An integrated printing system and method based on electric field assisted aerosol beam shaping

Abstract

The application discloses an integrated printing system and method based on electric field assisted aerosol beam flow shaping, and relates to the technical field of intelligent printing regulation and control.The system comprises the following steps: seamlessly integrating a programmable control auxiliary electric field in a nozzle system of aerosol jet printing; and through deep coupling of the electric field and the original pneumatic flow field, the spatial distribution and motion trajectory of aerosol droplets are actively regulated without relying on a physical mask.Not only can the jet flow be effectively compressed to realize super-high-precision printing, but also a controllable wide beam flow can be generated by combining the Coulomb repulsion between charged particles through specific electric field configuration, so that high-flux uniform deposition on a millimeter-wide width is realized.Through real-time adjustment of electric control parameters, the printing line width and mode can be continuously and dynamically adjusted in one system, and the long-standing problems in the aerosol jet printing technology, such as the precision-efficiency trade-off, difficulty in morphology control and insufficient stepless continuous variable scale adaptability, are fundamentally solved.

Description

Technical Field

[0001] This invention relates to the field of intelligent printing control technology, and more specifically to an integrated printing system and method based on electric field-assisted aerosol beam shaping. Background Technology

[0002] Aerosol jet printing is a promising non-contact, direct-write additive manufacturing technology. Its basic principle involves atomizing functional material ink into micron-sized aerosol droplets (1-5 micrometers), which are then transported to a nozzle via a carrier gas. Utilizing the aerodynamic focusing effect of the sheath gas, a collimated microjet is formed and deposited onto the substrate along a predetermined path. Aerosol jet printing technology offers advantages such as broad material compatibility, conformal printing capabilities, and high resolution, and is widely used in printed electronics, flexible devices, and micro / nano sensors.

[0003] However, traditional aerosol jet printing technology mainly relies on pneumatic focusing to control deposition accuracy. Its core limitations are: 1. The contradiction between resolution and efficiency. To achieve high resolution (typically <100μm), small-aperture circular nozzles and increased focusing gas flow are required, but this severely limits material deposition throughput and printing efficiency. Conversely, increasing throughput often requires increasing nozzle aperture, leading to a decrease in resolution. 2. Difficulty in controlling deposition uniformity and morphology. The deposition cross-section of the jet generated by a circular nozzle typically exhibits a Gaussian distribution, thicker at the center and thinner at the edges. 3. Trajectory deviation and insufficient positioning accuracy. After leaving the nozzle, aerosol droplets are highly susceptible to environmental airflow disturbances, Brownian motion, and the complex flow field between the nozzle and the substrate, causing their trajectory to deviate from the ideal path. This is especially problematic when printing fine features or structures with large aspect ratios, where accuracy and consistency are difficult to guarantee. 4. Limited dynamic control capability of the jet shape. Existing technologies cannot achieve continuous, dynamic mode switching from extremely high precision (cylindrical jet) to extremely high throughput (wide-bandgap jet) within the same system without hardware replacement. Especially when large areas need to be filled quickly, traditional circular fine beams are inefficient, while simply increasing the nozzle diameter will lead to uncontrollable beam shape and rough edges.

[0004] In recent years, researchers have explored methods to introduce external physical fields to improve the performance of aerosol jet printing. For example, by charging the aerosol and focusing it using an electrostatic lens, three-dimensional nanostructures have been printed, demonstrating the effectiveness of electric fields in overcoming Brownian motion and achieving ultra-high precision directional deposition. Other studies have employed a ring-shaped acoustic field to refocus the jet, effectively improving resolution and suppressing atomization. These works collectively indicate that moving beyond pure aerodynamic focusing and utilizing multi-physics synergy is a key direction for technological development. However, existing technologies still have significant limitations: mask-based electric field-induced methods are complex, lack flexibility, and struggle to meet the demands of high throughput and complex forming; while acoustic field-assisted methods are difficult to actively and extensively shape and control the jet cross-sectional morphology with high precision. In particular, there is no effective solution for generating controllable beam morphology. Currently, there is a lack of a solution that can implement flexible and dynamic intelligent control of aerosol jets without changing hardware, simultaneously achieving high homogeneous deposition and stepless continuous variable-scale printing capabilities.

[0005] Therefore, how to propose an integrated printing system and method based on electric field-assisted aerosol beam shaping to overcome the shortcomings of existing technologies is a problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0006] In view of this, the present invention provides an integrated printing system and method based on electric field-assisted aerosol beam shaping. Building upon the traditional pneumatic focusing flow field, a programmable electrostatic field is introduced. By utilizing the multi-physics coupling between the electric field, airflow, and microdroplets, the charge state, trajectory, and deposition dynamics of the aerosol microdroplets are precisely and actively controlled. This overcomes the inherent contradiction between precision and efficiency in a single system, enabling dynamic and continuous switching from high-resolution cylindrical beams to high-throughput wide-bandgap beams. To achieve the above objectives, the present invention adopts the following technical solution: An integrated printing system based on electric field-assisted aerosol beam shaping includes: Aerosol generation and printing module, aerosol printing nozzle, aerosol charging and electric field control module, vision module, in-situ curing module, five-axis motion module, computer control module; The aerosol generation and printing module is used to atomize functional material ink into aerosol droplets, and deliver them to the aerosol printing nozzle via a carrier gas. Sheath gas is used for initial aerodynamic focusing to form a collimated jet. The aerosol charging and electric field control module is integrated with the aerosol generation and printing module to charge aerosol droplets and generate a spatial electrostatic field for controlling the jet. The vision module is used to locate the printing substrate, measure its three-dimensional shape, and collect data during the printing process. The in-situ curing module is used to cure the deposited functional materials; The five-axis motion module is used to perform relative motion between the aerosol generation and printing module and the printing substrate. The computer control module is used to connect the aerosol generation and printing module, the aerosol charging and electric field control module, the vision module, the in-situ curing module, and the five-axis motion module for closed-loop control.

