Inkjet Research Articles

Effect of high-boiling point solvents on inkjet printing of catalyst layers for proton exchange membrane fuel cells

Inkjet printing (IJP) is considered as a promising and flexible method for low cost and drop-on-demand pattern formation in proton exchange membrane (PEM) fuel cells. Although significant advancements have been made in inkjet-printed electrodes, identifying the optimal ink formulations remains challenging due to severe restrictions on the ink properties. Generally, the catalyst layer prepared by IJP using low boiling point solvents (water/alcohol) show reasonable electrochemical performance. However, low boiling point solvents lead to clogging of the printhead nozzle due to fast evaporation of the solvent in the inkjet print head. In this study, high boiling point solvents (propylene glycol (PG) or ethylene glycol (EG)) were used as additives to reduce nozzle clogging and improve printing efficiency. In this context, the relationship between catalyst ink properties, CL microstructure, and electrochemical performance of the MEA is investigated. Results show that printing time is significantly reduced with adding high boiling point solvents in the ink (66.67 % reduction of time with 30 wt% PG). However, an increased amount of additive is detrimental in terms of electrochemical performance due to formation of larger agglomerates, lower porosity of the catalyst layer, and reduced ECSA. The results of this work can be used to develop a strategy to adjust the trade-off between printing time and electrochemical performance of electrodes prepared using IJP.

Sensitized Reynolds stress modeling of a bubbly jet emerging into a water cross-flow

The present work is concerned with the computational study of an air–water mixture stream emanating from a nozzle submerged in a water cross-flow inside a rectangular open channel to form a curved, intensively dispersed, bubbly jet. The work focuses on evaluating the predictive performance of an eddy-resolving turbulence model applied to the described case of a multiphase gas-liquid flow system characterized by a variety of closely coupled phenomena, including: turbulence anisotropy-induced secondary motion, free surface flow, bubbly jet propagation, and the varying interaction dynamics of the carrier water flow with the air bubble dispersion. Correspondingly, an appropriately extended differential near-wall Reynolds stress model, which describes the dynamics of unresolved subscale structures within the Sensitized Reynolds-Averaged Navier–Stokes (RANS) computational framework, is currently used in conjunction with a two-way coupled Euler–Lagrange approach to simulate this gas-water bubbly flow, with the operating and boundary conditions following the experimental reference of Zhang and Zhu (2013). Accordingly, the conditions at the free surface are adequately derived for all components of the residual turbulence stress tensor and the corresponding length scale determining variable. It is shown that the statistics of the bubble phase can be accurately captured, and the proper-orthogonal-decomposition analysis of the dynamic properties of the flow reveals at least two large-scale transient effects associated with the bubbly jet. Furthermore, in the preliminary part of this work it is shown that the currently applied turbulence model can be successfully used to correctly capture the effects of Reynolds stress anisotropy in the single-phase open-channel configuration, representing the incoming flow field of the main two-phase flow configuration.

Ejection and deposition of mica suspension droplets under electric field

Inkjet printing of ceramic materials is a shaping process of interest for building micrometer-sized components. It consists of depositing droplets of colloidal inks according to a printing pattern designed to obtain a given final part. Improving the printed part properties, e.g., thermal or electrical, requires to tailor the printed material's local structure and orientation. Electric field is an efficient external stimulus to control particle orientation. A major challenge is to efficiently couple the effects of electric field and those of capillary, viscous, and evaporation phenomena occurring during inkjet printing. In this paper, the effect of an external electric field on the structuration of inkjet deposits is investigated. Suspensions of mica platelets dispersed in binary mixtures of chloroform and silicone oil are ejected on demand on a glass plate. An electric potential difference is applied by means of a set of electrodes below the glass substrate, separated by a small gap in order to maximize the electric field on the surface of the plate. A cartography of splat morphology and structuration for different inks as a function of applied field is performed. Promising experimental conditions display particle arrangement and limited splat deformation, whereas others lead to fingering. This paves the way to a novel additive shaping process by adding another smaller scale of structuration to inkjet printed parts.

