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On the Resolution Limit of Electrohydrodynamic Redox 3D Printing.

Maxence Menétrey1, Cédric Kupferschmid1, Stephan Gerstl2

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Summary

Electrohydrodynamic redox 3D printing achieves high-purity copper nanostructures with resolutions down to 50 nm. This breakthrough enables advanced 3D nano-printing for novel materials.

Keywords:
Coulomb explosionatom probe tomographyelectrodynamic redox 3D printingnano 3D printing

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Area of Science:

  • Nanotechnology
  • Materials Science
  • Additive Manufacturing

Background:

  • Additive manufacturing (AM) offers geometrical freedom for nanotechnology but lacks sub-100 nm resolution for functional nanostructures.
  • Existing micro-AM techniques struggle to produce high-quality metal nanostructures with precise resolution.

Purpose of the Study:

  • To report breakthroughs in electrohydrodynamic redox 3D printing (EHD-RP) for fabricating high-purity copper nanostructures.
  • To demonstrate tunable feature sizes down to 50 nm and high growth rates for advanced 3D nano-printing.

Main Methods:

  • Utilizing electrohydrodynamic redox 3D printing (EHD-RP) to directly fabricate copper.
  • Controlling in-flight solvent evaporation of ion-loaded droplets to manage Coulomb explosion and tune voxel size from >6µm to 50 nm.
  • Fabricating high-aspect-ratio nanopillars and enabling spray deposition.

Main Results:

  • Achieved direct fabrication of high-purity copper (>98 at.%) with adjustable voxel sizes down to 50 nm.
  • Demonstrated the ultimate resolution limit for EHD printing with 50 nm-wide nanopillars.
  • Manufactured 30 µm-tall atom probe tomography (APT) tips with high growth rates (>100 voxel s-1).

Conclusions:

  • EHD-RP offers unprecedented control over feature size and purity for nanostructure fabrication.
  • The technique enables the direct manufacturing of complex nanostructures like APT tips for detailed material analysis.
  • This advancement opens new avenues for developing novel materials using 3D nano-printing.