[0007] Optionally, the aerosol generation and printing module includes: a gas supply device, a carrier gas mass flow controller, a sheath gas mass flow controller, an ink atomization device, and an aerosol printing nozzle; One end of the gas supply device is connected to the aerosol printing nozzle via the carrier gas mass flow controller. The other end is connected in sequence to the ink atomizing device and the aerosol printing nozzle via a sheath gas mass flow controller.

[0008] Optionally, the aerosol charging and electric field control module includes: a high-voltage DC power supply I, a high-voltage DC power supply II, an induction charging unit, and a space electric field control unit; The inductive charging unit is a ring electrode, which is tightly integrated into the nozzle outlet of the aerosol delivery channel and connected to a high-voltage DC power supply. When the aerosol droplets flow through the strong electric field region formed by the electrode, the surface of the droplets carries a net charge of a preset polarity through the inductive charging mechanism. The space electric field control unit consists of an independent electrode array set around the nozzle outlet. The electrode array is a rectangular sleeve-type electrode control device, which consists of four independent insulated metal electrode plates forming a rectangular channel. Each electrode plate can be independently energized by a high-voltage DC power supply.

[0009] Optionally, the independently applied voltage includes: When the two pairs of electrodes on the diagonal face are applied with the same voltage as the microdroplet and the other two pairs are grounded, a flattened electric field is formed, which, together with the Coulomb repulsion between particles, generates a wide beam. When a voltage of the same sign as the microdroplet is applied to all four electrodes, a radially inward repulsive electric field is formed, generating a focused cylindrical beam. When different voltages are applied to all four electrodes, a divergent electric field is formed, and the beam current expands.

[0010] Optionally, the vision module includes a camera bracket and a high-speed microscope camera.

[0011] Optionally, the in-situ curing module includes ultraviolet curing, thermal curing, electron beam curing, or near-infrared laser sintering.

[0012] Optionally, the five-axis motion module includes a high-precision five-axis linkage platform and a printing substrate, wherein the high-precision five-axis linkage platform cooperates with the printing substrate.

[0013] Optionally, the computer control module integrates multiphysics simulation, path planning and motion control functions. Based on the size and shape characteristics of the target pattern and according to the built-in coupling mechanism model, it automatically calculates and coordinates the control of atomization, airflow, electric field, motion trajectory and curing parameters to perform closed-loop control of the entire process.

[0014] Optionally, an integrated printing method based on electric field-assisted aerosol beam shaping includes: S1: System initialization and parameter matching: Based on the characteristic dimensions of the target structure and the properties of the ink material used, the initial set of process parameters is called from the pre-generated process state window diagram or calculated through the coupling model; S2: Aerosol generation and active charging: The aerosol generation and printing module is activated to generate aerosols. Simultaneously, the aerosol charging and electric field control module is activated to apply voltage to the induction charging electrode, so that the passing aerosol microdroplets are charged with a preset charge. S3: Multiphysics field coupling focusing and jet morphology control: Charged droplets form a preliminary focused jet under the action of sheath gas. The jet enters the electrostatic field region, and the droplets are subject to Coulomb force to control their motion trajectory. S4: Motion Deposition and Real-time Monitoring: The five-axis motion module moves along a preset path to deposit a stable jet after coupling field control onto the substrate. The vision module monitors the deposition morphology and feeds the data back to the computer control module for closed-loop fine-tuning of process parameters. S5: In-situ curing and structural forming: The in-situ curing module cures the deposited layer in real time, either synchronously or in stages, according to the curing characteristics of the material. S6: Multilayer structure manufacturing: For cases requiring the fabrication of multilayer, heterogeneous, or three-dimensional structures, after completing single-layer deposition and curing, process parameters can be maintained or updated, and steps S2 to S5 can be repeated according to a preset program.

[0015] As can be seen from the above technical solution, compared with the prior art, the present invention discloses an integrated printing system and method based on electric field-assisted aerosol beam shaping, which has the following beneficial effects: This invention introduces a programmable electrostatic field to achieve intelligent coupling and coordinated control with the aerodynamic flow field. Specifically, when a precision of hundreds of micrometers or even higher is required, the electric field force can provide an additional secondary tight focusing effect, allowing for ultra-high resolution under relatively relaxed airflow conditions and improving printing accuracy. When millimeter-level high-throughput printing is required, the specific electric field distribution (diagonal voltages of the same sign) and the Coulomb repulsion between charged droplets work together to actively flatten and homogenize the beam, achieving a uniform deposition morphology while maintaining high throughput.

[0016] This invention, through precise design and control of the spatial distribution of the electrostatic field at the nozzle exit, can actively intervene in the distribution of aerosol droplets across the jet cross-section. Particularly in high-throughput mode, the synergy between the external electric field and the electrostatic force between particles yields a uniformly deposited layer with a flat-top distribution, significantly improving the in-plane performance consistency and reliability of functional structures (such as conductive lines and sensitive films). The guiding and confining effect of the electrostatic field on the charged aerosol jet effectively resists environmental airflow disturbances and the Brownian motion of the droplets, ensuring high-fidelity trajectory printing. This is particularly beneficial for high-success-rate printing of complex curves, high aspect ratio structures, and conformal patterns on complex curved surfaces.

[0017] This invention is the first to realize dynamic switching between high-throughput and high-precision beam modes, and even stepless continuous variation of linewidth, on the same hardware platform through software programming. This greatly enhances the flexibility and adaptability of the printing process and provides a new path for cross-scale integrated manufacturing.