A Review on Preparation of Palladium Oxide Films

Fabrication aspects of PdO thin films and coatings are reviewed here. The work provides and organizes the up-to-date information on the methods to obtain the films. In recent years, the interest in Pd oxide for different applications has increased. Since Pd can be converted into PdO, it is instructive to pay attention to the preparation of the pure and the alloyed Pd films, heterostructures, and nanoparticles synthesized on different substrates. The development of PdO films is presented from the early reports on coatings’ formation by oxidation of Pd foils and wires to present technologies. Modern synthesis/growth routes are gathered into chemical and physical categories. Chemical methods include hydrothermal, electrochemical, electroless deposition, and coating methods, such as impregnation, precipitation, screen printing, ink jet printing, spin or dip coating, chemical vapor deposition (CVD), and atomic layer deposition (ALD), while the physical ones include sputtering and cathodic arc deposition, laser ablation, ion or electron beam-induced deposition, evaporation, and supersonic cluster beam deposition. Analysis of publications indicates that many as-deposited Pd or Pd-oxide films are granular, with a high variety of morphologies and properties targeting very different applications, and they are grown on different substrates. We note that a comparative assessment of the challenges and quality among different films for a specific application is generally missing and, in some cases, it is difficult to make a distinction between a film and a randomly oriented, powder-like (granular), thin compact material. Textured or epitaxial films of Pd or PdO are rare and, if orientation is observed, in most cases, it is obtained accidentally. Some practical details and challenges of Pd oxidation toward PdO and some specific issues concerning application of films are also presented.

Inkjet‐printed capacitively loaded Marchand baluns with enhanced fractional bandwidths

AbstractA comprehensive design methodology for the realization of ultra‐wideband and highly miniaturized capacitively loaded Marchand baluns (MBs), suitable for integration into balanced antenna systems is presented. A design technique to maximize the fractional bandwidth (FBW) for a given manufacturing process is demonstrated for the first time. Furthermore, a novel MB integration scheme using broadside‐coupled lines and 3D vertically integrated capacitors in a two‐material inkjet printing process is uniquely proposed. The concept has been experimentally validated within the S and C bands. It exhibits a footprint of 0.128 × 0.098 λg2, centre frequency of 4.4 GHz, and FBW of 121%. Its power loss, phase imbalance and amplitude imbalance were measured between 0.8 and 2.2 dB, 3 ± 2°, and 0.4 ± 0.4 dB, respectively.

Solvent-free Acrylate/BCB drop-on-demand (DOD) inkjet dielectric ink for 3D printing

Currently, drop-on-demand (DOD) inkjet-printed dielectric inks used to produce next-generation high-frequency electronic devices fail to meet the requirements of circuit board substrates in terms of thermal, mechanical, and dielectric properties. To address this gap, we synthesized a low-viscosity acrylate monomer featuring an intrinsically low dielectric structure (hexafluorobisphenol A) and multiple cross-linking sites, and a benzocyclobutene monomer with low curing shrinkage and excellent thermomechanical properties. By mixing these monomers with other reactive diluents and verifying them through theoretical calculations and printing, we have developed a range of dielectric inks suitable for inkjet 3D printing. To enhance the overall performance of the cured inks, a sequential UV/thermal curing strategy was employed to form interpenetrating networks (IPNs). The optimal ink formulations met the requirements of circuit board substrates, demonstrating excellent heat resistance (Td5% = 334 °C, Tg = 181 °C), mechanical properties (tensile strength = 85 MPa, elongation at break = 13.5 %), and dielectric properties (Dk = 2.526 and Df = 0.113 at 15 GHz). These formulations meet the performance requirements for circuit board substrates and lead the industry in mechanical and dielectric properties. Furthermore, the feasibility of inkjet printing heterogeneous integrated electronic devices was verified, showing excellent print resolution and continuity of the conductive network. This work provides new insights into the future development of dielectric materials for inkjet 3D printing.

A qualitative validation of an in-situ monitoring system for EHD inkjet printing via laser diffraction

Electrohydrodynamic inkjet printing enables high-resolution patterning for nano features. In-flight dynamics of EHD inkjet printing play an essential role in the quality control of printing results. We applied a laser diffraction/scattering in-situ analyzing setup for the EHD inkjet printing system to replace the zoom lens and high-speed camera imaging system. In contrast to conventional imaging systems, the laser diffraction/scattering system is based on analyzing the diffraction pattern and scattering intensity, respectively, which provided higher resolution for micro-scale jetting measurement and enabled sub-micron level jetting correlation between the voltage applied to the electrode and printing results. Furthermore, Taylor cone information from the nozzle head could also be analyzed in real-time to make adjustments to the printing process. In this work, we successfully validated the feasibility of laser diffraction analysis in-situ monitoring for EHD inkjet printing at micron and sub-micron levels.

