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Updated: Sep 9, 2025

Planar and Three-Dimensional Printing of Conductive Inks
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Direct-Write Printing for Flexible and 3D Electronics: Aerosol Jet vs. Micro Dispensing.

Ankur Gohel1, Mathieu Gratuze1, Mohsen Ketabi1

  • 1Laboratoire de Communication et d'Intégration de la Micro-Électronique (LaCIME), Regroupement Stratégique en Micro Systèmes du Québec (ReSMIQ), École de Technologie Supérieure, 1100 Notre Dame Ouest, Montreal, QC H3C 1K3, Canada.

Micromachines
|August 28, 2025
PubMed
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Aerosol Jet Printing (AJP) offers high resolution, while Micro Dispensing Technology (MDT) provides superior 3D printing capabilities, material versatility, and throughput for flexible electronics manufacturing.

Area of Science:

  • Materials Science
  • Manufacturing Engineering
  • Electrical Engineering

Background:

  • Direct-write manufacturing technologies are crucial for fabricating advanced electronic devices.
  • Aerosol Jet Printing (AJP) and Micro Dispensing Technology (MDT) are prominent methods for depositing functional inks.
  • Understanding their comparative performance is essential for selecting optimal manufacturing processes.

Purpose of the Study:

  • To conduct a comprehensive comparison of Aerosol Jet Printing (AJP) and Micro Dispensing Technology (MDT).
  • To evaluate their capabilities, limitations, and performance on 2D and 3D substrates.
  • To determine their suitability for flexible electronics applications based on ink morphology and electrical properties.

Main Methods:

  • Direct-write manufacturing process comparison.
Keywords:
3D printed electronicsdirect-writing technologyprinted and flexible electronics

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  • Characterization of printed materials on 2D and 3D substrates.
  • Analysis of ink morphology and electrical performance.
  • Main Results:

    • Aerosol Jet Printing (AJP) demonstrates superior resolution.
    • Micro Dispensing Technology (MDT) exhibits enhanced 3D conformality.
    • MDT offers greater material versatility and higher throughput compared to AJP.

    Conclusions:

    • Both AJP and MDT have distinct advantages for direct-write manufacturing.
    • AJP is ideal for applications requiring high resolution.
    • MDT is better suited for complex 3D structures, diverse materials, and high-volume production in flexible electronics.