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Related Experiment Video

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High-resolution Patterning Using Two Modes of Electrohydrodynamic Jet: Drop on Demand and Near-field Electrospinning
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Wide-Flow Aerosol Jet Printing Enables High-Throughput, Ultra-Low Aspect Ratio Patterning.

Zenan Niu1, Hao Yi1, Yufeng Jin1

  • 1State Key Laboratory of Mechanical Transmission for Advanced Equipment, Chongqing University, Chongqing, 400044, China.

Advanced Science (Weinheim, Baden-Wurttemberg, Germany)
|November 3, 2025
PubMed
Summary

A new wide-flow aerosol jet printing (WF-AJP) method enables high-throughput fabrication of precise, low-aspect-ratio functional films. This breakthrough addresses key challenges in scalable manufacturing for advanced electronics and sensors.

Keywords:
functionally uniform filmshigh throughputmorphology controlultra‐low aspect ratiowide‐flow aerosol jet printing

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Area of Science:

  • Materials Science
  • Additive Manufacturing
  • Nanotechnology

Background:

  • Functional films are crucial for flexible electronics, biosensing, and energy devices.
  • Scalable fabrication of uniform, low-aspect-ratio functional films presents significant challenges.
  • Achieving both structural precision and processing efficiency in film deposition is difficult.

Purpose of the Study:

  • To introduce a novel high-throughput printing method for functional films.
  • To overcome limitations of conventional printing techniques in achieving precise film architectures.
  • To demonstrate the application of this new method in wearable and bio-integrated electronics.

Main Methods:

  • Development and implementation of wide-flow aerosol jet printing (WF-AJP) with a flattened nozzle.
  • Systematic characterization of the film formation process across multiple scales.
  • Application of a staggered deposition strategy to optimize film properties.

Main Results:

  • WF-AJP enables millimeter-scale deposition in a single pass with aspect ratios below 1:6000 and thickness under 500 nm.
  • The method achieves a balance between macroscopic morphology and functional performance.
  • Staggered deposition reduces interlayer accumulation and electrical anisotropy.

Conclusions:

  • WF-AJP offers a scalable and structure-controlled patterning paradigm for functional films.
  • This technique is versatile for applications in conformal electrodes and skin-interfaced sensors.
  • The study paves the way for innovations in high-throughput additive manufacturing of advanced materials.