Additive Electronics & Printed Nanomaterials

Aerosol Jet Printing (AJP) & Direct-Write Nanoparticle Calculator

Precision aerodynamic sheath focusing calculator for direct-write printed electronics, RF interconnects, and 3D conformal sensor arrays.

1. Input Parameters

Nozzle Tip Diameter (D_nozzle, µm)

Sheath Gas Flow Rate (Q_sheath, sccm)

Nitrogen (N2) annular sheath gas flow (typical 20 - 100 sccm)

Aerosol / Carrier Gas Flow (Q_aerosol, sccm)

Atomizer carrier gas flow rate (typical 5 - 30 sccm)

Printhead Traverse Speed (v_print, mm/s)

Substrate/gantry translation speed (typical 2 - 20 mm/s)

Nozzle Standoff Distance (z_gap, mm)

Z-height from tip orifice to 3D substrate plane

Nanoparticle Ink Solid Loading (wt %)

Silver/Gold/Copper nanoparticle concentration

2. Calculation Results

Sheath Focusing Ratio (s)

3.33

Estimated Line Width (W_line)

32.8 µm

Dry Film Thickness (t_dry)

420 nm

Line Aspect Ratio (H / W)

0.013

Spot Overspray Collimation

Optimal (98.2%)

Deposition Volumetric Rate

0.138 nL/s

3. Dynamic Visualizer & CAM Preview

4. Engineering Notes & Physics Specifications

Aerosol Jet Printing (AJP) is an advanced additive direct-write technology capable of depositing functional nanoparticle inks (silver, copper, carbon nanotubes, PEDOT:PSS, dielectrics) onto complex 2D and conformal 3D substrates with line resolutions down to 10 µm.

Sheath Gas Focusing: The focused aerosol beam diameter is governed by the sheath-to-aerosol flow ratio $s = Q_{\text{sheath}} / Q_{\text{aerosol}}$. Higher ratios aerodynamically compress the droplet stream: $W_{\text{beam}} \approx D_{\text{nozzle}} / \sqrt{1 + s}$.
Standoff Distance & Collimation: AJP maintains high beam collimation across long focal distances ($1.0 - 5.0\text{ mm}$), enabling deposition across stepped topologies, cavity recesses, and curved 3D geometries without head collisions.
CAM Vector Toolpaths: Vector trajectories must avoid sharp instantaneous stops ($>90^\circ$ acute turns) which cause aerosol droplet pooling. Toolpaths should incorporate tangent arc transitions and smooth continuous acceleration profiles.

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