[0018] The electric field induction mechanism of this invention has relatively broad requirements on the physical properties of ink materials, such as conductivity, and maintains the inherent advantage of wide material compatibility of aerosol jet printing technology. It is convenient to integrate multiple functional materials such as conductors, semiconductors, and insulators on the same component, so as to achieve true multi-material integrated manufacturing.

[0019] In summary, this invention addresses the shortcomings of existing aerosol jet printing technology in terms of stepless continuous scale variation capability, morphology control, and intelligent regulation. Through an original electric field-airflow multi-physics coupling mechanism, it achieves a paradigm shift in the printing process from passive constraint to active design. Attached Figure Description

[0020] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on the provided drawings without creative effort.

[0021] Figure 1 The present invention provides a structural framework diagram of an integrated printing system based on electric field-assisted aerosol beam shaping.

[0022] Figure 2 This is a schematic diagram illustrating the principle by which the electric field force and the electrostatic force between particles significantly improve the uniformity of aerosol deposition, as provided by the present invention.

[0023] Figure 3 This is a schematic diagram illustrating the principle of multi-mode control of the electric field of charged sol provided by the present invention.

[0024] Figure 4This is a schematic diagram of the integrated printing of the continuous variable linewidth interconnection structure of the aircraft radar antenna provided by the present invention.

[0025] Figure 5 The experimental verification results of speed compensation printing control measurement provided for this invention are shown in the figure.

[0026] Among them, 1-Aerosol generation and printing module, 2-Aerosol charging and electric field control module, 3-Vision module, 4-In-situ curing module, 5-Five-axis motion module, 6-Computer control module, 1-1-Gas supply device, 1-2-Carrier gas mass flow controller, 1-3-Sheath gas mass flow controller, 1-4-Ink atomization device, 1-5-Aerosol printing nozzle, 2-1-High voltage DC power supply one, 2-2-High voltage DC power supply two, 2-3-Inductive charging unit, 2-4-Spatial electric field control unit, 5-1-High precision five-axis linkage platform, 5-2-Printing substrate. Detailed Implementation

[0027] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0028] This invention discloses an integrated printing system based on electric field-assisted aerosol beam shaping, such as... Figure 1 As shown, it includes: The module consists of: 1. Aerosol generation and printing module; 2. Aerosol charging and electric field control module; 3. Vision module; 4. In-situ curing module; 5. Five-axis motion module; and 6. Computer control module. The aerosol generation and printing module 1 is used to atomize functional material ink into aerosol droplets and deliver them to the aerosol printing nozzle 1-5 via a carrier gas; the aerosol printing nozzle 1-5 receives the aerosol from the atomizing device and uses sheath gas for preliminary aerodynamic focusing to form a collimated jet. The aerosol charging and electric field control module 2 is integrated with the aerosol generation and printing module 1. It is used to charge aerosol droplets and generate a spatial electrostatic field for controlling the jet. The design is optimized through flow field-electrostatic field co-simulation to ensure multi-physics field matching and realize the co-operational or competitive control of the jet. The vision module 3 is used to locate the printing substrate, measure its three-dimensional shape, and collect data during the printing process. The in-situ curing module 4 is used to cure the deposited functional materials; The five-axis motion module 5 is used to perform relative motion between the aerosol printing module 2 and the printing substrate; The computer control module 6 is used to connect the aerosol generation and printing module 1, the aerosol charging and electric field control module 2, the vision module 3, the in-situ curing module 5, and the five-axis motion module 6 for closed-loop control.

[0029] Furthermore, the aerosol printing generation module 1 includes: an air supply device 1-1, a carrier gas mass flow controller 1-2, a sheath gas mass flow controller 1-3, an ink atomization device 1-4, and an aerosol printing nozzle 1-5; One end of the gas supply device 1-1 is connected to the aerosol printing nozzle 1-5 via the carrier gas mass flow controller 1-2; The other end is connected in sequence to the ink atomizing device 1-4 and the aerosol printing nozzle 1-5 via the sheath gas mass flow controller 1-3.

[0030] The ink atomizing devices 1-4 can be selected from ultrasonic atomization, pneumatic atomization, or electro-atomization methods according to the material characteristics. This module can be expanded into a multi-channel independent supply system to realize the printing of multiple materials or functionally graded materials.

[0031] Furthermore, the aerosol charging and electric field control module 2 includes: a high-voltage DC power supply 2-1, a high-voltage DC power supply 2-2, an induction charging unit 2-3, and a spatial electric field control unit 2-4. The inductive charging unit 2-3 is a ring electrode, which is tightly integrated into the printing nozzle outlet of the aerosol delivery channel and connected to the high voltage DC power supply 2-1. When the aerosol droplets flow through the strong electric field region formed by the electrode, the surface of the droplets carries a net charge of a preset polarity through the inductive charging mechanism. The space electric field control unit 2-4 consists of an independent electrode array set around the nozzle outlet. The electrode array is a rectangular sleeve-type electrode control device, which consists of four independent insulated metal electrode plates forming a rectangular channel. Each electrode plate can be independently charged by a high-voltage DC power supply 2-2.

[0032] Furthermore, the independent application of voltage includes the ability to flexibly generate different modes of electric field distribution by programming and configuring the voltage combinations of each electrode: When the two pairs of electrodes on the diagonal face are applied with the same voltage as the microdroplet and the other two pairs are grounded, a flattened electric field is formed, which, together with the Coulomb repulsion between particles, generates a wide beam. When a voltage of the same sign as the microdroplet is applied to all four electrodes, a radially inward repulsive electric field is formed, generating a focused cylindrical beam. When opposite voltages are applied to all four electrodes, a divergent electric field is formed, and the beam current expands. By adjusting the charging voltage and regulating the electric field to adjust the beam size in real time, dynamic and continuous changes in deposition linewidth from micrometers to millimeters can be achieved without changing the nozzle during a single printing process.

