Application of pulse width modulation control in EHD waveform to optimize printing performance

High-resolution 3D printing, particularly electrohydrodynamic (EHD) printing, represents a transformative approach for advanced manufacturing applications, including wearable electronics, bioelectronics, and soft robotics. Despite its potential, EHD printing faces challenges such as complex waveform control, limited material compatibility, satellite droplet formation, and continuous charge accumulation. To address these issues, the use of pulse-width modulation (PWM) control is proposed to enhance EHD printing performance. The influence of duty cycles and pulse subdivisions on EHD printing was systematically investigated through experiments and simulations, analyzing their effects on jetting dynamics, droplet formation, charge accumulation, and line quality. The results demonstrate that PWM modulation significantly improves jetting stability, reduces droplet diameter by up to 25%, minimizes satellite droplet formation, and effectively mitigates charge accumulation. Furthermore, PWM control was shown to facilitate the production of high-quality patterns. Notably, the proposed PWM approach is compatible with existing waveform control setups, offering enhanced precision and stability without requiring substantial modifications. These findings underscore the potential of PWM-controlled EHD printing for achieving high-resolution, versatile manufacturing in electronics and functional device production.