Study on the jetting characteristics of an underwater explosion bubble collapsing near a floating body

This study explores the dynamic behavior and jet characteristics of underwater explosion (UNDEX) bubble oscillating near a rigid floating body using the arbitrary Lagrangian–Eulerian (ALE) method. Experiments on UNDEX bubble oscillating in a free field or oscillating near a rigid floating body in an explosion tank are used to validate the effectiveness of the ALE method in simulating the behaviors of high pressure bubble oscillating near a boundary in water. The numerical results are in good agreement with the experimental data. On this basis, the distribution of the field pressure and velocity of the oscillating bubble are further analyzed in detail. The evolution characteristics of the bubble jets are discussed for various values of the stand-off distance and explosion attack angle. The results reveal that a bubble produces two jet patterns for close stand-off distances (from γD=0.800 to γD=1.336) and attack angles of 0°, 45°, 75°, and 90°. The first bubble jet results in an annular splitting of the bubble, while the second jet is pointed toward the floating body. The aim of this study is to provide a reference for further understanding the jet dynamics of UNDEX bubble collapsing near a structure and the effective attack on ship sides.

Predictive models for 3D inkjet material printer using automated image analysis and machine learning algorithms

Additive manufacturing (AM) is a smart manufacturing process to fabricate components with high precision, minimal post-processing, and increased component complexity in a variety of materials. This research focuses on developing automated image analysis and predictive models for a widely used 3D material inkjet printing (IJP) process. The interplay of four input process parameters, which include frequency, voltage, temperature, and meniscus vacuum, on the output metrics of the inkjet printer was evaluated using statistical measures (ANOVA). Droplet types were classified as no drop, satellite drop, and normal drop using four machine learning classifiers, including random forest, support vector classifier, k-nearest neighbor, and decision trees. Hyperparameter tuning was performed for each model for over 486 data points. Regression predictive models were developed for both ink droplet velocity and volume with three linear models (linear, lasso, and ridge regression) and four non-linear models (random forest, decision tree, support vector regression, and k-nearest neighbor). Mean squared error and the coefficient of determination, r-squared value, were used to evaluate the performance of the predictive models. For the drop type classification models, k-fold of 5 yielded the highest accuracy for the RF, KNN, and DT models of around 98%. Similarly, for the regression based predictive models RF, DT and KNN accuracy results ranged from 97 to 99%. All the machine learning models were validated with experimental data with high prediction accuracies accuracy. This research serves as a foundation for developing design guidelines for 3D material inkjet printing with applications in biosensors, flexible electronics, and regenerative tissue engineering.

Inkjet printing of silver/graphene flexible composite electrodes for high-performance supercapacitors

Inkjet printing of silver/graphene flexible composite electrodes for high-performance supercapacitors

MATHEMATICAL MODEL OF NICKEL-GRAPHENE COMPOSITE INKS FOR JETTING PROPERTIES IN INKJET PRINTING

The droplet formation process in inkjet printing is studied numerically and verified through a simulation model. The droplet formation process decides the printing quality of the coating, and a mathematical model is developed to understand the complete process from droplet formation to detachment. The Navier-Stokes equation is used to mathematically derive the droplet radius (rnumerical). COMSOL multiphysics is used for simulation and the radius (rsimulation) is calculated from the droplet mass. The rnumerical and rsimulation are compared for inks containing nickel, graphene, and nickel-graphene composite ink it is observed that the composite ink radiuses have the lowest difference (rsimulation - rnumerical =0.085µm). A droplet is formed at 1.47mm from the nozzle inlet, for nickel-graphene ink, and after 1.5mm for other pristine inks. The results are verified through Z number, velocity profile, and droplet mass. The droplet formation observed from the velocity profile is earliest at 120µs. It is seen that a stable droplet is generated at 100µs for nickel-graphene ink and at 200 µs for individual inks.

Flexible and Large‐Scale Liquid Metal Frequency‐Selective Surfaces: Enhanced Tuning through Mechanical Reconfiguration

The tuning capability is crucial for broadening the application possibilities of frequency‐selective surfaces (FSSs). Flexible and stretchable FSSs have attracted widespread research interest due to their ability for adhering to curved surfaces conformally and reconfiguring electromagnetic (EM) wave transmission performance mechanically. However, conventional metal FSSs lack sufficient flexibility and deformability due to material constraints, resulting in diminished durability and limited EM tuning range. In this article, a design approach for flexible liquid metal FSS (LMFSS), which can conform to curved structures and achieve a wide range of EM wave tuning via mechanical stretching without structural damage, is presented. The fabrication of LMFSS is simplified using silicone elastomer curing and liquid metal inkjet printing, avoiding the complexities of traditional microchannel techniques. In the experimental results, it is demonstrated that the designed LMFSS achieves a tuning range of up to 16% under biaxial stretch strains not more than 25%. The tuning mechanism is explored through mechanical–EM simulations and equivalent circuit analyses. Additionally, the tuning phenomenon observed in another flexible LMFSS in this study underscores the portability of the design approach and tuning mechanism. In this research, a promising direction for tunable flexible LMFSS applications is offered.

