana L. Simonenko ◽  
Ivan S. Vlasov ◽  
...  
Keyword(s):  
Gas Sensors ◽  
Printed Electronics ◽  
Polycrystalline Material ◽  
Platinum Oxide ◽  
Oxide Semiconductor ◽  
Feed Material ◽  
Jet Printing ◽  
Maximum Production Rate ◽  
Aerosol Jet Printing ◽  
Pulsed Spark Discharge

We have applied spark ablation technology for producing nanoparticles from platinum ingots (purity of 99.97 wt. %) as a feed material by using air as a carrier gas. A maximum production rate of about 400 mg/h was achieved with an energy per pulse of 0.5 J and a pulse repetition rate of 250 Hz. The synthesized nanomaterial, composed of an amorphous platinum oxide PtO (83 wt. %) and a crystalline metallic platinum (17 wt. %), was used for formulating functional colloidal ink. Annealing of the deposited ink at 750 °C resulted in the formation of a polycrystalline material comprising 99.7 wt. % of platinum. To demonstrate the possibility of application of the formulated ink in printed electronics, we have patterned conductive lines and microheaters on alumina substrates and 20 μm thick low-temperature co-fired ceramic (LTCC) membranes with the use of aerosol jet printing technology. The power consumption of microheaters fabricated on LTCC membranes was found to be about 140 mW at a temperature of the hot part of 500 °C, thus allowing one to consider these structures as promising micro-hotplates for metal oxide semiconductor (MOS) gas sensors. The catalytic activity of the synthesized nanoparticles was demonstrated by measuring the resistance transients of the non-sintered microheaters upon exposure to 2500 ppm of hydrogen.

Temperature Cycling Study of Aerosol-Jet Printed Conductive Silver Traces in Printed Electronics

2021 ◽  
Author(s):  
Beihan Zhao ◽  
Christopher Riso ◽  
David Leslie ◽  
Abhijit Dasgupta ◽  
Siddhartha Das ◽  
...  
Keyword(s):  
Printed Electronics ◽  
Local Stress ◽  
Temperature Cycling ◽  
Early Failures ◽  
History Of ◽  
Jet Printing ◽  
Component Manufacturing ◽  
Reliability Of Electronics ◽  
Aerosol Jet Printing ◽  
Stress Raisers

Abstract Aerosol-Jet Printing (AJP) provides a new method for electronic component manufacturing. Understanding the reliability of electronics printed using the AJP process is essential to take full advantage of this technology and realize its industrial potential. In the current study, we have designed and tested AJP printed samples and conducted failure analysis of those samples that have exhibited early failures. Failures first occurred in the short traces that connect the main traces to the silver pads, due to local stress-raisers caused by local geometric features in the printing geometry. Thermal-Mechanical Finite-Element-Modeling (FEM) has been performed to analyze the cyclic history of thermo-mechanical stress distribution and plastic strain distribution.

A State-of-the-Art Review on Aerosol Jet Printing (AJP) Additive Manufacturing Process

2019 ◽  
Author(s):  
Roozbeh Ross Salary ◽  
Jack P. Lombardi ◽  
Darshana L. Weerawarne ◽  
Prahalad K. Rao ◽  
Mark D. Poliks
Keyword(s):  
Additive Manufacturing ◽  
Flexible Electronics ◽  
Manufacturing Process ◽  
Device Fabrication ◽  
Synthesis Process ◽  
Monitoring And Control ◽  
Loop Control ◽  
Wide Range ◽  
Jet Printing ◽  
Aerosol Jet Printing

Abstract The goal of this work is to forward a comprehensive framework, relating to the most recent research works carried out in the area of flexible and hybrid electronics (FHE) fabrication with the aid of aerosol jet printing (AJP) additive manufacturing process. In pursuit of this goal, the objective is to review and classify a wide range of articles, published recently, concerning various aspects of AJP-based device fabrication, such as material synthesis, process monitoring, and control. AJP has recently emerged as the technique of choice for integration as well as fabrication of a broad spectrum of electronic components and devices, e.g., interconnects, sensors, transistors, optical waveguides, quantum dot arrays, photodetectors, and circuits. This is preeminently because of advantages engendered by AJP process. AJP not only allows for high-resolution deposition of microstructures, but also accommodates a wide renege of ink viscosity. However, AJP is intrinsically complex and prone to gradual drifts of the process output (stemming from ink chemistry and formulation). Consequently, a large number of research works in the literature has focused on in situ process characterization, real-time monitoring, and closed-loop control with the aim to make AJP a rapid, reliable, and robust additive manufacturing method for the manufacture of flexible and hybrid electronic devices. It is expected that the market for flexible electronics will be worth over $50 billion by 2020 [1].