[0033] Furthermore, the vision module 3 includes a 3D laser scanner and a high-speed microscope camera, used for locating the printing substrate, measuring its 3D morphology, and monitoring the printing process in real time.

[0034] Furthermore, the in-situ curing module 4 includes ultraviolet curing, thermal curing, electron beam curing, or near-infrared laser sintering. It is used to instantly cure the deposited functional materials, promoting their phase change and functionalization. An independent motion mechanism enables precise control of the irradiation position and range, dynamically following the printing points or operating according to a preset timing sequence.

[0035] Furthermore, the five-axis motion module 5 includes a high-precision five-axis linkage platform 5-1 and a printing substrate 5-2, wherein the high-precision five-axis linkage platform 5-1 cooperates with the printing substrate 5-2. This is used for high-precision control of the relative movement between the aerosol coaxial focusing nozzle and the substrate, with a positioning accuracy better than 5 micrometers, to meet the requirements of conformal printing on complex curved surfaces.

[0036] Furthermore, the computer control module 6 integrates multiphysics simulation, path planning, and motion control functions. Based on the size and shape characteristics of the target pattern and according to the built-in coupling mechanism model, it automatically calculates and coordinates the control of atomization, airflow (carrier gas / sheath gas velocity), electric field (voltage of each electrode), motion trajectory, and curing parameters to perform closed-loop control of the entire process.

[0037] In a specific embodiment, an integrated printing method based on electric field-assisted aerosol beam shaping includes: S1: System Initialization and Parameter Matching: Based on the characteristic dimensions of the target structure (such as line width and thickness) and the properties of the ink material used, an initial set of process parameters is called from a pre-generated process state window diagram or calculated through a coupled model. This parameter set includes: carrier gas flow rate ( ), sheath gas flow rate ( Define the aerodynamic focusing ratio ), sensing electrode voltage ( ), and the configuration of the regulating electrode voltage ( ), substrate bias voltage ( ) and nozzle-substrate distance ( ); S2: Aerosol generation and active charging: Start aerosol generation and printing module 1 to generate aerosol, and simultaneously start aerosol charging and electric field control module 2 to apply voltage to the induction charging electrode so that the passing aerosol microdroplets are charged with a preset charge. S3: Multiphysics field coupling focusing and jet morphology control: Charged droplets form a preliminary focused jet under the action of sheath gas. The jet enters the electrostatic field region, and the droplets are subject to Coulomb force to control their motion trajectory. Specifically, charged droplets form a preliminary focused jet under the action of sheath gas. The jet enters the electrostatic field region formed by the spatial electric field control unit 2-4 and the substrate electrode, where the droplets are subjected to Coulomb force, and their trajectory is further controlled. By programming different combinations of airflow and electric field parameters, various printing methods can be achieved. Several schemes are listed below: ① Beam focusing scheme: A combination of high sheath gas flow rate (high focusing ratio) and high converging electric field voltage is used (the same voltage as the droplet is applied to all four sides of the rectangular sleeve, or the focusing voltage is applied to the annular electrode). The electric field force and the aerodynamic focusing force work together to perform secondary tight focusing on the jet, greatly suppressing diffusion and achieving high-resolution printing with a linewidth of less than 100 micrometers. ② High throughput scheme: A lower sheath gas flow rate (low focusing ratio) is used, and the same voltage as the droplet is applied to the diagonal electrodes of the rectangular sleeve of the spatial electric field control unit (the other two sides are grounded). At this point, the external electric field provides a unidirectional flattening potential well, while the Coulomb repulsion between charged droplets generates isotropic expansion. Under this dual synergistic effect, the beam significantly broadens in a specific direction, forming a uniform deposition morphology with a width of 1-3 mm and an approximately rectangular cross-section, suitable for large-area rapid filling. ③ Variable linewidth printing scheme: During continuous printing, the linewidth is continuously adjusted in real time and synchronously by a computer control module. and These parameters enable seamless gradient changes in deposition linewidth from micrometers to millimeters, achieving truly stepless, continuous, variable-scale integrated printing.

[0038] S4: Motion Deposition and Real-time Monitoring: The five-axis motion module 5 moves along a preset path to deposit the stable jet after coupling field control onto the substrate. The vision module 3 monitors the deposition morphology and feeds the data back to the computer control module 6 for closed-loop fine-tuning of process parameters. S5: In-situ curing and structural forming: The in-situ curing module 4 cures the deposited layer in real time according to the curing characteristics of the material, either synchronously or in stages, to shape the functional structure. S6: Multilayer Structure Manufacturing: For applications requiring the fabrication of multilayer, heterogeneous, or three-dimensional structures, after single-layer deposition and curing, process parameters can be maintained or updated, and steps S2 to S5 can be repeated according to a preset program. By precisely controlling the material selection, deposition path, and process mode (high precision, high throughput, or transition mode) for each layer, combined with the motion positioning and interlayer alignment of a five-axis platform, integrated manufacturing of complex three-dimensional structures, including vertical interconnects, embedded structures, and various functional materials such as conductors / dielectrics / semiconductors, can be achieved.

