Silver nanoparticle electrospray laser deposition for additive manufacturing of microlayers on rigid or flexible substrates

Abstract

Nanoparticles of various materials are known to possess excellent mechanical, chemical, electrical, and optical properties. However, it is difficult to deposit and transform nanoparticles into large two-dimensional and threedimensional structures in a controlled manner. A laser-based new additive manufacturing process is presented for depositing nanoparticles using an electrospray technology. This process is versatile and scalable, and uses less materials and energy. In this process, aqueous microdroplets of nanoparticle suspension are injected into a hollow laser beam that vaporizes the water, sinters the nanoparticles and deposits nanoparticles on rigid or flexible substrates. Nanoparticles of silver have been deposited on silicon wafer, card stock and polyimide film, and high precision deposition has been observed to occur under a particular microfluidic regime called microdripping mode. This process can promote roll-toroll manufacturing of a variety of energy and electronic devices such as conformal solar cells, sensors, and actuators.