The apparatus of claim 1 wherein a linewidth of deposited material is less than approximately 40 times smaller than a capillary orifice size.
The method of claim 8 further comprising the step of focusing the annular jet. Facebook Comments Stay up-to-date on all the latest news from the 3D printing industry and receive information and offers from third party vendors. Miniaturization of the deposition head also facilitates a direct write process in which the deposition head is mounted on a moving gantry, and deposits material on a stationary target.
The 3D printing technology could also be used by NASA in the near future to print antennas, wiring harnesses, and other types of hardware directly onto a spacecraft. Thus the diameter or width of the miniature deposition head is preferably approximately 1 cm, but could be smaller or larger.
In many applications, it is advantageous to perform deposition from multiple deposition heads. The cross sectional area of the valve is large with respect to the cross sectional area of the final orifice, so that the flow is diverted through the exhaust valve. Sheath gas channels are preferably equally spaced about the axis of the device.
BRIEF SUMMARY OF THE INVENTION The present invention is a method for depositing material, the method comprising the steps of aerosolizing the material to form an aerosol flow, surrounding the aerosol flow with a first sheath gas flow to form a first combined flow, surrounding the first combined flow with a second sheath gas flow to form a second combined flow, passing the second combined flow through at least one first capillary, and depositing the material.
The primary and secondary sheaths enter through ports 12 and 14 respectively.
In general, each stage is comprised of a single sheath flow that enters through port and single capillary Increased aerosol focusing may however be obtained using a multiple sheath configuration. The sheath gas flow enters sheath plenum chamber through at least one sheath gas port The aerosol mist enters each mist tube 20 and is focused by a primary sheath which enters through port The droplets may then impact onto the substrate within a few microns from the deposit or as far as tens of microns from the deposited feature.
Enhanced deposition characteristics are obtained by attaching an extended nozzle to the deposition head. Variations and modifications of the present invention will be obvious to those skilled in the art and it is intended to cover in the appended claims all such modifications and equivalents.
The design allows for a reduction in the size of the deposition headand easier fabrication of the device. The third chamber is preferably connected to the first chamber by a plurality of passages which are parallel to and circumferentially arranged around the channel.
The apparatus preferably further comprises an atomizer comprising a cylindrical chamber for holding the material, a thin polymer film disposed on the bottom of the chamber, an ultrasonic bath for receiving the chamber and directing ultrasonic energy up through the film, a carrier tube for introducing carrier gas into the chamber, and one or more pickup tubes for delivering the aerosol to the plurality of channels.
However, the use of nozzle arrays increases the complexity of aerodynamic flow, so that the use of a second stage of arrays or capillaries for the purpose of increased focusing may not be feasible. SUMMARY OF THE INVENTION The present invention is a deposition head assembly for depositing a material on a target, the deposition head assembly comprising a deposition head comprising a channel for transporting an aerosol comprising the material, one or more inlets for introducing a sheath gas into the deposition head; a first chamber connected to the inlets; a region proximate to an exit of the channel for combining the aerosol with the sheath gas, thereby forming an annular jet comprising an outer sheath flow surrounding an inner aerosol flow; and an extended nozzle.
The configuration of FIG. For example, when the aerosol is formed from an aqueous solution, water vapor may be added to the carrier gas or the sheath gas to prevent droplet evaporation.
The method preferably further comprises the step of opening an exhaust valve to prevent the aerosol flow from passing through the first capillary. In this configuration, the sheath gas enters the plenum chamber from ports located on the side of the chamber, and flows upward to the sheath gas channels Example applications for the Aerosol Jet Series include: The use of multiple deposition heads for direct printing applications may be facilitated by using miniaturized deposition heads to increase the number of nozzles per unit area.
Inside the deposition head, the aerosol stream is preferably initially collimated by passing through a millimeter-size orifice.
To re-engage aerosol flow, the valve is closed so that the flow is redirected through the length of the jet and through the final exit orifice. Aerosol Jet printing is an additive manufacturing solution that reduces the overall size of electronic systems by using nanomaterials to produce fine feature circuitry and embedded components without the use of masks or patterns.
The orifice diameter of each capillary is preferably between approximately 50 microns and approximately one millimeter. Development of the sheath gas flow within the deposition head is critical to the deposition characteristics of the system, determines the final width of the jetted aerosol stream and the amount and the distribution of satellite droplets deposited beyond the boundaries of the primary deposit, and minimizes clogging of the exit orifice by forming a barrier between the wall of the orifice and the aerosol-laden carrier gas.
The first chamber is optionally external to the deposition head and develops a cylindrically symmetric distribution of sheath gas pressure about the channel before the sheath gas is combined with the aerosol. The mass throughput is preferably controlled by an aerosol carrier gas mass flow controller.
A cross-section of a miniature deposition head is shown in FIG. A second aerosolized material is optionally fed to at least one of the channels.
The invention is also an apparatus for depositing a material on a target, the apparatus comprising a plurality of channels for transporting an aerosol comprising the material, a sheath gas chamber surrounding the channels, a region proximate to an exit of each of the channels for combining the aerosol with sheath gas, thereby forming an annular jet for each channel, the jet comprising an outer sheath flow surrounding an inner aerosol flow, and an extended nozzle corresponding to each of the channels.
What is claimed is: An example of one such configuration is a Multi-Nozzle Array, which is an array of two or more capillaries used to simultaneously print parallel lines onto a substrate.3D Printed Electronics via Aerosol Jet® • Aerosol Jetting technology!
• Maskless deposition of functional inks! • CAD Driven, Direct Write process! Capability! • Non-contact! • 2D & 3D process! • Scalability: ﬁne printed features to wide area!
High Utility!. Optomec Aerosol Jet technology is a high volume printing solution for the production of 3D antennas and 3D sensors that are tightly integrated with an underlying product ranging from Smartphones to Industrial Components.
The aerosol jetting technique is a bit different than your everyday FDM printer. Although it does build components layer by layer, the process works by using a carrier gas and printer head, which. The term “Direct Write” (DW) in its broadest sense can mean any technology which can create two- or three-dimensional functional structures directly onto flat or conformal surfaces in complex shapes, without any tooling or masks .Although directed energy deposition, material jetting, material extrusion, and other AM processes fit this definition; for the purposes of distinguishing.
Aerosol Jet systems print fine-feature electronic, structural and biological patterns -such as 3D conformal sensors and antennas for aerospace, defense, consumer electronics, wearables and the Internet of Things (IoT) – on to almost any substrate. The technology behind Aerosol Jet enables printing of interconnects on both 2D and 3D substrates.
For 2D applications, multi-level interconnects can be created by printing a dielectric material at circuit cross over points – in essence emulating a multi-layer circuit board but on a single layer.Download