All Screen Printed and Flexible Silicon Carbide NTC Thermistors for Temperature Sensing Applications.

In this study, Silicon Carbide (SiC) nanoparticle-based serigraphic printing inks were formulated to fabricate highly sensitive and wide temperature range printed thermistors. Inter-digitated electrodes (IDEs) were screen printed onto Kapton® substrate using commercially avaiable silver ink. Thermistor inks with different weight ratios of SiC nanoparticles were printed atop the IDE structures to form fully printed thermistors. The thermistors were tested over a wide temperature range form 25 °C to 170 °C, exhibiting excellent repeatability and stability over 15 h of continuous operation. Optimal device performance was achieved with 30 wt.% SiC-polyimide ink. We report highly sensitive devices with a TCR of -0.556%/°C, a thermal coefficient of 502 K (ß-index) and an activation energy of 0.08 eV. Further, the thermistor demonstrates an accuracy of ±1.35 °C, which is well within the range offered by commercially available high sensitivity thermistors. SiC thermistors exhibit a small 6.5% drift due to changes in relative humidity between 10 and 90%RH and a 4.2% drift in baseline resistance after 100 cycles of aggressive bend testing at a 40° angle. The use of commercially available low-cost materials, simplicity of design and fabrication techniques coupled with the chemical inertness of the Kapton® substrate and SiC nanoparticles paves the way to use all-printed SiC thermistors towards a wide range of applications where temperature monitoring is vital for optimal system performance.

The Influence of Microstructure on TCR for Inkjet-Printed Resistive Temperature Detectors Fabricated Using AgNO3/Ethylene-Glycol-Based Inks.

This study investigated the influence of microstructure on the performance of Ag inkjet-printed, resistive temperature detectors (RTDs) fabricated using particle-free inks based on a silver nitrate (AgNO3) precursor and ethylene glycol as the ink solvent. Specifically, the temperature coefficient of resistance (TCR) and sensitivity for sensors printed using inks that use monoethylene glycol (mono-EG), diethylene glycol (di-EG), and triethylene glycol (tri-EG) and subjected to a low-pressure argon (Ar) plasma after printing were investigated. Scanning electron microscopy (SEM) confirmed previous findings that microstructure is strongly influenced by the ink solvent, with mono-EG inks producing dense structures, while di- and tri-EG inks produce porous structures, with tri-EG inks yielding the most porous structures. RTD testing revealed that sensors printed using mono-EG ink exhibited the highest TCR (1.7 × 10-3/°C), followed by di-EG ink (8.2 × 10-4/°C) and tri-EG ink (7.2 × 10-4/°C). These findings indicate that porosity exhibits a strong negative influence on TCR. Sensitivity was not strongly influenced by microstructure but rather by the resistance of RTD. The highest sensitivity (0.84 Ω/°C) was observed for an RTD printed using mono-EG ink but not under plasma exposure conditions that yield the highest TCR.

An Approach to a Silver Conductive Ink for Inkjet Printer Technology.

Silver-based metal-organic decomposition inks composed of silver salts, complexing agents and volatile solvents are now the subject of much research due to the simplicity and variability of their preparation, their high stability and their relatively low sintering temperature. The use of this type of ink in inkjet printing allows for improved cost-effective and environmentally friendly technology for the production of electrical devices, including flexible electronics. An approach to producing a silver salt-based reactive ink for jet printing has been developed. The test images were printed with an inkjet printer onto polyimide substrates, and two-stage thermal sintering was carried out at temperatures of 60 °C and 100-180 °C. The structure and electrical properties of the obtained conductive lines were investigated. As a result, under optimal conditions an electrically conductive film with low surface resistance of approximately 3 Ω/square can be formed.

An investigation of methods to enhance adhesion of conductive layer and dielectric substrate for additive manufacturing of electronics.

