US Researchers Create Aerosol Jet Printing for Complex 3D Electronic Circuits

Breakthrough in Aerosol Jet Printing Technology

According to НВ — Техно: On September 20, 2023, scientists unveiled an advanced aerosol jet printing method that transforms liquid ink into a fine mist-like aerosol. This cutting-edge technique enables the precise application of electronic circuits onto intricate, curved three-dimensional surfaces, paving the way for new technological possibilities across multiple industries.

The innovation is led by a research team headed by Ethan Secor, an associate professor at Iowa State University and co-founder of the startup Contour Circuits. Their system produces patterns ranging from 10 to 100 microns in size, with a printer mounted on a jointed manipulator arm that ensures exceptional accuracy when working on uneven objects. This precision is crucial for depositing high-quality electronic circuits on complex substrates.

Wide-Ranging Applications and Future Prospects

This technology holds significant promise in sectors such as:

• energy
• healthcare
• aerospace
• communications

Researchers are also exploring ink materials that can withstand the extreme temperature fluctuations found in space, as well as the ability to print multiple materials in a single pass. The project receives funding from the US National Science Foundation and NASA, while Contour Circuits is actively working to commercialize the technology at the Roy J. Carver Laboratory.

This innovation arrives at a time when industries demand greater flexibility and efficiency in electronics manufacturing. Supported by leading scientific institutions, this development is set to accelerate the integration of novel materials and techniques into practical production, driving advancements in fields where precision and adaptability are paramount.

This innovative approach to 3D printing complex structures aligns with recent advancements in additive manufacturing, where multiple technologies are converging to enhance production capabilities. As seen in recent projects like the collaboration of robots to print steel reactor vessels, the integration of diverse materials and techniques is becoming crucial in modern engineering, highlighting the growing synergy between robotics and advanced printing technologies.