3D Printed Electronics Conductive Tracks via Laser Scribed Trenches
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Solution Overview
Problem
Additive manufacturing methods produce 3D objects with rough surface finishes, making it challenging to form continuous and defect-free conductive tracks due to the uncontrollable flow of conductive materials on these surfaces, which limits the application of 3D printed electronics.
Innovation Solution
A method involving irradiating a 3D object's surface with light to create trenches and ridges, forming a material receiving track where conductive materials can be accurately deposited, allowing for the formation of continuous and precise conductive tracks without the need to remove the object from the manufacturing frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If additive manufacturing methods are used to form conductive tracks on 3D objects, then the conductive tracks can be deposited directly on the object surface, but the rough surface finish causes uncontrolled material flow and poor track continuity
Solution Approach 1:
The patent applies preliminary action by creating a recessed track structure in the object surface before depositing the conductive material. The recessed track is formed by removing material to create a groove with controlled dimensions, which then serves as a precise receptacle for the conductive material. This preliminary structural preparation ensures that when the conductive material is deposited, it flows into the predefined recess rather than uncontrolledly across the rough surface, guaranteeing continuous and precisely defined tracks.
2Device complexity
If the object surface is left rough from additive manufacturing, then the manufacturing process remains simple, but narrow conductive tracks cannot be formed continuously without defects
Solution Approach 1:
The patent applies local quality by transforming only the specific region where the conductive track will be formed, while leaving the rest of the object surface unchanged. A recessed track is created locally at the desired track position through controlled material removal, providing a smooth, defined pathway for the conductive material. This localized modification ensures reliable track continuity without requiring processing of the entire object surface, maintaining simplicity while improving reliability.
3Ease of manufacture
If material is deposited in a liquid state on a rough surface to form conductive tracks, then the deposition process is straightforward, but the material flows uncontrollably along the surface
Solution Approach 1:
The patent uses the recessed track structure as an intermediary element between the deposited conductive material and the rough object surface. The recessed track acts as a mediator that guides and confines the liquid-state conductive material, preventing uncontrolled flow along the surface while still allowing the material to be deposited relatively simply. The recessed structure provides the precise geometry that controls track width and edge definition, solving the contradiction between deposition simplicity and precision.
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
Enables the creation of conductive tracks with widths below 50 μm and embedded tracks with improved edge definition and continuity, enhancing the accuracy and performance of 3D printed electronics by controlling the length, shape, and width of the material receiving tracks.
Implementation Method 1
a first surface s of an object (10) comprising a base material (B) is irradiated with a light (L) along a first trajectory (T1). By irradiating the object, a volume of the object under the light may be locally heated.
Implementation Method 2
Forming a trench or groove, e.g. by local laser ablation
Data Source
AI summary
The present disclosure concerns methods for the manufacturing of products with printed conductive tracks. The process comprising scribing a first trench into the surface of the object, wherein on a border of the trench a first ridge is formed to define a first edge of a material receiving track. At a distance from the first trench a second trench is formed, wherein on the borders of the second trench a second ridge is formed facing the first ridge. The first and second ridges define a material receiving track which may be provided with a material suited to form a conductive track.