Measurement of inkjet droplet speed using interference fringe by diffracted light

Inkjet printers are key technologies in manufacturing organic light-emitting diodes and quantum dot light-emitting diode panels, but precise measurement and control of inkjet droplets remains challenging. The international standard, IEC 62899-302-1, uses shadow image-based measurement with high magnification microscopes to observe picoliter-sized droplets. However, high magnification lens results in a shallow depth of field or narrow optimal measurement area, causing the blurring image if the droplet does not pass through the optimal measurement area. To solve this, we propose using the interference image-based measurement with interference fringe patterns by inkjet droplets as a tool to measure the flight speed of droplets. The interference fringe patterns can be obtained simply passing the droplet through within the light beam path, providing approximately 1000× wider measurement area compared to the shadow image-based measurement, making it practical to use in the industry. The flight speed of droplets analyzed with the interference image-based measurement at various frequencies and amplitudes of the inkjet driving voltage were compared with the shadow image-based measurement. The interference image-based measurement showed a coefficient of variation of less than 3%, showing higher repeatability than the shadow image-based measurements.

Anomalous Temperature Effect on the Deposition Morphology in Reactive Inkjet Printing

Reactive inkjet (RIJ) printing represents an important approach for printed electronics. Different from the traditional inkjet printing of colloidal inks with nanosized metal particles, RIJ prints the solution of metal organic compound, that is, metal‐organic decomposition (MOD) ink, and reduces it to the pure metal during the post‐treatment to form conductive electrodes. Successful RIJ printing of MOD inks has been demonstrated; however, the fundamental understanding of droplet deposition involved in RIJ printing is lacking. Herein, the effect of substrate temperature and nozzle temperature during inkjet printing of copper MOD ink on the deposition morphology is investigated. It exhibits distinct behaviors in the deposition morphology at elevated temperatures when compared with the ones at room temperature. The different deposition morphology of the copper ink at various temperatures is attributed to the generation of a localized seeding layer which attracts the copper ions to deposit. In addition, the copper MOD ink printing is compared with a silver MOD ink. The different deposition morphology between the copper ink and silver ink is due to the solvent system. Understanding the deposition mechanism for reactive inks provides valuable information and guidance in the fabrication of printed functional devices using particle‐free reactive inks.

Residual Vibration Suppression of Piezoelectric Inkjet Printing Based on Particle Swarm Optimization Algorithm.

Piezoelectric inkjet printing technology, known for its high precision and cost-effectiveness, has found extensive applications in various fields. However, the issue of residual vibration significantly limits its printing quality and efficiency. This paper presents a method for suppressing residual vibration based on the particle swarm optimization (PSO) algorithm. Initially, an improved PI model considering the nonlinear hysteresis characteristics of piezoelectric ceramics is established, and the model is identified through a strain gauge circuit to ensure its accuracy in describing the nonlinear hysteresis characteristics. Subsequently, a dynamic model of the piezoelectric inkjet printing system is constructed, with precise parameter identification achieved using the self-induction principle. This enables precise simulation of residual vibration. Finally, the driving waveform is optimized based on the PSO algorithm, with iterative calculations employed to find the optimal combination of driving waveform parameters, effectively suppressing residual vibration while ensuring sufficient injection energy. The results indicate that this method significantly reduces the amplitude of residual vibration, thereby effectively enhancing printing quality and stability. This research offers a novel solution for residual vibration suppression in piezoelectric inkjet printing technology, potentially advancing its applications in printing and biofabrication.

Novel 3D printed bioactive SiC orthopedic screw promotes bone growth associated activities by macrophages, neurons, and osteoblasts.

Ceramic additive manufacturing currently relies on binders or high-energy lasers, each with limitations affecting final product quality and suitability for medical applications. To address these challenges, our laboratory has devised a surface activation technique for ceramic particles that eliminates the necessity for polymer binders or high-energy lasers in ceramic additive manufacturing. We utilized this method to 3D print bioactive SiC orthopedic screws and evaluated their properties. The study's findings reveal that chemical oxidation of SiC activated its surface, enabling 3D printing of orthopedic screws in a binder jet printer. Post-processing impregnation with NaOH and/or NH4OH strengthened the scaffold by promoting silica crystallization or partial conversion of silicon oxide into silicon nitride. The silica surface of the SiC 3D printed orthopedic screws facilitated osteoblast and neuron adhesion and extensive axon synthesis. The silicate ions released from the 3D printed SiC screws favorably modulated macrophage immune responses toward an M1 phenotype as indicated by the inhibition of TNFα secretions and of reactive oxygen species (ROS) expression along with the promotion of IL6R shedding. In contrast, under the same experimental conditions, Ti ions released from Ti6Al4V discs promoted macrophage TNFα secretion and ROS expression. In vivo tests demonstrated direct bone deposition on the SiC scaffold and a strong interfacial bond between the implanted SiC and bone. Immunostaining showed innervation, mineralization, and vascularization of the newly formed bone at the interface with SiC. Taken altogether, the 3D printed SiC orthopedic screws foster a favorable environment for wound healing and bone regeneration. The novel 3D printing method, based on ceramic surface activation represents a significant advancement in ceramic additive manufacturing and is applicable to a wide variety of materials.

