Abstract
Aerosol Jet Printing (AJP) is an emerging contactless direct write approach aimed at the production of fine features on a wide range of substrates. Originally developed for the manufacture of electronic circuitry, the technology has been explored for a range of applications, including, active and passive electronic components, actuators, sensors, as well as a variety of selective chemical and biological responses. Freeform deposition, coupled with a relatively large stand-off distance, is enabling researchers to produce devices with increased geometric complexity compared to conventional manufacturing or more commonly used direct write approaches. Wide material compatibility, high resolution and independence of orientation have provided novelty in a number of applications when AJP is conducted as a digitally driven approach for integrated manufacture. This overview of the technology will summarise the underlying principles of AJP, review applications of the technology and discuss the hurdles to more widespread industry adoption. Finally, this paper will hypothesise where gains may be realised through this assistive manufacturing process.
Highlights
Direct write covers a range of processes that can selectively deposit material to produce freeform patterns
The outcome was the development of a number of deposition mechanisms, most notably the Aerosol Jet and Nanojet systems that have since been commercialised by Optomec Inc. and Integrated Deposition Systems (IDS), respectively
This review has avoided a comprehensive comparison with similar direct write technologies, such as inkjet printing, as this is can be found in existing literature [3, 19]
Summary
Direct write covers a range of processes that can selectively deposit material to produce freeform patterns. AJP (Fig. 1) introduced new capabilities to direct write through its use of a directed aerosol stream to provide consistent deposition at nozzle–substrate offsets of 1–5 mm [13]. This approach enables the patterning of more complex surfaces, which was well illustrated through the deposition of a spiral pattern on the surface of a golf ball [14]. For an assistive manufacturing technology—one that is intended to be used as part of a greater, hybrid manufacturing process—this flexibility simplifies control, accommodates less precise articulation and enables patterning on surfaces that cannot be reached by physical nozzles This combination greatly simplifies process integration when compared with other direct write technologies. This review has avoided a comprehensive comparison with similar direct write technologies, such as inkjet printing, as this is can be found in existing literature [3, 19]
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