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Conformal printed electronics on flexible substrates and inflatable catheters using lathe-based aerosol jet printing
Hansel Alex Hobbie1, James L Doherty1, Brittany N Smith1
1Department of Electrical and Computer Engineering, Duke University, Durham, NC USA.
Npj Flexible Electronics
|September 2, 2024
Summary
Lathe-based aerosol jet printing enables conformal electronics fabrication on 3D surfaces. This additive manufacturing technique allows for printing flexible electronics and sensors on complex geometries, overcoming previous limitations.
Area of Science:
- Additive Manufacturing
- Materials Science
- Electronics Engineering
Background:
- Growing demand for conformal electronics integrated with larger components for advanced functionality.
- Challenges in fabricating conformal electronics due to substrate curvilinearity, topography, and material diversity.
Purpose of the Study:
- To develop and characterize a novel additive manufacturing method for printing conformal electronics on 3D curvilinear surfaces.
- To demonstrate the versatility of the developed technique for various electronic applications.
Main Methods:
- Utilized aerosol jet (AJ) printing, an additive manufacturing technique for ink-based electronics.
- Developed a custom lathe mechanism for mounting and rotating flexible substrates and 3D objects.
- Implemented cylindrical-coordinate motion for precise printing on rotational bodies.
Main Results:
- Successfully printed conformal electronics around the circumference of rotational bodies with 3D curvilinear surfaces.
- Demonstrated the fabrication of flexible conformal electronics, including multilayer carbon nanotube transistors.
- Showcased a graphene sensor conformally printed on an inflated catheter balloon for real-time monitoring.
Conclusions:
- Lathe-based aerosol jet (LAJ) printing is a versatile additive manufacturing method for fabricating conformal electronics on complex 3D geometries.
- LAJ printing overcomes previous fabrication challenges, enabling integration of electronics on diverse and curvilinear surfaces.
- The demonstrated applications highlight the potential of LAJ printing for advanced electronic devices and sensors.
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