Aerosol Jet Printing Research Articles

High-Resolution Bioprinting of Recombinant Human Collagen Type III.

The development of commercial collagen inks for extrusion-based bioprinting has increased the amount of research on pure collagen bioprinting, i.e., collagen inks not mixed with gelatin, alginate, or other more common biomaterial inks. New printing techniques have also improved the resolution achievable with pure collagen bioprinting. However, the resultant collagen constructs still appear too weak to replicate dense collagenous tissues, such as the cornea. This work aims to demonstrate the first reported case of bioprinted recombinant collagen films with suitable optical and mechanical properties for corneal tissue engineering. The printing technology used, aerosol jet® printing (AJP), is a high-resolution printing method normally used to deposit conductive inks for electronic printing. In this work, AJP was employed to deposit recombinant human collagen type III (RHCIII) in overlapping continuous lines of 60 µm to form thin layers. Layers were repeated up to 764 times to result in a construct that was considered a few hundred microns thick when swollen. Samples were subsequently neutralised and crosslinked using EDC:NHS crosslinking. Nanoindentation and absorbance measurements were conducted, and the results show that the AJP-deposited RHCIII samples possess suitable mechanical and optical properties for corneal tissue engineering: an average effective elastic modulus of 506 ± 173 kPa and transparency ≥87% at all visible wavelengths. Circular dichroism showed that there was some loss of helicity of the collagen due to aerosolisation. SDS-PAGE and pepsin digestion were used to show that while some collagen is degraded due to aerosolisation, it remains an inaccessible substrate for pepsin cleavage.

Digitally Driven Aerosol Jet Printing to Enable Customisable Neuronal Guidance.

Digitally driven manufacturing technologies such as aerosol jet printing (AJP) can make a significant contribution to enabling new capabilities in the field of tissue engineering disease modeling and drug screening. AJP is an emerging non-contact and mask-less printing process which has distinct advantages over other patterning technologies as it offers versatile, high-resolution, direct-write deposition of a variety of materials on planar and non-planar surfaces. This research demonstrates the ability of AJP to print digitally controlled patterns that influence neuronal guidance. These consist of patterned poly(3,4-ethylenedioxythiophene)-poly(styrenesulfonate) (PEDOT:PSS) tracks on both glass and poly(potassium 3-sulfopropyl methacrylate) (PKSPMA) coated glass surfaces, promoting selective adhesion of SH-SY5Y neuroblastoma cells. The cell attractive patterns had a maximum height ≥0.2 μm, width and half height ≥15 μm, Ra = 3.5 nm, and RMS = 4.1. The developed biocompatible PEDOT:PSS ink was shown to promote adhesion, growth and differentiation of SH-SY5Y neuronal cells. SH-SY5Y cells cultured directly onto these features exhibited increased nuclei and neuronal alignment on both substrates. In addition, the cell adhesion to the substrate was selective when cultured onto the PKSPMA surfaces resulting in a highly organized neural pattern. This demonstrated the ability to rapidly and flexibly realize intricate and accurate cell patterns by a computer controlled process.

Fabrication of Conductive and Gas-Sensing Microstructures Using Focused Deposition of Copper Nanoparticles Synthesized by Spark Discharge

Solvent-free aerosol jet printing has been investigated for fabricating metallic and semiconductor (gas-sensitive) microstructures based on copper nanoparticles on alumina, borosilicate glass, and silicon substrates. The synthesis of nanoparticles was carried out using a spark discharge directly in the printing process without the stage of preparing nano-ink. Printed lines with a width of 100–150 µm and a height of 5–7 µm were formed from submicron agglomerates consisting of primary nanoparticles 10.8 ± 4.9 nm in size with an amorphous oxide shell. The electrical resistivity, surface morphology, and shrinkage of printed lines were investigated depending on the reduction sintering temperature. Sintering of copper oxides of nanoparticles began at a temperature of 450 °C in a hydrogen atmosphere with shrinkage at the level of 45–60%. Moreover, aerosol heat treatment was used to obtain highly conductive lines by increasing the packing density of deposited nanoparticles, providing in-situ transformation of submicron agglomerates into spherical nanoparticles with a size of 20–50 nm. Copper lines of spherical nanoparticles demonstrated excellent resistivity at 5 μΩ·cm, about three times higher than that of bulk copper. In turn, semiconductor microstructures based on unsintered agglomerates of oxidized copper have a fairly high sensitivity to NH3 and CO. Values of response of the sensor based on non-sintered oxidized copper nanoparticles to ammonia and carbon monoxide concentration of 40 ppm were about 20% and 80%, respectively.

