Aerosol Jet ® Printing onto 3 D and Flexible Substrates

As technology continues to produce smaller and more intricate systems, we find that they cannot always be supported by conventional processing techniques. The chief issue is that traditional multi-step fabrication techniques require a rigid, planar framework for the entirety of the production. By using a three dimensional (3D) additive manufacturing approach, systems can have improved integration, smaller packaging footprints, fewer steps, less waste, reduced weight, and potentially lower fabrication costs. Here we demonstrate how direct-write printing has establishing itself as an enabling technology for production of both circuits and sensors on 3D and flexible surfaces that could not otherwise be fabricated with conventional techniques. For the past five years QUEST Integrated (Qi2) has been utilizing an Optomec Aerosol Jet® (AJ) direct write printing system that can deposit a variety of materials onto nearly any type of substrate, provided the materials have compatible surface energies. A key advantage for AJ is that the process is non-contact, allowing for nearly any surface topography provided the surface of interest can be exposed to the nozzle. Through internal process development, varied contract research and extensive experience with inks and deposition, Qi2 has developed broad AJ deposition expertise that can be offered to customers for a wide variety of new projects.