[0039] Example 1: An integrated printing system based on electric field-assisted aerosol beam shaping, comprising: 1. Aerosol generation and printing module; 2. Aerosol charging and electric field control module; 3. Vision module; 4. In-situ curing module; 5. Five-axis motion module; 6. Computer control module; The aerosol printing generation module 1 includes an air supply device 1-1, a carrier gas mass flow controller 1-2, a sheath gas mass flow controller 1-3, and an ink atomizing device 1-4, which are used to atomize functional material ink into microdroplets with uniform particle size and deliver them to the aerosol printing nozzle 1-5 in the form of an aerosol beam. The flux of the aerosol beam can be adaptively adjusted according to the target structure to be formed.

[0040] The aerosol charging and electric field control module 2 includes a high-voltage DC power supply (aerosol charging) 2-1, a high-voltage DC power supply (electric field control) 2-2, an inductive charging unit 2-3, and a spatial electric field control unit 2-4 (rectangular sleeve-type electrode control device). The inductive charging unit 2-3 is a ring electrode integrated into the aerosol delivery channel. Voltage is applied through the high-voltage DC power supply 2-1 to inject a controllable amount of net charge into the flowing aerosol droplets, forming an charged aerosol. The spatial electric field control unit 2-4 consists of four independent, insulated metal electrode plates forming a rectangular channel, installed below the nozzle outlet. Each electrode plate is independently energized by the high-voltage DC power supply 2-2. By programming and controlling the voltage combinations of each electrode, different electric field distribution modes can be achieved: ① When the two pairs of electrodes on the diagonal face are applied with the same voltage as the droplet (the other two pairs are grounded), a flattened electric field is formed, generating a wide beam current, suitable for high-throughput rapid filling; ② When all four electrodes are applied with the same voltage as the droplet, a radially inward repulsive electric field is formed, generating a focused cylindrical beam current, and the linewidth can be compressed to the sub-hundred-micron level; ③ When all four electrodes are applied with opposite voltages, a divergent electric field is formed, and the beam current expands. By adjusting the charging voltage and controlling the electric field to change the beam current size in real time, the deposition linewidth can be dynamically and continuously changed without changing the nozzle during a single printing process, switching from micron-level precision wiring to millimeter-level rapid filling.

[0041] The computer control module 6 integrates path planning, multiphysics simulation and motion control functions. Based on the 3D model of the workpiece obtained by the vision module 3, it automatically plans the variable-scale printing path and collaborative curing strategy, and synchronously coordinates and controls all subsystems.

[0042] The vision module 3 is used to locate and measure the structural components that are actually installed and processed, and to monitor the beam morphology and deposition process in the micro-domain in real time during the in-situ manufacturing process.

[0043] The in-situ curing module 4 is mainly composed of a near-infrared laser and is used to selectively sinter the deposited metal or ceramic materials. This module dynamically follows the printing point or works according to a preset timing sequence.

[0044] The five-axis motion module 5 includes a high-precision five-axis linkage platform 5-1 and a printing substrate 5-2, which are used to support and precisely move the workpiece, with a positioning accuracy better than 5 micrometers.

[0045] Example 2: A preferred embodiment of the induced charge unit 2-3 and the spatial electric field control unit 2-4 is as follows: Figure 1 As shown. The inductively charged unit 2-3 is a copper ring with an inner diameter of 0.8 mm and an electrode thickness of 1.0 mm, integrated into the aerosol delivery channel of the aerosol generation and printing module 1, and connected to the high-voltage DC power supply 2-1. A DC voltage of -2.5 kV to -10.0 kV is applied to it, and the flowing aerosol droplets are negatively charged through the inductive charging mechanism.

[0046] The empirical formula for the charge q of a droplet can be approximately expressed as: ; Where ε is the dielectric constant of the ink, For the drop diameter, The electric field strength is in the charged region.

[0047] By controlling the voltage and carrier gas flow rate, the microdroplet charge-to-mass ratio can be stabilized at 1×10⁻⁶. -4 Up to 5×10 -4 Within the C / kg range, this forms the basis for subsequent effective electric field control. The spatial electric field control unit 2-4 is a rectangular metal cylinder with sides of 15mm and a height of 10mm. Its four sides are copper electrodes on which voltage can be applied independently, and the electrodes are insulated from each other with polytetrafluoroethylene (PTFE). This device is installed 12mm below the nozzle outlet, with its center coaxial with the nozzle. Each electrode is independently connected to a different output channel of the high-voltage DC power supply 2-2, with a voltage adjustment range of 0 to ±15kV and a resolution of 1V.

[0048] The functional material ink is a functional slurry that can be charged and atomized, with a solvent dielectric constant typically in the range of 12-35 and a conductivity controlled at 10. -6 ~10 -3 The ink viscosity ranges from 5 to 500 cP, and the surface tension ranges from 25 to 70 mN / m, ensuring stable atomization to form 1-10 μm microdroplets while maintaining good spreading and fusion properties after deposition. Material systems include conductive metal nanoparticles (such as silver and gold), semiconductor oxides (such as ITO and ZnO), dielectric ceramics, or polymer precursors.

[0049] Example 3: As Figure 2 As shown, the underlying mechanism by which an electric field is applied through a rectangular sleeve multi-electrode device, utilizing the synergistic effect of the electric field force and the electrostatic force between particles, significantly improves the uniformity of aerosol deposition. This mechanism includes: In conventional circular nozzle systems, aerosol particles are primarily affected by the combined effects of airflow drag, Suffman lift, and gravity. Due to the axisymmetric geometry of the nozzle exit, the flow field formed by the sheath gas and carrier gas exhibits an axisymmetric distribution, resulting in a Gaussian distribution of particle number density across the jet cross-section: denser particles in the central region and sparser particles at the edges. Consequently, the deposition cross-section profile exhibits a peak characteristic, with a high center and gradually decreasing edge. When printing large-area patterns using a multi-pass stitching method, the thickness superposition between adjacent scan tracks inevitably produces periodic fluctuations, making it difficult to control thickness deviation even with optimal scan spacing. This inherent non-uniformity of the Gaussian distribution becomes a key bottleneck restricting the improvement of print quality.

