Real-Time Optical Process Monitoring for Structure and Property Control of Aerosol Jet Printed Functional Materials

Rebecca R. Tafoya, Adam W. Cook, Bryan Kaehr, Julia R. Downing, Mark C. Hersam, Ethan B. Secor

Research output: Contribution to journalArticlepeer-review

Abstract

Aerosol jet printing is a popular digital additive manufacturing method for flexible and hybrid electronics, but it lacks sophisticated real-time process control schemes that would enable more widespread adoption in manufacturing environments. Here, an optical measurement system is introduced to track the aerosol density upstream of the printhead. The measured optical extinction, combined with the aerosol flow rate, is directly related to deposition rate and accurately predicts functional materials properties such as the electrical resistance of printed graphene films. This real-time system offers a compelling solution for process drift and batch-to-batch variability, rendering it a valuable tool for both real-time control of aerosol jet printing and fundamental studies of the underlying process science.

Original languageEnglish
Article number2000781
JournalAdvanced Materials Technologies
Volume5
Issue number12
DOIs
Publication statusPublished - Dec 2020

Keywords

  • additive manufacturing
  • aerosol jet printing
  • printed electronics
  • process control

ASJC Scopus subject areas

  • Materials Science(all)
  • Mechanics of Materials
  • Industrial and Manufacturing Engineering

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