An official website of the United States government
Abstract The growing demand for flexible and wearable hybrid electronics has triggered the need for advanced manufacturing techniques with versatile printing capabilities. Complex ink formulations, use of surfactants/contaminants, limited source materials, and the need for high‐temperature heat treatments for sintering are major issues facing the current inkjet and aerosol printing methods. Here, the nanomanufacturing of flexible hybrid electronics (FHE) by dry printing silver and indium tin oxide on flexible substrates using a novel laser‐based additive nanomanufacturing process is reported. The electrical resistance of the printed lines is tailored during the print process by tuning the geometry and structure of the printed samples. Different FHE designs are fabricated and tested to check the performance of the devices. Mechanical reliability tests including cycling, bending, and stretching confirm the expected performance of the printed samples under different strain levels. This transformative liquid‐free process allows the on‐demand formation and in situ laser crystallization of nanoparticles for printing pure materials for future flexible and wearable electronics and sensors.
more »
« less
Self-aligned, inkjet-printed resistors on flexible substrates with excellent mechanical stability, high yield, and low variance
Abstract Resistors are basic yet essential circuit components that must be fabricated with high precision at low cost if they are to be viable for flexible electronic applications. Inkjet printing is one of many additive fabrication techniques utilized to realize this goal. In this work, a process termed self-aligned capillarity-assisted lithography for electronics (SCALE) was used to fabricate inkjet-printed resistors on flexible substrates. Capillary channels and reservoirs imprinted onto flexible substrates enabled precise control of resistor geometry and straightforward alignment of materials. More than 300 devices were fabricated using poly(3,4-ethylene dioxythiophene):poly(styrene sulfonate) (PEDOT:PSS) as the resistive material and silver as the electrode material. By varying PEDOT:PSS ink formulation and resistor geometry, resistances spanning from 170 Ω to 3.8 MΩ were achieved. Over 98% of devices were functional and the relative standard deviation in resistance ranged from 3% to 18% depending on resistor length and ink composition. The resistors showed no significant change in resistance after 10 000 cycles of bend testing at 1.6% surface tensile strain. In summary, this work demonstrated a fully roll-to-roll compatible process for inkjet printing resistors with superior properties.
more »
« less
- PAR ID:
- 10502187
- Publisher / Repository:
- IOP Publishing
- Date Published:
- Journal Name:
- Flexible and Printed Electronics
- Volume:
- 9
- Issue:
- 2
- ISSN:
- 2058-8585
- Format(s):
- Medium: X Size: Article No. 025006
- Size(s):
- Article No. 025006
- Sponsoring Org:
- National Science Foundation
More Like this
-
-
Abstract Poly(3,4‐ethylenedioxythiophene):poly(styrenesulfonate) (PEDOT:PSS) is a promising material because of its favorable electrical and mechanical properties, stability in ambient environments, and biocompatibility. It finds broad application in energy storage, flexible electronics, and bioelectronics. Additive manufacturing opens a plethora of new avenues to form and shape PEDOT:PSS, allowing for the rapid construction of customized geometries. However, there are difficulties in printing PEDOT:PSS while maintaining its attractive properties. A 3D printing method for PEDOT:PSS using a room‐temperature coagulation bath‐based direct ink writing technique is reported. This technique enables fabrication of PEDOT:PSS into parts that are of high resolution and high conductivity, while maintaining stable electrochemical properties. The coagulation bath can be further modified to improve the mechanical properties of the resultant printed part via a one‐step reaction. Furthermore, it is demonstrated that a simple post‐processing step allows the printed electrodes to strongly adhere to several substrates under aqueous conditions, broadening their use in bioelectronics. Employing 3D printing of PEDOT:PSS, a cortex‐wide neural interface is fabricated, and intracranial electrical stimulation and simultaneous optical monitoring of mice brain activity with wide field calcium imaging are demonstrated. This reported 3D‐printing technique eliminates the need for cumbersome experimental setups while offering desired material properties.more » « less
-
Abstract Inkjet printing has emerged as a versatile technique for the fabrication of functional materials towards non-traditional electronics, offering high precision maskless fabrication capability, low material waste, and wide substrate compatibility. However, the realization of high-quality printing of microscale features requires precise control over the jetting behavior and film formation. In this work, we systematically investigate the printing parameters for the PEDOT:PSS ink on the flexible substrates used in wearable and flexible electronics. By exploring the interplay between the printing waveform parameters, such as drive voltage, dwell time, and jetting frequency, we establish a robust operational window enabling stable droplet ejection and tunable deposition. Droplet spacing is further studied to achieve reliable droplet coalescence for high quality fabrication of the continuous patterns with high line resolution and pattern uniformity. Multilayer printing reveals consistent improvements in film thickness and electrical conductivity, with a pronounced enhancement in early layers due to percolation and phase rearrangement. The achieved printing strategy is successfully applied in functional circuit demonstrations, showing excellent electrical stability under mechanical deformation. This work offers a reproducible and scalable printing approach tailored to the PEDOT:PSS inks, providing a technical foundation for the fabrication of high-performance flexible and printed electronics.more » « less
-
Abstract Direct write Inkjet Printing is a versatile additive manufacturing technology that allows for the fabrication of multiscale structures with dimensions spanning from nano to cm scale. This is made possible due to the development of novel dispensing tools, enabling controlled and precise deposition of fluid with a wide range of viscosities (1 – 50 000 mPas) in nanoliter volumes. As a result, Inkjet printing has been recognized as a potential low-cost alternative for several established manufacturing methods, including cleanroom fabrication. In this paper, we present a characterization study of PEDOT: PSS polymer ink deposition printing process realized with the help of an automated, custom Direct Write Inkjet system. PEDOT: PSS is a highly conductive ink that possesses good film forming capabilities. Applications thus include printing thin films on flexible substrates for tactile (touch) sensors. We applied the Taguchi Design of Experiment (DOE) method to produce the optimal set of PEDOT:PSS ink dispensing parameters, to study their influence on the resulting ink droplet diameter. We experimentally determined that the desired outcome of a printed thin film with minimum thickness is directly related to 1) the minimum volume of dispensed fluid and 2) the presence of a preprocessing step, namely air plasma treatment of the Kapton substrate. Results show that an ink deposit with a minimum diameter of 482 μm, and a thin film with approximately 300 nm thickness were produced with good repeatability.more » « less
-
Direct write Inkjet Printing is a versatile additive manufacturing technology that allows for the fabrication of multiscale structures with dimensions spanning from nano to cm scale. This is made possible due to the development of novel dispensing tools, enabling controlled and precise deposition of fluid with a wide range of viscosities (1 – 50 000 mPas) in nano-liter volumes. As a result, Inkjet printing has been recognized as a potential low-cost alternative for several established manufacturing methods, including cleanroom fabrication. In this paper, we present a characterization study of PEDOT: PSS polymer ink deposition printing process realized with the help of an automated, custom Direct Write Inkjet system. PEDOT: PSS is a highly conductive ink that possesses good film forming capabilities. Applications thus include printing thin films on flexible substrates for tactile (touch) sensors. We applied the Taguchi Design of Experiment (DOE) method to produce the optimal set of PEDOT:PSS ink dispensing parameters, to study their influence on the resulting ink droplet diameter. We experimentally determined that the desired outcome of a printed thin film with minimum thickness is directly related to 1) the minimum volume of dispensed fluid and 2) the presence of a preprocessing step, namely air plasma treatment of the Kapton substrate. Results show that an ink deposit with a minimum diameter of 482 μm, and a thin film with approximately 300 nm thickness were produced with good repeatability.more » « less