Electroplating of Aerosol Jet‐Printed Silver Inks

Aerosol jet printing of silver inks is a promising approach for 3D printing of electronics, particularly for obtaining very complex circuits with high‐resolution conductive pads and traces. Common silver inks are however not competitive with traditional bulk metal conductors, requiring sintering at high temperatures as well as having significant porosity that can result in early failure. Herein, the possibility of using electroplating to deposit bulk metal copper on aerosol jetted inks is investigated, and more than an order of magnitude reduction in electrical resistivity is shown. The plating rate, resistivity, and adhesion are characterized, along with the morphology of the resulting deposits. This approach is then shown to allow high‐strength soldering to the electroplated metal traces, demonstrating the capability of this technology for integration of soldered surface mount components with aerosol jet‐printed electronics.

Additive Manufacturing of a Wideband Capable W-Band Packaging Strategy

In this letter, we demonstrate a fully additively manufactured packaged $W$ -band amplifier with integrated bypass capacitors. This package was fabricated using a chip-first approach and aerosol jet printing (AJP). Package substrates (dielectrics), conductors, and interconnects are printed around a bare die attached to a carrier. This package uses shaped ramp interconnects, allowing for frequency agnostic performance of the interconnect with no impedance discontinuity, within the physical limits of the printer. High dielectric constant thin films of a polymer-matrix nanocomposite for bypass capacitors were printed using multimaterial AJP. The maximum measured packaged gain is 14.9 dB in the $W$ -band compared to the maximum bare die gain of 15.5 dB in the same frequency range. From 75 to 92 GHz, the average package loss is 1.1 dB including 3-mm transmission line, interconnects, and a ground-signal-ground (GSG) launch structure correlating to an average loss of 0.37 dB/mm.

Reviews on Machine Learning Approaches for Process Optimization in Noncontact Direct Ink Writing.

Recently, machine learning has gained considerable attention in noncontact direct ink writing because of its novel process modeling and optimization techniques. Unlike conventional fabrication approaches, noncontact direct ink writing is an emerging 3D printing technology for directly fabricating low-cost and customized device applications. Despite possessing many advantages, the achieved electrical performance of produced microelectronics is still limited by the printing quality of the noncontact ink writing process. Therefore, there has been increasing interest in the machine learning for process optimization in the noncontact direct ink writing. Compared with traditional approaches, despite machine learning-based strategies having great potential for efficient process optimization, they are still limited to optimize a specific aspect of the printing process in the noncontact direct ink writing. Therefore, a systematic process optimization approach that integrates the advantages of state-of-the-art machine learning techniques is in demand to fully optimize the overall printing quality. In this paper, we systematically discuss the printing principles, key influencing factors, and main limitations of the noncontact direct ink writing technologies based on inkjet printing (IJP) and aerosol jet printing (AJP). The requirements for process optimization of the noncontact direct ink writing are classified into four main aspects. Then, traditional methods and the state-of-the-art machine learning-based strategies adopted in IJP and AJP for process optimization are reviewed and compared with pros and cons. Finally, to further develop a systematic machine learning approach for the process optimization, we highlight the major limitations, challenges, and future directions of the current machine learning applications.

Light scattering measurements to support real-time monitoring and closed-loop control of aerosol jet printing

Process monitoring and control is highly desired for additive manufacturing technologies. For aerosol jet printing, in particular, process drift and batch-to-batch variability have hindered widespread adoption beyond research environments. Addressing these key challenges is critical for emerging applications in multilayer, conformal, and 3D applications of this technology. Here, an in situ light scattering method is introduced to track the aerosol stream during printing, providing a real-time quantitative measurement directly related to the deposition rate. The generality of this method for different functional inks is demonstrated, including its applicability to functional electrical properties such as electrical resistance. Finally, the stability of this measurement supports closed-loop control over extended, continuous printing runs, offering a compelling technology to advance aerosol jet printing for hybrid electronics and high resolution functional additive manufacturing.

