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A novel approach to improve reliability of aerosol jet printing process

Winnicki Marcin, Łapa Wojciech, Świadkowski Bartosz

Eksploatacja i Niezawodność

2024

Vol. 26, no. 2

art. no. 180012

Additive manufacturingis gaining interest for printing of noble metals. In this study, aerosol jet printingwas applied to fabricate traces from commercialsilver nanoparticleink. A self-built three dimensional printing machine was used without or with in-line substrate heating. A conductive traces were printed on flexible polyimide substrates. Subsequently, sintering was conducted by furnace or near-infrared source. Examination of the sample using scanning electron and atomic force microscopy revealed the existence of both micro-and nanoscale pores in the structure. Local open porosity, aerosol extensive spatter and wide porous overspray were key defects found in samples printed without substrate heating. All the features affect the properties and reliability of silver prints.In-line process heating increased the concentration of nanoparticles and limited defects formation. What is more, the width of traces decreased from 31 µm to 19 µm with simultaneous thickness increase from 1.2 to 5.5 µm due to substrate heating. The final structure was influenced by sintering method and its time. Elongated time of sintering decreased porosity and roughness of the printed traces. Nevertheless,IR sintering provided the smoothest sample surface with lowest Sa roughness of 16 nm,and significantly improved bonding of aggregates. What is more, the printed structure had a measured sheet resistance of 8.3×10−2Ω/□.

Investigation of aerosol droplets diameter generated in aerosol jet printing

Łapa Wojciech, Winnicki Marcin, Orłowska Karolina

Materials Science Poland

2022

Vol. 40, No. 4

78--90

Aerosol jet printing is a contactless direct-write technique that could be used for the deposition of a variety of materials. First, used for electric paths, the technology was explored for many applications. The substantial part of the process is the generation of aerosols. The size of the droplets and the stability of the process affect the quality of the sprayed lines. This article investigates the diameter of the sprayed droplets, allowing future comparison of the results with sprayed lines. Droplets from ultrasonic and pneumatic generators were sprayed at their outlet on the polyethylene terephthalate (PET) foil. Using a digital microscope and the built-in algorithm, the diameter of the droplets was measured, and the dataset was collected as CSV files and served as a background to the box plot. Scanning electron microscopy (SEM) and atomic force microscopy (AFM) scans were applied to verify the results obtained. The ink parameters used in the process have an influence on the aerosol generation and droplet diameter, whereas the carrier gas pressure has an impact mostly on the droplet diameter. In this case, the aerosol was produced from three types of ink in combination with two generators. For inks with a dynamic viscosity below 6.5 m·Pa-1·s-1a stable range of 5–10 μm droplet diameter was observed. A high-viscosity ink (7.5–10.5 m·Pa-1·s-1) produced droplets with diameter in the range of 6–25 μm. The diameter of the droplet decreased from 7–22 μm to 1–5 μm with a reduction in the dynamic viscosity from 7.5–10.5 m·Pa-1·s-1 to 4.5–5.5 m·Pa-1·s-1.