Additive manufacturing of conductive layers on a dielectric substrate has garnered significant interest due to its promise to produce printed electronics efficiently and its capability to print on curved substrates. A considerable challenge encountered is the conductive layer's potential peeling due to inadequate adhesion with the dielectric substrate, which compromises the durability and functionality of the electronics. This study strives to facilitate the binding force through dielectric substrate surface modification using concentrated sulfuric acid and ultraviolet (UV) laser treatment. First, polyetheretherketone (PEEK) and nanoparticle silver ink were employed as the studied material. Second, the surface treatment of PEEK substrates was conducted across six levels of sulfuric acid exposure time and eight levels of UV laser scanning velocity. Then, responses such as surface morphology, roughness, elemental composition, chemical bonding characteristics, water contact angle, and surface free energy (SFE) were assessed to understand the effects of these treatments. Finally, the nanoparticle silver ink layer was deposited on the PEEK surface, and the adhesion force measured using a pull-off adhesion tester. Results unveiled a binding force of 0.37 MPa on unmodified surface, which escalated to 1.99 MPa with sulfuric acid treatment and 2.21 MPa with UV laser treatment. Additionally, cross-approach treatment investigations revealed that application sequence significantly impacts results, increasing binding force to 2.77 MPa. The analysis further delves into the influence mechanism of the surface modification on the binding force, elucidating that UV laser and sulfuric acid surface treatment methods hold substantial promise for enhancing the binding force between heterogeneous materials in the additive manufacturing of electronics.

Cost-Driven Design of Printed Wideband Antennas with Reduced Silver Ink Consumption for the Internet of Things.

The Internet of Things (IoT) accelerates the need for compact, lightweight and low-cost antennas combining wideband operation with a high integration potential. Although screen printing is excellently suited for manufacturing conformal antennas on a flexible substrate, its application is typically limited due to the expensive nature of conductive inks. This paper investigates how the production cost of a flexible coplanar waveguide (CPW)-fed planar monopole antenna can be reduced by exploiting a mesh-based method for limiting ink consumption. Prototypes with mesh grids of different line widths and densities were screen-printed on a polyethylene terephthalate (PET) foil using silver-based nanoparticle ink. Smaller line widths decrease antenna gain and efficiency, while denser mesh grids better approximate unmeshed antenna behavior, albeit at the expense of greater ink consumption. A meshed prototype of 34.76×58.03mm with almost 80% ink reduction compared to an unmeshed counterpart is presented. It is capable of providing wideband coverage in the IMT/LTE-1/n1 (1.92-2.17 GHz), LTE-40/n40 (2.3-2.4 GHz), 2.45 GHz ISM (2.4-2.4835 GHz), IMT-E/LTE-7/n7 (2.5-2.69 GHz), and n78 5G (3.3-3.8 GHz) frequency bands. It exhibits a peak radiation efficiency above 90% and a metallized surface area of 2.46 cm2 (yielding an ink-to-total-surface ratio of 12.2%).

Rotation Grids for Improved Electrical Properties of Inkjet-Printed Strain Gauges.

We report an image data driven approach for inkjet printing (IJP) to improve the electrical properties of printed metallic strain gauges (SGs). The examined SGs contain narrow conducting paths of multiple orientations and therefore suffer from two challenges: 1. The printing direction of inkjet printed conducting paths has an impact on film formation and electrical properties. 2. A loss-free rotation algorithm for IJP image data is lacking. New ways of IJP image data processing are required to compensate for quality-reducing effects. Novel grid types in terms of loss-free rotation algorithms are introduced. For this purpose, a new grid (e.g., 45° tilted) with a different grid constant is placed over a given pixel grid in such a way that all cell centers of the given pixel grid can be transferred to the rotated grid. Via straightening the tilt, the image data is rotated without interpolation and information loss. By applying these methods to measurement gratings of a full bridge with two perpendicular grating orientations, the influence on the manufacturing quality is investigated. It turns out that the electrical detuning of full bridges can be reduced by one order of magnitude compared to state-of-the-art printing by using so-called diagonal rotation grids.

Robotic written silver ink on photographic paper for detection of thiram residues in fruits.