Fully printed resonance-free broadband conical inductors using engineered magnetic inks

The current technologies of 3D printing have a huge potential in the domain of printed radio frequency (RF) electronic components, such as resistors, capacitors, inductors, and transmission lines. In this paper, we present the design, fabrication, and characterization of fully 3-D printed conical inductors for broadband applications. The cores of these conical-shaped inductors were all printed by engineered magnetic/dielectric materials: the first one with a polymer core was printed by the aerosol-jet (AJ) printing technology as a reference, the second one with an iron-cobalt core fabricated by a paste-extrusion (PE) method using our developed iron-cobalt-based magnetic ink, and the third one with a core fabricated (by the PE method) using iron-based powder. The conical inductor was placed at a 45° angle by mounting it on a lattice support structure, and this configuration ensured a reduction of the parasitic capacitance between the inductor and the substrate. As a result, it was possible, to achieve a resonant-free broadband performance beyond the Ka-band (26.5–40 GHz), thereby outperforming the commercial off-the-shelf (COTS) products. Numerical simulations were also performed to explain the inductor performance and pinpoint the optimal model parameters. As suggested by the lumped circuit model, the operational frequency of the fully 3D printed iron-powder-based-core inductor could be as high as 67 GHz, which is nearly two times larger than the commercial iron core inductor.

Additive Manufacturing of a W-Band System-on-Package

In this article, we demonstrate the design, fabrication, and characterization of a <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"> <tex-math notation="LaTeX">$W$ </tex-math></inline-formula> -band system-on-package (SoP). This package is fully additively manufactured using a chip-first process and aerosol jet printing. With this method, we implement a transceiver consisting of two bare die amplifiers for transmitted and received signals, a bare die switch, printed bypass capacitors, surface-mount resistors for biasing networks, and a printed patch antenna, operating between 77.1 and 79.0 GHz. The second patch antenna of the same design, fabricated simultaneously, is used to characterize the antenna performance alone and the packaged components. Package substrates (dielectrics), conductors, and interconnects are printed around bare die attached to a carrier. Thin-film bypass capacitor dielectrics were printed using multimaterial aerosol jet printing (MMAJP), where aerosols of barium titanate and polyimide inks are mixed in place to form a high <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"> <tex-math notation="LaTeX">$\epsilon _{r}$ </tex-math></inline-formula> polymer matrix nanocomposite film. <inline-formula xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink"> <tex-math notation="LaTeX">$W$ </tex-math></inline-formula> -band interconnect performance is achieved using conformal-shaped ramp interconnects, allowing for frequency agnostic performance of the interconnect with no impedance discontinuity, within the physical limits of the printer. The antenna alone achieves a maximum gain of 6.7 dBi at 78.3 GHz, and the SoP achieves a gain of 16.4 dBi for the package. We estimate the package loss to be 2.8 dB or 0.6 dB/mm, including interconnects.

Carbon nanotube thermoelectric devices by direct printing: Toward wearable energy converters

Thermoelectric devices convert thermal energy to electrical energy and are particularly well-suited for energy harvesting from waste heat. Even as the number of electronic devices used in daily life proliferates, technical advances diminish the average power such devices require to perform a given function. Localized thermal gradients that abound in our living environments, despite having modest energy densities, are therefore becoming increasingly viable and attractive to power such devices. With this motivation, we report the design, fabrication, and characterization of single-wall carbon nanotube thermoelectric devices (CNT-TDs) on flexible polyimide substrates as a basis for wearable energy converters. Our aqueous-solution-based film fabrication process could enable readily scalable, low-cost TDs; here, we demonstrate CNT-hydroxypropyl cellulose (HPC) composite thermoelectric films by aerosol jet printing. The electrical conductivity of the composite films is controlled through the number of CNT/HPC layers printed in combination with control of the annealing conditions. The HPC initially disperses the CNTs in deionized water, the greenest of solvents, and is subsequently partially eliminated from the film by annealing, with concomitant morphological changes that we characterized by TEM. HPC removal is key to obtaining good electrical conductivity (0.94 to 1.10 × 105 S/m) and Seebeck coefficients (36 to 43 μV/K). We also report a power factor of 208 μW m−1 K−2 for a CNT-TD composed of 15 layers of CNT/HPC, promising performance for CNT-based flexible TDs that are deposited from aqueous solution, stable in air, and require no additional doping or sorting processes.