[0050] This invention employs a rectangular sleeve-type electrode control device, where voltage can be applied independently to each rectangular surface, generating a potential difference in the space below the nozzle. This electric field exerts a Coulomb repulsion force on the charged droplets, forcing them to move to both sides. Simultaneously, a large number of charged droplets also exhibit mutual Coulomb repulsion. The synergistic effect of these two forces fundamentally alters the particle distribution across the jet cross-section. The external electric field pushes particles outward from the central region, suppressing the central peak of the Gaussian distribution; while the isotropic repulsion between particles causes them to redistribute spatially, filling the density troughs at the edges. This dual effect makes the particle number density across the jet cross-section more uniform, transforming the deposition profile from a Gaussian distribution to a flat-topped distribution. Compared to conventional circular nozzles, this invention exhibits a more uniform particle distribution along the deposition width, lower thickness deviation within a single channel, and a significantly reduced width of the edge transition zone. These advantages stem from the active shaping of droplet motion by the electric field and the self-homogenizing effect of inter-particle repulsion, which is impossible to achieve with pure pneumatic focusing.

[0051] Example 4: Figure 3 As shown, the spatial electric field control unit 2-4, i.e., the rectangular sleeve-type electrode control device, achieves four distinct printing modes by programming and controlling the voltage combination of each electrode: (1) Normal mode: All electrodes are grounded or have zero voltage applied, and there is no external electric field. The beam shape is entirely determined by pneumatic focusing, and the linewidth is adjusted by the focusing ratio (sheath gas / carrier gas). This mode is suitable for normal printing scenarios where a balance between accuracy and efficiency is required.

[0052] (2) Focusing Mode: When printing fine lines or high-resolution patterns, the control module applies a voltage (e.g., -4kV to -8kV) of the same polarity as the droplet to all four electrodes. At this time, the radially inward electric field generated by the electrodes compresses the charged droplet towards the axis, reducing the beam diameter to the hundreds of micrometers and significantly lowering the edge roughness. This mode enables high-precision deposition and is suitable for manufacturing structures such as fine lines in sensors and fine electrodes in flexible electronics.

[0053] (3) High-throughput mode: When rapid and uniform deposition is required over a large area, the control module applies a voltage (e.g., -4kV to -8kV) of the same polarity as the aerosol droplets to the diagonal electrodes in the device, while the other two pairs of electrodes are grounded or subjected to zero voltage. At this time, the lateral electric field force in the diagonal direction flattens the charged droplets to both sides, while the Coulomb repulsion between the droplets further promotes the uniform broadening of the beam, ultimately forming a wide jet with a width of several millimeters and a flat-topped cross-section. This mode has a large coverage area per scan and high deposition efficiency, and is suitable for the rapid prototyping of large-area structures such as conductive films and electrode contact points.

[0054] (4) Extended mode: A pair of diagonal electrodes is applied with a voltage of the same polarity as the droplet (e.g., -6kV), and another pair of diagonal electrodes is applied with a voltage of opposite polarity (e.g., +2kV to +4kV). In this mode, the same polarity side generates a repulsive force that pushes the droplet outward, while the opposite polarity side generates an attractive force that further stretches the edge droplets outward. The synergistic effect of these two forces can significantly increase the beam broadening, resulting in an ultra-wide beam. This mode is suitable for the rapid filling or pre-deposition layer preparation of ultra-large areas.

[0055] The four modes can be switched in real time via computer control module 6 without replacing any hardware. During the printing process, by continuously adjusting the combination of voltages of each electrode (such as gradually transitioning from diagonal pressure to four-sided pressure), stepless continuous variation of linewidth from millimeters to micrometers can be achieved, meeting the needs of cross-scale integrated printing.

[0056] Example 5: Figure 4 As shown, through real-time collaborative control of multiple parameters, the ability to dynamically switch between wide beam and cylindrical beam in electric field-assisted aerosol printing is realized, which is suitable for integrated printing of flexible interconnected structures that require impedance matching or stress transition.

[0057] This design pattern represents a radar antenna for an aircraft, used to connect a miniature sensor and a power module, enabling a smooth transition between signal and power transmission. The target structure comprises two parts: a large area (for connection to the sensor) and a high-precision sensitive circuitry area. A 2.0mm inner diameter circular nozzle is used (to provide initial space for a wide beam), coupled with a rectangular sleeve-type electrode control device (15mm side length, 10mm height, installed 5mm below the nozzle exit). The printing material is PEDOT:PSS water-based conductive polymer ink (1.2% solids content, 25cP viscosity, 42mN / m surface tension). The system charges aerosol microdroplets via an inductively charged electrode, providing a foundation for subsequent electric field manipulation.

[0058] During printing, the computer control module 6 switches the electric field configuration in real time according to the characteristic areas of the target structure. In large areas (requiring rapid filling), a high-throughput mode is used: the diagonal electrodes of the rectangular sleeve apply a voltage of the same sign as the microdroplets (the other two electrodes are grounded). The external electric field generates a flattened potential well, which, in conjunction with the Coulomb repulsion between charged microdroplets, forms a flat-top beam approximately 2.5 mm wide. The deposition time is only about 3 seconds, and the thickness uniformity is better than 92%. In areas requiring high printing precision, the system switches to a focusing mode: all four electrodes apply a voltage of the same sign as the microdroplets, generating a radially inward repulsive force. The beam is compressed to a diameter of approximately 0.12 mm-0.2 mm, a linewidth of 0.15 mm-0.25 mm, an edge roughness as low as 0.8 μm, and a line resistance uniformity better than 98%. The computer control module continuously adjusts the electrode voltage group in real time according to the preset correspondence between printing width, printing height, gas flow rate, and printing speed. To maintain uniform deposition layer thickness (target thickness ~2 μm), the system synchronously calculates and controls the scanning speed of the five-axis platform. Based on the real-time beam diameter and material flux According to the formula Dynamic adjustment ,in, To determine the pattern deposition density, ensure a constant deposition amount per unit area.

