Wide-Flow Aerosol Jet Printing Enables High-Throughput, Ultra-Low Aspect Ratio Patterning

Functional films have been widely utilized in flexible electronics, biosensing, and energy devices owing to their unique mechanical compliance and excellent interfacial transport efficiency. However, balancing structural precision with processing efficiency remains a key challenge in the scalable fabrication of uniform, low-aspect-ratio architectures across diverse material systems. Here, wide-flow aerosol jet printing (WF-AJP), a high-throughput printing method capable of generating planar aerosol jets, is introduced. Reshaping the nozzle into a flattened rectangular geometry generates a collimated planar flow that enables millimeter-scale deposition in a single pass (aspect ratio < 1:6000, thickness < 500 nm), a capability unattainable by conventional circular-nozzle printing. Systematic cross-scale characterization of the film formation process further reveals a delicate balance between macroscopic morphology and functional performance. A staggered deposition strategy that reduces interlayer accumulation and lowers electrical anisotropy is further implemented. Applications in conformal electrodes and skin-interfaced sensors highlight the versatility of WF-AJP for wearable and bio-integrated electronics. This work establishes a structure-controlled and scalable patterning paradigm for functional films, paving the way for future innovations in high-throughput additive manufacturing.