All-aerosol-jet-printed highly sensitive and selective polyaniline-based ammonia sensors: a route toward low-cost, low-power gas detection

We report the design and scalable fabrication of a low-cost and low-power polyaniline-based (PANI) ammonia (NH3) gas sensor on polyimide (PI) substrates using additive manufacturing techniques. The silver interdigitated electrode (IDE) arrays and conducting polymer films are printed onto PI using a direct-write technology of aerosol-jet printing. Morphological characteristics are examined by scanning electron microscopy and energy-dispersive X-ray analysis which reveal homogeneously printed PANI film on the IDE platform. The gas sensing performance is evaluated in the analytical early leak detection range of 5–1000 ppm NH3 in air as a function of both thermal (23 °C, 50 °C, 80 °C) and relative humidity (RH = 0%, 30%, 50%) exposures. The sensor exhibits sensitivity down to 5 ppm NH3 with a sub-ppm detection limit and good repeatability. We observe rapid NH3 detection at 0% RH with very extended times for equilibration and recovery. However, at both 30 and 50% RH, the room temperature response and recovery times are reduced to only about 1 min and 5 min, respectively. Experiments also reveal good sensitivity toward the analyte even at higher operating temperatures. Present results merit the practical application of aerosol-jet-printed, low-power sensors for industrial applications where low-level hazardous gas detection is essential.

Optimization of the conductivity of microwave components printed by inkjet and aerosol jet on polymeric substrates by IPL and laser sintering

AbstractIn this work, microwave planar resonators are printed with silver nanoparticle inks using two printing technologies, inkjet printing and aerosol jet printing, on polyimide substrates. The microwave resonators used in this paper operate in the frequency band 5–21 GHz. The printing parameters, such as the number of printed layers of silver nanoparticle inks, drop spacing, and sintering time, were optimized to ensure repeatable and conductive test patterns. To improve the electrical conductivity of silver deposits, which are first dried using a hot plate or an oven, two complementary sintering methods are used: intense pulsed light (IPL) and laser sintering. This paper presents the results of different strategies for increasing the final quality factor of printed planar resonators and the trade-offs (sintering time versus final conductivity/unloaded Q) that can be reached. Improvement of the resonator unloaded quality factor (up to +55%) and of the equivalent electrical conductivity (up to 14.94 S/μm) at 14 GHz have been obtained thanks to these nonconventional sintering techniques. The total sintering durations of different combinations of sintering techniques (hot plate, oven, IPL, and laser) range from 960 to 90 min with a final conductivity from 14.94 to 7.1 S/μm at 14 GHz, respectively.

Multimaterial Aerosol Jet Printed Magnetic Nanocomposites for Microwave Circuits

This article demonstrates the process and characterization of additively manufactured polymer-matrix magnetic nanocomposites. These nanocomposites are composed of nickel-zinc ferrite (Ni <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">0.5</sub> Zn <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">0.5</sub> Fe <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</sub> O <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">4</sub> ) nanoparticles in a polyimide matrix. These materials are printed using multimaterial aerosol jet printing where aerosols of nickel-zinc ferrite and polyimide inks are mixed in place to fabricate structures with nonunity relative permeability. To characterize these materials, we use energy-dispersive X-ray spectroscopy to estimate the content of ferrite in the composite, fitted simulation models, and ring resonator measurements to estimate the permeability. In fully aerosol jet printed 1-mm <sup xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</sup> inductors, we demonstrate an increase in inductance density of 40% in a 4.5-turn microstrip spiral inductor using this printed composite. These fully printed inductors demonstrate an inductance density of 4.2-nH/mm <sup xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</sup> . EDS analysis shows films with 18 wt.% Ni <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">0.5</sub> Zn <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">0.5</sub> Fe <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">2</sub> O <sub xmlns:mml="http://www.w3.org/1998/Math/MathML" xmlns:xlink="http://www.w3.org/1999/xlink">4</sub> . Finally, we show microstrip transmission lines on printed composite compared to the same on polyimide subjected to a dc magnetic bias, displaying a magnetic resonance behavior.

