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Toward Defect-Free Additive Fabricating of Flexible and Hybrid Electronics: Physics-Based Computational Modeling and Control of Aerosol Jet Printing

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Advances in Additive Manufacturing, Modeling Systems and 3D Prototyping (AHFE 2019)

Part of the book series: Advances in Intelligent Systems and Computing ((AISC,volume 975))

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Abstract

Aerosol jet printing (AJP) is a direct-write, additive manufacturing technique, which has emerged as the process of choice for the fabrication of a broad spectrum of electronics – such as, interconnects, sensors, transistors, electrodes, and antennae – toward consistent and uniform manufacture of flexible and hybrid electronic devices. The AJP has paved the way for rapid high-resolution device fabrication; it accommodates a wide range of ink viscosity and allows for material deposition with high placement accuracy, edge definition, and adhesion on non-planer surfaces. Despite the unique advantages and engendered strategic applications, the AJP process is intrinsically unstable and complex, prone to non-linear gradual drifts, which stem from process, machine, and metrical interactions. Consequently, real-time process monitoring and control, corroborated with physical models, is a burgeoning need.

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Acknowledgments

This material is based upon work supported, in part, by Air Force Research Laboratory under agreement number FA8650-15-2-5401. The U.S. Government is authorized to reproduce and distribute reprints for Governmental purposes notwithstanding any copyright notation thereon. The views and conclusions contained herein are those of the authors and should not be interpreted as necessarily representing the official policies or endorsements, either expressed or implied, of Air Force Research Laboratory or the U.S. Government. The authors would also like to sincerely acknowledge the Small Scale Systems Integration and Packaging (S3IP) as well as the Center for Advanced Microelectronics Manufacturing (CAMM) at State University of New York at Binghamton. One of the authors (PKR) thanks the National Science Foundation for funding his work through Grant Nos. CMMI- 1719388, 1739696, and 1752069. Specifically, the development and application of data analytics and modeling approaches for process modeling and monitoring towards closed-loop control in AM was conceptualized and funded through CMMI-1752069 (CAREER).

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Authors and Affiliations

  1. Division of Engineering-Mechanical, College of IT and Engineering, Marshall University, Huntington, WV, 25755, USA

    Roozbeh (Ross) Salary

  2. Center for Advanced Microelectronics Manufacturing, State University of New York, Binghamton, NY, 13902, USA

    Roozbeh (Ross) Salary, Jack P. Lombardi, Darshana L. Weerawarne & Mark D. Poliks

  3. Department of Mechanical and Materials Engineering, University of Nebraska-Lincoln, Lincoln, NE, 68588, USA

    Prahalada K. Rao

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  1. Roozbeh (Ross) Salary
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  4. Prahalada K. Rao
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  5. Mark D. Poliks
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Correspondence to Mark D. Poliks .

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Editors and Affiliations

  1. Architecture Department, University of Chieti-Pescara, Pescara, Pescara, Italy

    Massimo Di Nicolantonio

  2. Emilio Rossi Design Consulting, Ortona, Chieti, Italy

    Emilio Rossi

  3. Bonn, Nordrhein-Westfalen, Germany

    Thomas Alexander

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Salary, R.(., Lombardi, J.P., Weerawarne, D.L., Rao, P.K., Poliks, M.D. (2020). Toward Defect-Free Additive Fabricating of Flexible and Hybrid Electronics: Physics-Based Computational Modeling and Control of Aerosol Jet Printing. In: Di Nicolantonio, M., Rossi, E., Alexander, T. (eds) Advances in Additive Manufacturing, Modeling Systems and 3D Prototyping. AHFE 2019. Advances in Intelligent Systems and Computing, vol 975. Springer, Cham. https://doi.org/10.1007/978-3-030-20216-3_33

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  • DOI: https://doi.org/10.1007/978-3-030-20216-3_33

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