Next Generation Aerosol-Based Printing for Production ... Dave Keicher.pdf · Next Generation...
Transcript of Next Generation Aerosol-Based Printing for Production ... Dave Keicher.pdf · Next Generation...
Next Generation Aerosol-Based Printing for Production-Level
Printed ElectronicsD. Keicher1, M. Essien2, J. Lavin1, S. Whetten1, S. Mani1
1 - Sandia National Laboratories2 – Integrated Deposition Solutions
Introduction• Background• Development Goals• Print Head • Print Process Results
– Run time testing– Conductors– Capacitors
• Conclusions• Future Development
Background• Key Personnel
– Inventor of AJ Technology– Other AM Technology– Technical Staff and Student Interns
• Significant Experience with AJ Printing– Strengths– Weaknesses
• Leverage Sandia Technology for Improvements– Brockman, et.al. Patent, September 1999
Development Goals• Focus on User Experience with Printing
– Consistent print performance – Ease of use– Reliable– Quick material change over– Remove “Art” from operation
• Production Oriented Solution– MTBA > 4 hours– Print quality
• Well defined print edges• <5% variation for key parameters during print
– Cost of ownership
Multiple Aerodynamic Lens Aerosol Focusing• Poly dispersed particle source
– Droplets range from 200 nm to 3-5µm.– Multiple Aerodynamic Lenses
• Optimal focusing of all droplets sizes• Highly collimated print stream
– Minimizes overspray/satellites of smaller droplet sizes
2nd Lens Focuses Smaller Droplets Coaxial with Larger Droplets, Creates Highly Collimated
Aerosol Stream
Multiple Aerodynamic Lenses Enhance Focusing for Polydispersed Aerosol
Next Generation NanoJet™ Print Head Operation
1.6 cm
Cartridge Based Prototype Print Head Generation 4
Print Process Results 4 Hour Run Testing• Inks
– Clariant Preselect TPS 50 – UTDots Ag 40 silver np inks
• Substrate– Poylimide
• Configuration– New Cartridge Installation and Testing
• Analysis– Optical measurements of printed linewidth– Resistivity measurement
• Target Line width: ~ 60 microns • Test Duration – 4 hours
Results 4-Hour Test Clariant TPS 50 Ink Note Edge Definition and Line width Consistency for 4-Hour Print Test
Results Clariant TPS 50 Ink
Results 4-Hour Test UTDots Ag40x
Note Clean Edge Definition and
Line width Consistency for
4-Hour Print Test
Results UTDots Ag40X
Apparatus: NanoJet™ Ink: UTDots gold
nanoparticle ink Sintering: Thermal:
300° C Resistivity: ~3X bulk
ELECTRICAL CHARACTERIZATION OF GOLD TRACES
12
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
0 2 4 6 8
RESI
STIV
ITY
[XBU
LK]
SAMPLE #
Au [TRIAL 1]
Au [TRIAL 2]
Experiment: Repeatability test - Au ink printing Procedure: Print 2 sets of traces, same
parameters, Printed one week apart. Apparatus: 2-orifice NanoJet™ printer Ink: UTDots Au in xylenes
SINGLE PASS LINE HEIGHT MEASUREMENTS
v=2 mm/s
v=20 mm/s
Line height varies from ~4 to 1 micron/pass for print speeds from 2 to 10 mm/s.
13
0.5
1
1.5
2
2.5
3
3.5
4
0 2 4 6 8 10 12
Hei
ght (µ
m)
Velocity (mm/s)
Printed Dielectric Film PropertiesCross-sectional view of STA spray UTDPI sample, showing surface roughness and overspray of polymer on the film surface
Printed film thickness
Group N*avg. thickness
(μm)κ Df
AM spray UTD PI 81 6.6 (1.8) 3.05 (0.77) 0.0021 (0.0005)commercial 90 13.3 (0.2) 3.25 (0.02) 0.0021 (0.0004)
solvent cast UTD PI 31 2.6 (0.9) 3.25 (0.64) 0.0036 (0.0005)
Group N Weibull α (kV/cm) Weibull βAM spray UTD PI 69 2402 1.5
solvent cast UTD PI 54 2060 1.0commercial 89 4891 13.0
Permittivity and Dielectric Loss Mean (St. Dev)
Dielectric breakdown strength
MULTI-MATERIAL PRINTING: 3D CAPACITORSNJ Printed capacitor (a) Au (b) polyimide (c) Au with Dektak profile showing surface roughness ~±0.5µm
AB
Au/polyimide/Ag Polyimide and Ag printed using syringe dispense Single-pass (polyimide deposition) Cavg= 32.5 pF ± 2pF
Printing Ag Electrode onto Polyimide on Au Coated Glass Cylinder Printed Capacitors on Cylinder 64 – 75 pF
Printed Resistors on Glass SlideEXPERIMENTAL• UTDAg40X (0.2ml) Terpeniol (20 drops)• 200 micron tip• Sintered at 200C for 90 minutes• Sintered 50C for 60 minutesRESULTS• Lines measured ~60 microns x 20mm• Resistance = 2 kohm consistently • Lines adhered extremely well to surface
after sintering. Rubbing with isopropyl alcohol did not remove any material
• No overspray observed
Conclusions• Accomplished Goals and Objectives of Effort• Developed and Demonstrated Robust Aerosol
Print Solution• Working with Internal Customers to
Demonstrate Applications
Future Work• Test Printing to Failure• Large Area Printing• Multi Nozzle Printing• Multi Material Printing• Work with Internal and External Customers to
Apply Technology