Aerosol jet printing of advanced capacitive strain gauge for vibration monitoring of the human body

Aerosol jet printing of advanced capacitive strain gauge for vibration monitoring of the human body

Inkjet-printed p-type tellurene and n-type MoS2 transistors for CMOS electronics

Abstract Two-dimensional semiconductor materials combine exceptional electronic transport properties with mechanical flexibility and hence can be an ideal choice for large-area flexible and wearable electronics. While inkjet printing may be a suitable approach to fabricate high throughput electronic components on polymer substrates, solution-processed 2D semiconductor network transistors suffer from two major hindrances: extremely high inter-flake resistance and the lack of high-performance p-type semiconductors. This study shows that inkjet-printed tellurium nanowires or tellurene nanoflakes can offer high-performance p-type TFTs with current density up to 100 μA/μm and an On-Off ratio >105. In order to circumvent the high inter-flake junction resistance, a narrow-channel, near-vertical device architecture has been used that ensures predominantly intra-flake/ intra-nanowire transport, which resulted in three orders of magnitude increase in the current density compared to conventional devices without compromising on the On-Off ratio. Moreover, we show the whole device operation within ± 2 V, with a threshold voltage close to 0 V. The complete device fabrication is carried out at room temperature, thereby making it compatible with inexpensive polymer substrates. Next, outstanding device performance has also been realized with electrochemically-exfoliated and inkjet-printed n-type MoS2 TFTs, demonstrating a current density of 60 μA/μm and an On-Off ratio of 106. Furthermore, we show tellurene-based p-type depletion-load unipolar inverters and CMOS inverters alongside n-type MoS2 TFTs, demonstrating a signal gain of 12 and 11, respectively. The CMOS inverters are found to operate at a frequency of 1 kHz.

Advances and Challenges in Large-Area Perovskite Light-Emitting Diodes.

Metal halide perovskite light-emitting diodes (PeLEDs) have shown promise for high-definition displays and flat-panel lighting because of their wide color gamut, narrow emission band, and high brightness. The external quantum efficiency of PeLEDs increased rapidly from ≈1% to more than 25% in the past few years. However, most of these high-performance devices are fabricated using a spin coating method with a small device area of <0.1 cm2, limiting their commercial applications. Recently, large-area PeLEDs have attracted growing attention and significant breakthroughs have been reported. This perspective first introduces the pros and cons of each technique in making large-area PeLEDs. The advances in the fabrication of large-area PeLEDs are then summarized using spin coating and mass-production methods such as inkjet printing, blade coating, and thermal evaporation. Moreover, the challenging issues will be discussed that are urgent to be solved for large-area PeLEDs.

Direct Printing of Disperse Dye Inks to Polyester Fabrics without Chemical Pretreatment.

Direct inkjet digital printing is a relatively green and environmentally friendly textile printing method with a wide range of applications in the textile printing and dyeing industry. However, pretreatment of the fabric is required before digital printing, which will generate certain energy consumption and wastewater. In this study, a digital direct inkjet printing method was developed to improve the printing accuracy of poly(ethylene terephthalate) (PET) fabrics without any pretreatment. A kind of direct inkjet printing ink was prepared by the response change in temperature viscosity. The increase in viscosity inhibits ink bleeding on the fabric, thereby improving printing accuracy. A thermosensitive direct inkjet printing disperse dye ink was prepared by adding cetyltrimethylammonium bromide (CTAB) and 3-methylsalicylic acid (3MS) to the ink. By evaluating the changes in the ink particle size, shear viscosity, and temperature viscosity, it was found that this thermosensitive ink has an excellent average particle size and special changes in viscosity with increasing temperature. When this heat-sensitive ink is printed on a polyester fabric, the fabric does not need pretreatment to improve the clarity of printing, and the printed fabric has satisfactory color fastness to friction and washing.