High Resolution Aerosol Jet Printed Components with Electrodeposition-Enhanced Conductance

Aerosol Jet Printing (AJP) is one technique of additive manufacturing used in the printing of electronics components. AJP enables the patterning of features at the ∼10 μm–100 μm scale based on hardware and print parameters. Optimization of print conditions enables the printing of high-resolution features with linewidths approaching 10 μm. The aerosol jet printing of electronic parts can be limited by the conductivities which are achievable by Ag nanoparticle inks (typically 15%–25% of bulk Ag). For certain electronics applications, the increased conductivity produces unacceptable loses during operation and methods are needed to increase the conductance of the devices without sacrificing resolution. Here, we report on the AJP of inductor spirals conductor traces of linewidth 50 μm separated by 55 μm gaps. The conductivity of these features is enhanced by electrodeposition of Cu onto the Ag, resulting in a decrease in resistance of 35–45x. Impedance measurements demonstrate that the addition of Cu by electrodeposition to a 27-turn spiral inductor resulted in an inductance of 3.6 μH. Finally, we demonstrate the use of a lift-off process to produce free-standing, flexible, conductive films using AJP.

Printable and recyclable carbon electronics using crystalline nanocellulose dielectrics

Electronic waste can lead to the accumulation of environmentally and biologically toxic materials and is a growing global concern. Developments in transient electronics-in which devices are designed to disintegrate after use-have focused on increasing the biocompatibility, whereas efforts to develop methods to recapture and reuse materials have focused on conducting materials, while neglecting other electronic materials. Here, we report all-carbon thin-film transistors made using crystalline nanocellulose as a dielectric, carbon nanotubes as a semiconductor, graphene as a conductor and paper as a substrate. A crystalline nanocellulose ink is developed that is compatible with nanotube and graphene inks and can be written onto a paper substrate using room-temperature aerosol jet printing. The addition of mobile sodium ions to the dielectric improves the thin-film transistor on-current (87 μA mm-1) and subthreshold swing (132 mV dec-1), and leads to a faster voltage sweep rate (by around 20 times) than without ions. The devices also exhibit stable performance over six months in ambient conditions and can be controllably decomposed, with the graphene and carbon nanotube inks recaptured for recycling (>95% recapture efficiency) and reprinting of new transistors. We demonstrate the utility of the thin-film transistors by creating a fully printed, paper-based biosensor for lactate sensing.

Aerosol-jet-printed, conformable microfluidic force sensors

SummaryForce sensors that are thin, low-cost, flexible, and compatible with commercial microelectronic chips are of great interest for use in biomedical sensing, precision surgery, and robotics. By leveraging a combination of microfluidics and capacitive sensing, we develop a thin, flexible force sensor that is conformable and robust. The sensor consists of a partially filled microfluidic channel made from a deformable material, with the channel overlaying a series of interdigitated electrodes coated with a thin, insulating polymer layer. When a force is applied to the microfluidic channel reservoir, the fluid is displaced along the channel over the electrodes, thus inducing a capacitance change proportional to the applied force. The microfluidic molds themselves are made of low-cost sacrificial materials deposited via aerosol-jet printing, which is also used to print the electrode layer. We envisage a large range of industrial and biomedical applications for this force sensor.

Optimizing Aerosol Jet Printing Process of Platinum Ink for High-Resolution Conductive Microstructures on Ceramic and Polymer Substrates.

