Computational fluid dynamics and experimental validation of aerosol jet printing with multi-stage flow focusing lenses

Abstract

A 3D computational fluid dynamics (CFD) framework is presented to model and explain critical aerodynamic interactions occurring in the printhead during aerosol jet printing (AJP) with multi-stage flow focusing lenses. AJP has demonstrated great potential to fabricate complex circuits and conductive devices for numerous applications, including flexible electronics, medical diagnostic devices, and fuel cells. However, the devices manufactured by AJP are currently relegated to prototype roles due to poor repeatability of the deposited structures. The lack of process consistency in AJP arises from an incomplete understanding of causal aerodynamic interactions that influence the structure and repeatability of the printed features. Herein, a comprehensive CFD framework is presented to analyze the effects of gas flow rates, nozzle geometry, stand-off distance, printhead design, and aerosol droplet size on the resolution and morphology of printed features. Compressible Navier-Stokes equations with a k-ε turbulence model are solved to simulate flow conditions in the aerosol jet printhead. Additionally, a Lagrangian discrete phase model is used to simulate the transport of aerosolized ink droplets through the turbulent shear flow. The results highlight the crucial role of the design of the mist tube and the first aerodynamic lens, the density of the sheath gas, and the size of the droplets in the aerosol stream in determining print resolution and quality. A favorable comparison was found between numerically calculated results and experimental data obtained using the NanoJet™ system. CFD models presented in this work are expected to aid in identifying optimal process windows a priori, to improve process consistency.