Flexible Patterned Electrohydrodynamic Jet Printing Using Orthogonal Deflection Electrodes

Electrohydrodynamic jet (E-Jet) printing technology provides unmatched advantages in the fabrication of patterned micro/nanostructures. However, the rapid jets generated during printing can lead to localized droplet accumulation on complex structures due to the relatively slow motion control achieved with motorized translation stages, resulting in distorted patterns. To address this challenge, we introduce two jet-deflecting electrodes orthogonally placed on each other, which can rapidly change the electric field in the vicinity of the jet and thus flexibly adjust the flight trajectory of the fast jet to avoid the region where droplets have been deposited. In this way, the jet droplets are precisely controlled to generate high-fidelity microstructures with arbitrary predefined patterns on the stationary substrate. The maximum deflection distance of the jet droplets reaches several hundred microns. Furthermore, the positioning error of the printed structure is less than 3%. Moreover, we successfully obtained a diverse range of complex patterns by combining this technique with stage motion. This innovative printing technology not only enables the fabrication of complex patterned structures with high fidelity but also opens up exciting possibilities for new applications that require complete control of fast droplet positioning.