Aerosol-jet 3D printer creates electronic circuits on 3D objects

Researchers at Iowa State University have advanced the application of electronic circuits onto curved and complex three-dimensional surfaces using aerosol-jet printing. This method allows for space-efficient integration of electronics and the creation of components that are not feasible with traditional flat manufacturing techniques.

Aerosol-jet printers function similarly to inkjet printers, utilizing a gas stream to atomize ink into a fine mist, which is then precisely applied through a nozzle in software-defined patterns. This precision enables the printing of electronic circuits on 3D objects, facilitated by a movable robot arm that maneuvers the print head over the objects under computer control.

The project, led by mechanical engineering professor Ethan Secor, involves the use of special inks, including graphene inks previously developed by Secor for Sigma-Aldrich. These inks are suitable for flexible electronics, liquid metal applications, micro-supercapacitors, and lithium-ion batteries. The interdisciplinary team comprises experts from electrical engineering, mechanical engineering, materials science, and chemistry, combining their expertise to adapt aerosol-jet printing for 3D structures.

To transition this technology from the laboratory to commercial use, consistent manufacturing processes and stable printed components are essential. Secor's team has developed a sensor to monitor and automatically correct the printing process. With support from the U.S. National Science Foundation, they are researching new ink materials for electronics that can endure extreme space conditions, addressing challenges like semiconductor interface failures during 3D printing.

NASA is backing Contour Circuits, Secor's startup, with $150,000 to aid in the commercialization of this technology. The team is exploring the printing of multiple materials in a single process to enhance control over the electrical and physical properties of printed components.