[0059] Computer control module 6 uses a preset linewidth-position function. It calculates and outputs two sets of key instructions in real time: Based on the core model that shows a negative correlation between beam diameter and focusing intensity, the carrier gas / sheath gas velocity ratio is generated. Printing speed and ring focusing electrode voltage Synchronization change instructions.

[0060] Sheath gas flow rate (SGFR) directly determines the beam width of the aerodynamic focusing system, and the electrode voltage V of space electric field control unit 2-4. focus Provides electrostatic compression / broadening correction, and combined with experimentally calibrated linearity, the formula for calculating beam width W is: W=W0-k1 (SGFR-SGFR0)+k2 V focus ; In the formula: W0 is the reference beam width (the basic beam width when SGFR=SGFR0, Vfocus=0 and no external electric field is applied); SGFR is the real-time sheath gas flow rate, SGFR0 is the reference sheath gas flow rate; k1 is the sheath gas focusing coefficient, calibrated experimentally, with a reference value of 7.6×10. -4 mm sccm -1 For every 500 sccm increase in sheath gas flow rate, the pure aerodynamic beam width decreases by 0.38 mm; Vfocus The equivalent focusing voltage applied to the space electric field control unit, V in the four-sided same-sign focusing mode. focus Taking a positive value produces a beamwidth compression effect; in diagonal wideband mode, V... focus Negative values ​​are used to broaden the beam current; k2 is the electric field shaping correction coefficient, calibrated by the electrode structure and droplet charge-to-mass ratio. As the focusing voltage increases with polarity, the beam width decreases linearly. The carrier gas flow rate (CGFR) controls the total aerosol flux. To avoid turbulence disturbances, the system limits the stable operating range of CGFR to 300–800 sccm, allowing only minor adjustments and not using it as the primary variable for beam width control.

[0061] When a narrow line width is required, the instruction is... and Increase, forming a strong electrostatic focusing field; when a wider linewidth is required, the instruction is... By reducing the electric field and applying only a diagonal electric field, the beam naturally broadens.

[0062] The linewidth of the printed structure achieves a high degree of consistency with the design function. Observing the surface contour of the entire pattern, its changes are gradual, with no abrupt changes in width, indicating dense and uniform material deposition. The system has achieved the ability to dynamically traverse complex transition zones in the process state window diagram, solving the problems of interface impedance mismatch and weak mechanical connections caused by traditional multi-nozzle switching or segmented printing, and providing a new solution for the integrated manufacturing of high-performance heterogeneous integrated electronics.

[0063] Example 6: Taking a specific application of decoupled control of linewidth and thickness as an example. In the aerosol printing process, when continuous variation of linewidth is required, if only the sheath gas flow rate is adjusted, the deposition thickness will fluctuate significantly along with the linewidth, leading to a deterioration in pattern thickness uniformity. To solve this coupling problem, the computer control module 6, with its built-in relationships between parameters such as gas flow rate, linewidth, thickness, and printing speed, automatically calculates and outputs a set of synergistically varying process parameters based on the target linewidth and target thickness: while adjusting the sheath gas flow rate, it simultaneously compensates for the moving speed of the printing platform. Specifically, when the sheath gas flow rate increases to reduce the linewidth, the computer control module 6 simultaneously increases the platform moving speed, shortening the deposition time per unit area, thereby offsetting the increase in thickness caused by enhanced sheath gas focusing and maintaining a constant particle flux per unit area. Figure 5 The experimental results show that after adopting this speed synchronization compensation strategy, the line width can be continuously varied within the range of 0.5mm to 1mm, the thickness fluctuation of the printed pattern is within ±5%, and the entire area maintains a flat-top uniform deposition morphology.

[0064] This invention seamlessly integrates a programmable auxiliary electric field into the nozzle system of aerosol jet printing. Through deep coupling between this electric field and the original aerodynamic flow field, the spatial distribution and trajectory of aerosol droplets are actively controlled without relying on a physical mask. This technology not only effectively compresses the jet to achieve ultra-high precision printing, but also uniquely generates a controllable wide beam through a specific electric field configuration combined with the Coulomb repulsion between charged particles, achieving high-throughput uniform deposition on millimeter-wide surfaces. By adjusting the electronic control parameters in real time, the printing linewidth and mode can be continuously and dynamically adjusted within a single system, fundamentally solving the long-standing bottlenecks in aerosol jet printing technology, such as the trade-off between precision and efficiency, difficulty in morphology control, and insufficient adaptability to continuously varying scales.

[0065] The various embodiments in this specification are described in a progressive manner, with each embodiment focusing on its differences from other embodiments. Similar or identical parts between embodiments can be referred to interchangeably. For the apparatus disclosed in the embodiments, since they correspond to the methods disclosed in the embodiments, the description is relatively simple; relevant parts can be referred to the method section.

[0066] The above description of the disclosed embodiments enables those skilled in the art to make or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be implemented in other embodiments without departing from the spirit or scope of the invention. Therefore, the invention is not to be limited to the embodiments shown herein, but is to be accorded the widest scope consistent with the principles and novel features disclosed herein.

