Graduate Thesis Or Dissertation
 

Plasma-Jet Printing and In Situ Sintering of Electronic Materials for Flexible Hybrid Electronic Applications

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  • Additive manufacturing has become a promising method for the fabrication of inexpensive, green, flexible sensors and electronics. Printed electronics on low- temperature substrates are very appealing for the flexible hybrid electronics market for their use in disposable and biocompatible electronic applications and in areas like packaging, wearables, and consumer electronics. Plasma jet printing uses a dielectric barrier discharge plasma to focus aerosolized nanoparticles onto a target substrate. The same plasma can be used to change the properties of the printed material and even sinter in situ. The voltage of the plasma has a significant effect on the deposition of nanomaterials. The effect of the plasma on deposition and sintering mechanisms are observed and discussed as an exploration into the practicality of the printer to additively manufacture electronics. The technology can also be utilized in space and microgravity environments since the plasma-assisted deposition is independent of gravity. Since plasma-jet printing is a new technology, significant developments in optimizing the printer for many materials and applications were made. Plasma jet printing has advantages of self-sintering and gravity-independent deposition over other methods like inkjet and aerosol-jet printing. This dissertation explores the direct printing of thermoelectric generators with excellent flexibility and comparable thermoelectric properties. As printing and sintering of metallic nanomaterials are an important part of flexible hybrid electronics, we will also show the direct manufacturing of conductive gold structures on glass polymer, and low-temperature substrates without the need for thermal or photonic post-processing. The addition of polymer into the ink was explored, and increased adhesion of the printed gold was achieved. This advancement in gold deposition can be utilized in additive manufacturing for biocompatible, corrosion-resistant electronics on low-temperature substrates. This is shown in demonstrations of a functional plasma jet-printed heater and LED interconnects without thermal post-processing.
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