Printing nano-ink with platinum nanoparticles to generate conductive microstructures for electronics on different types of substrates has gained increasing interest in recent years. To solve the problem of the low conductivity of platinum (Pt) nano-ink, we synthesized chemically pure Pt nanoparticles with sizes of 18.2 ± 9.0 nm by spark discharge method. A low toxic solvent, ethylene glycol with water, was used to ensure the aggregation stability of Pt nanoparticles. Polyvinylpyrrolidone was used as an adhesive additive and binder in the nano-ink. Narrow and conductive Pt lines were generated by aerosol jet printing technology. The resistivity of the Pt lines sintered at 750 °C on alumina substrate was found to exceed the bulk Pt by about 13%. Moreover, the Pt film fabricated on polymer substrates has demonstrated excellent mechanical flexibility in terms of twisting tests.

Modular motion control software development to support a versatile, low-cost aerosol jet platform for printed electronics

A wide variety of digital fabrication methods rely on computer numerical control motion systems for positioning and synchronization of complex functions. Although low-cost microcontrollers have supported widespread adoption of 3D printing and greatly reduced barriers to market entry, higher precision printing methods such as aerosol jet printing continue to rely on expensive, purpose-built motion control platforms. Advances in low-cost and versatile microcontrollers present a compelling opportunity for the design of inexpensive, simple, and modular motion control applications suitable for precision printing modalities that require multitasking. Here, an aerosol jet printer is developed with an inexpensive 32-bit microcontroller using real-time operating system features. Multitasking enables robust synchronization of the motion system with a variety of peripheral hardware devices necessary for functional patterning. This is demonstrated for electronic inks with competitive performance compared to high-end commercial printing platforms, while maintaining a modular, accessible, and versatile framework to support portability for hybrid manufacturing capabilities.

MODs vs. NPs: Vying for the Future of Printed Electronics.

This Minireview compares two distinct ink types, namely metal‐organic decomposition (MOD) and nanoparticle (NP) formulations, for use in the printing of some of the most conductive elements: silver, copper and aluminium. Printing of highly conductive features has found purpose across a broad array of electronics and as processing times and temperatures reduce, the avenues of application expand to low‐cost flexible substrates, materials for wearable devices and beyond. Printing techniques such as screen, aerosol jet and inkjet printing are scalable, solution‐based processes that historically have employed NP formulations to achieve low resistivity coatings printed at high resolution. Since the turn of the century, the rise in MOD inks has vastly extended the range of potentially applicable compounds that can be printed, whilst simultaneously addressing shelf life and sintering issues. A brief introduction to the field and requirements of an ink will be presented followed by a detailed discussion of a wide array of synthetic routes to both MOD and NP inks. Unindustrialized materials will be discussed, with the challenges and outlook considered for the market leaders: silver and copper, in comparison with the emerging field of aluminium inks.

A knowledge transfer framework to support rapid process modeling in aerosol jet printing

Aerosol jet printing (AJP) technology recently gained considerable attention in an electronic manufacturing industry due to its ability to fabricate parts with fine resolution and high flexibility. However, morphology control has been identified as the main limitation of AJP process, which drastically affects the electrical performance of printed components. Even though previous researches have made significant efforts in process modeling to improve the controllability of the the printed line morphology, the modeling process is still inefficient under modified operating conditions due to the repeated experiments. In this paper, a knowledge transfer framework is proposed for efficient modeling of the AJP process under varied operating conditions. The proposed framework consists of three critical steps for rapid process modeling of AJP. First, a sufficient source domain dataset at a certain operating condition is collected to develop a source model based on Gaussian process regression. Then, the representative experimental points are selected from the source domain to construct a target dataset under different operating conditions. Finally, classical knowledge transfer approaches are adopted to extract the built-in knowledge from the source model; thus, a new process model can be developed efficiently by the transferred knowledge and the representative dataset from the target domain. The validity of the proposed framework for the rapid process modeling of AJP is investigated by case study, and the limitations of the classical knowledge transfer approaches adopted in AJP are also analyzed systematically. The proposed framework is developed based on the principles of knowledge discovery, which is different from traditional process modeling approaches in AJP. Therefore, the modeling process is more systematic and cost-efficient, which will be helpful to improve the controllability of the line morphology. Additionally, due to its data-driven based characteristics, the proposed framework can be applied to other additive manufacturing technologies for process modeling researches.