In-line Static Mixer for Multimaterial Aerosol Jet Printhead
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Solution Overview
Problem
Conventional multimaterial aerosol jet printing heads face limitations in directional grading and are susceptible to process drift and inadequate stream convergence, resulting in inhomogeneous and nonuniform deposits.
Innovation Solution
An in-line static mixer, such as a helix or x-grid mixer, is integrated into the aerosol jet printhead to continuously mix multiple ink streams without moving components, ensuring effective mixing of micron-scale droplets and preventing droplet settling, with designs optimized through COMSOL simulations and CFD modeling to enhance mixing efficacy and reduce droplet loss.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If two distinct inks are atomized separately and converged prior to entering a printhead, then binary multimaterial printing is achieved, but the deposits become inhomogeneous and nonuniform due to limited directional grading and inadequate stream convergence
Solution Approach 1:
The ink streams are segmented into multiple substreams through the static mixer elements, creating numerous smaller flow paths that enhance mixing while maintaining control over material distribution. This segmentation allows for better convergence of multiple ink streams without sacrificing deposit uniformity.
Solution Approach 2:
The static mixer acts as an intermediary device between the separate ink atomization sources and the deposition substrate. It provides a controlled environment for stream convergence and mixing, eliminating the inadequate convergence problems of direct convergence while maintaining binary multimaterial printing capability.
2Quantity of substance
If conventional multimaterial printheads are used, then binary multimaterial printing is achieved, but process drift occurs resulting in inhomogeneous deposits
Solution Approach 1:
The static mixer is a passive, self-service device with no moving parts that requires no active control or adjustment during operation. The mixing action is generated automatically by the flow dynamics itself, eliminating process drift associated with active control systems while maintaining reliable multimaterial printing.
Solution Approach 2:
The active mechanical mixing system with moving parts is replaced by a passive static mixer that relies on flow-induced mixing mechanisms. This substitution eliminates mechanical wear, calibration drift, and control instability while achieving reliable material mixing and deposition.
3Manufacturing precision
If static mixer elements are added to the printhead, then mixing efficacy is improved, but device complexity increases
Solution Approach 1:
The static mixer elements are merged into a single integrated component that combines multiple mixing stages within one compact structure. This merging approach achieves effective material mixing while minimizing the increase in device complexity compared to multiple separate mixing devices.
Solution Approach 2:
Multiple mixing elements are nested within each other in a compact arrangement, with smaller mixing features contained within larger structural elements. This nesting approach maximizes mixing efficacy within a compact volume, minimizing the impact on overall printhead complexity.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables the production of laterally-graded, functionally-graded materials with improved mixing efficacy and reduced droplet loss, allowing for the printing of diverse materials like nanoparticles and reactive species, facilitating applications in optics, electronics, and mechanical components.
Implementation Method 1
The static mixer enables continuous mixing of the ink streams, without moving components. A variety of static mixer designs can be used with the invention, comprising a plurality of mixing elements or baffles contained in a hollow tube
Implementation Method 2
Aerosol jet printing (AJP) uses focused deposition of micron-scale ink droplets suspended in a carrier gas flow
Implementation Method 3
Aerosol jet printing (AJP) uses focused deposition of micron-scale ink droplets suspended in a carrier gas flow
Implementation Method 4
Binary multimaterial printing has been achieved by atomizing two distinct inks separately
Data Source
AI summary
An aerosol jet printhead comprising an in-line static mixer can mix multiple aerosol streams for co-deposition from a single nozzle. A printhead was designed, fabricated, and tested, demonstrating in-plane functionally graded films. The inline mixing printhead can be used with a compact aerosol jet deposition system.