A quantitative analysis of overspray in Aerosol Jet® printing

气溶胶 GSM演进的增强数据速率 环境科学 工艺工程 机械工程 计算机科学 工程类 气象学 电信 物理
作者
James Q. Feng,Alex Ramm,Michael J. Renn
出处
期刊:Flexible and printed electronics [IOP Publishing]
卷期号:6 (4): 045006-045006 被引量:12
标识
DOI:10.1088/2058-8585/ac3019
摘要

Abstract As Aerosol Jet® (AJ) printing is becoming more attractive to additive manufacturing, printed electronics, among other applications, reducing or minimizing the amount of ink droplets landing in unintended regions—known as the overspray—has been elevated on the agenda for print quality control and improvement. Many AJ users had discussed the overspray issue associated with AJ printing, while the metrology for quantified evaluation of overspray is still lacking. In this work, the likely physical mechanism for inducing overspray is analyzed along with a set of computational fluid dynamics (CFD) simulations. We then present a 2D image processing method for quantitatively evaluating the severity of overspray in terms of its percent area coverage versus a normalized distance from printed line edge. Our results show that the amount of overspray of AJ printing seems to scale with the printed line width (LW), and usually to become negligible (e.g. percent area coverage of overspray < 1%) beyond 30%–40% of LW from line edges. The overspray is shown to often decrease by increasing the jet velocity and sheath-to-mist ratio. Without loss of generality and for concise illustration, herewith we use only one representative ink to print test samples for the quantitative overspray analysis. The results have been found to bear a resemblance to AJ printed features with many other inks.
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