Comparison of Laser Sintering of Silver Nanoparticles in Form of Microdroplets of Nanoink and Dry Nanoparticles Obtained in a Gas Discharge

2020 ◽  
Vol 834 ◽  
pp. 37-41 ◽  
Author(s):  
Pavel V. Arsenov ◽  
Alexey A. Efimov ◽  
Kirill M. Khabarov ◽  
Denis V. Kornyushin ◽  
Victor V. Ivanov
Keyword(s):  
Silver Nanoparticles ◽  
Electrical Resistivity ◽  
Printed Electronics ◽  
Specific Resistance ◽  
Laser Sintering ◽  
Gas Discharge ◽  
Bulk Silver ◽  
Aerosol Printing ◽  
Jet Printing ◽  
Aerosol Jet Printing

This article presents a comparison of laser sintering of deposited nanoparticles obtained by two methods of aerosol jet printing. The first printing method was based on the use of silver nanoparticles in the form of microdroplets contained in nanoink. In the second method, dry nanoparticles were obtained as a result of gas-discharge synthesis without the use of solvents. The nanoparticles in both experiments were deposited on a glass substrate in the form of a line with a width of about 50 ± 5 μm and a height of about 1.0 ± 0.2 μm. Then, the obtained lines were sintered using laser radiation with a wavelength of 1064 nm. As a result of experiments on the deposition and sintering, it was found that the electrical resistivity of the lines of sintered nanoparticles in the form of nanoink and dry nanoparticles obtained in a gas discharge was 8.1 and 4.9 μΩ·cm, respectively. Thus, it has been demonstrated that laser sintering of nanoparticles obtained in a gas discharge makes it possible to achieve a lower specific resistance of lines than the method of aerosol printing using nanoink. In addition, the electrical resistivity of the lines of sintered nanoparticles obtained in a gas discharge is 3 times greater than the electrical resistivity of bulk silver, which is a sufficient result for the creation of conductive elements of printed electronics.

scholarly journals Support-Material-Free Microfluidics on an Electrochemical Sensors Platform by Aerosol Jet Printing

Sensors ◽  
2019 ◽  
Vol 19 (8) ◽  
pp. 1842 ◽  
Author(s):  
Nicolò Giuseppe Di Novo ◽  
Edoardo Cantù ◽  
Sarah Tonello ◽  
Emilio Sardini ◽  
Mauro Serpelloni
Keyword(s):  
Electrochemical Sensors ◽  
Printed Electronics ◽  
Limit Of Detection ◽  
Support Material ◽  
Uv Curable ◽  
Sensor Platform ◽  
Relative Standard ◽  
Wide Range ◽  
Jet Printing ◽  
Aerosol Jet Printing

Printed electronics have led to new possibilities in the detection and quantification of a wide range of molecules important for medical, biotechnological, and environmental fields. The integration with microfluidics is often adopted to avoid hand-deposition of little volumes of reagents and samples on miniaturized electrodes that strongly depend on operator’s skills. Here we report design, fabrication and test of an easy-to-use electrochemical sensor platform with microfluidics entirely realized with Aerosol Jet Printing (AJP). We printed a six-electrochemical-sensors platform with AJP and we explored the possibility to aerosol jet print directly on it a microfluidic structure without any support material. Thus, the sacrificial material removal and/or the assembly with sensors steps are avoided. The repeatability observed when printing both conductive and ultraviolet (UV)-curable polymer inks can be supported from the values of relative standard deviation of maximum 5% for thickness and 9% for line width. We designed the whole microfluidic platform to make the sample deposition (20 μL) independent from the operator. To validate the platform, we quantified glucose at different concentrations using a standard enzyme-mediated procedure. Both mediator and enzyme were directly aerosol jet printed on working electrodes (WEs), thus the proposed platform is entirely fabricated by AJP and ready to use. The chronoamperometric tests show limit of detection (LOD) = 2.4 mM and sensitivity = 2.2 ± 0.08 µA/mM confirming the effectiveness of mediator and enzyme directly aerosol jet printed to provide sensing in a clinically relevant range (3–10 mM). The average relative standard inter-platform deviation is about 8%. AJP technique can be used for fabricating a ready-to-use microfluidic device that does not need further processing after fabrication, but is promptly available for electrochemical sample analysis.

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