Advances In Aerosol Direct-Write Technology For Fine Line Applications

Aerosol deposition tools including Aerosol Jet (TM) and Collimated Aerosol Beam Direct-Write (CAB-DW (TM)) have been used to create fine metallic traces with line widths as thin as 5 mu m by focusing and accelerating aerosol particles through a nozzle and onto a substrate. These tools excel at applications requiring a non-contact method of rapid prototyping. We developed the CAB-DW system after an understanding of the fluid-particle interactions inside the Aerosol Jet system was realized. CAB-DW offers both narrower line widths and reduced overspray due to its 3-component converging-diverging-converging nozzle system. The details behind how this system was designed, subsequent progress in aerosol focusing designs, and applications of aerosol deposition systems will be discussed: In addition, a comparison of these aerosol direct-write systems to other direct-write systems and the future prospects of these tools will be presented.