Claims

1. An integrated printing system based on electric field assisted aerosol beam shaping, characterized by, include: Aerosol generation and printing module (1), aerosol charging and electric field control module (2), vision module (3), in-situ curing module (4), five-axis motion module (5), computer control module (6); The aerosol generation and printing module (1) is used to atomize functional material ink into aerosol droplets and deliver them to the aerosol printing nozzle (1-5) via carrier gas, and use sheath gas for preliminary aerodynamic focusing to form a collimated jet; The aerosol charging and electric field control module (2) is integrated with the aerosol generation and printing module (1) to charge aerosol droplets and generate a spatial electrostatic field for controlling the jet. The vision module (3) is used to locate the printing substrate, measure its three-dimensional shape, and collect data during the printing process. The in-situ curing module (4) is used to cure the deposited functional materials; The five-axis motion module (5) is used to perform relative motion between the aerosol generation and printing module (1) and the printing substrate; The computer control module (6) is used to connect the aerosol generation and printing module (1), the aerosol charging and electric field control module (2), the vision module (3), the in-situ curing module (4), and the five-axis motion module (5) for closed-loop control.

2. An integrated printing system based on electric field assisted aerosol beam shaping according to claim 1, wherein, The aerosol generation and printing module (1) includes: an air supply device (1-1), a carrier gas mass flow controller (1-2), a sheath gas mass flow controller (1-3), an ink atomizing device (1-4), and an aerosol printing nozzle (1-5). One end of the gas supply device (1-1) is connected to the aerosol printing nozzle (1-5) through the carrier gas mass flow controller (1-2). The other end is connected in sequence to the ink atomizing device (1-4) and the aerosol printing nozzle (1-5) via the sheath gas mass flow controller (1-3).

3. The integrated printing system based on electric field assisted aerosol beam shaping of claim 1, wherein, The aerosol charging and electric field control module (2) includes: a high voltage DC power supply (2-1), a high voltage DC power supply (2-2), an induction charging unit (2-3), and a space electric field control unit (2-4). The inductively charged unit (2-3) is a ring electrode, which is tightly integrated at the nozzle outlet of the aerosol delivery channel and connected to a high-voltage DC power supply (2-1). When the aerosol droplets flow through the strong electric field region formed by the electrode, the surface of the droplets carries a net charge of a preset polarity through the inductively charged mechanism. The space electric field control unit (2-4) consists of an independent electrode array set around the nozzle outlet. The electrode array is a rectangular sleeve electrode control device, which consists of four independent insulated metal electrode plates forming a rectangular channel. Each electrode plate can be independently charged by a high-voltage DC power supply (2-2).

4. An integrated printing system based on electric field assisted aerosol beam shaping according to claim 3, wherein, The independently applied voltage includes: When the two pairs of electrodes on the diagonal face are applied with the same voltage as the microdroplet and the other two pairs are grounded, a flattened electric field is formed, which, together with the Coulomb repulsion between particles, generates a wide beam. When a voltage of the same sign as the microdroplet is applied to all four electrodes, a radially inward repulsive electric field is formed, generating a focused cylindrical beam. When different voltages are applied to all four electrodes, a divergent electric field is formed, and the beam current expands.

5. The integrated printing system based on electric field-assisted aerosol beam shaping according to claim 1, characterized in that, The vision module (3) includes a camera bracket and a high-speed microscope camera.

6. The integrated printing system based on electric field assisted aerosol beam shaping of claim 1, wherein, The in-situ curing module (4) includes ultraviolet curing, thermal curing, electron beam curing or near-infrared laser sintering.

7. The integrated printing system based on electric field assisted aerosol beam shaping of claim 1, wherein, The five-axis motion module (5) includes a high-precision five-axis linkage platform (5-1) and a printing substrate (5-2), wherein the high-precision five-axis linkage platform (5-1) cooperates with the printing substrate (5-2).

8. The integrated printing system based on electric field assisted aerosol beam shaping of claim 1, wherein, The computer control module (6) integrates multiphysics simulation, path planning and motion control functions. Based on the size and shape characteristics of the target pattern and the built-in coupling mechanism model, it automatically calculates and coordinates the control of atomization, airflow, electric field, motion trajectory and solidification parameters to perform closed-loop control of the whole process.

9. An integrated printing method based on electric field assisted aerosol beam shaping, characterized in that, include: S1: System initialization and parameter matching: Based on the characteristic dimensions of the target structure and the properties of the ink material used, the initial set of process parameters is called from the pre-generated process state window diagram or calculated through the coupling model; S2: Aerosol generation and active charging: Start the aerosol generation and printing module (1) to generate aerosols, and simultaneously start the aerosol charging and electric field control module (2) to apply voltage to the induction charging electrode so that the passing aerosol microdroplets are charged with a preset charge. S3: Multiphysics field coupling focusing and jet morphology control: Charged droplets form a preliminary focused jet under the action of sheath gas. The jet enters the electrostatic field region, and the droplets are subject to Coulomb force to control their motion trajectory. S4: Motion deposition and real-time monitoring: The five-axis motion module (5) moves along a preset path to deposit the stable jet after coupling field control onto the substrate. The vision module (3) monitors the deposition morphology and feeds the data back to the computer control module (6) for closed-loop fine-tuning of process parameters. S5: In-situ curing and structural forming: The in-situ curing module (4) cures the deposited layer in real time in a synchronous or stepwise manner according to the curing characteristics of the material; S6: Multilayer structure manufacturing: For cases requiring the fabrication of multilayer, heterogeneous, or three-dimensional structures, after completing single-layer deposition and curing, process parameters can be maintained or updated, and steps S2 to S5 can be repeated according to a preset program.

Images