With the widespread application of pesticide in agriculture, pesticide residues in food have posed serious health risks to human. There is an urgent requirement to detect pesticide residues in food. In this work, a sensitive and effective method was employed to measure thiram residues in fruit using surface-enhanced Raman scattering (SERS) technique. Silver ink was written on photographic paper (AgNPs-photographic paper) directly by robotic writing technique. The AgNPs-photographic paper substrates possessed good SERS activities and high stability among four months. A good linear response between the peaks intensities and the logarithmic concentrations of thiram was obtained with the limit of detection (LOD) of 0.024 ppb. The substrates also exhibited excellent reproducibility with relative standard deviation (RSD) value less than 10% from ten different substrates. SERS mapping was tested to characterize the uniformity of AgNPs-photographic paper, and the RSD value was calculated to be 14.34% at 1377 cm-1 measured by 120 points. The LOD values of apple and peach juice adulterated with thiram were 0.0024 and 0.024 ppm, respectively. The LOD values of thiram residues on apple and peach peels were both 0.25 ng/cm2. It was demonstrated that the substrates prepared by robotic writing technique had great potential for practical application in food safety inspection.

Efficient fabrication of highly sensitive AgNPs-drawing paper SERS substrates by robotic writing approach.

Inspired by hand writing approach for preparing surface-enhanced Raman scattering (SERS) substrates, silver nanoparticles (AgNPs) decorated drawing paper substrates were prepared by robotic writing technique. The wettabilities and surface morphologies of the drawing paper before and after the deposition of AgNPs were characterized by contact angle analyzer and scanning electron microscope, respectively. Malachite green was employed as a probe molecule to evaluate the SERS activities of the AgNPs-drawing paper substrates. The AgNPs-drawing paper substrates exhibited extremely high sensitivity that the detection limit for malachite green was down to 10-18 mol/L and the Raman enhancement factor was calculated to be 1015. The relative standard deviation (RSD) values of the Raman peaks intensities collected from twelve points on a single substrate and fifteen substrates were used to evaluate the uniformity and reproducibility of the AgNPs-drawing paper substrates. It was found that the substrates had good reproducibility and uniformity with RSD values of 7.29% and 9.70%, respectively. Furthermore, the prepared AgNPs-drawing paper substrates exhibited long-term stability among six months.

Microstructures in All-Inkjet-Printed Textile Capacitors with Bilayer Interfaces of Polymer Dielectrics and Metal-Organic Decomposition Silver Electrodes.

Soft printed electronics exhibit unique structures and flexibilities suited for a plethora of wearable applications. However, forming scalable, reliable multilayered electronic devices with heterogeneous material interfaces on soft substrates, especially on porous and anisotropic structures, is highly challenging. In this study, we demonstrate an all-inkjet-printed textile capacitor using a multilayered structure of bilayer polymer dielectrics and particle-free metal-organic decomposition (MOD) silver electrodes. Understanding the inherent porous/anisotropic microstructure of textiles and their surface energy relationship was an important process step for successful planarization. The MOD silver ink formed a foundational conductive layer through the uniform encapsulation of individual fibers without blocking fiber interstices. Urethane-acrylate and poly(4-vinylphenol)-based bilayers were able to form a planarized dielectric layer on polyethylene terephthalate textiles. A unique chemical interaction at the interfaces of bilayer dielectrics performed a significant role in insulating porous textile substrates resulting in high chemical and mechanical durability. In this work, we demonstrate how textiles' unique microstructures and bilayer dielectric layer designs benefit reliability and scalability in the inkjet process as well as the use in wearable electronics with electromechanical performance.

Printed Strain Gauge on 3D and Low-Melting Point Plastic Surface by Aerosol Jet Printing and Photonic Curing.

Printing sensors and electronics directly on the objects is very attractive for producing smart devices, but it is still a challenge. Indeed, in some applications, the substrate that supports the printed electronics could be non-planar or the thermal curing of the functional inks could damage temperature-sensitive substrates such as plastics, fabric or paper. In this paper, we propose a new method for manufacturing silver-based strain sensors with arbitrary and custom geometries directly on plastic objects with curvilinear surfaces: (1) the silver lines are deposited by aerosol jet printing, which can print on non-planar or 3D surfaces; (2) photonic sintering quickly cures the deposited layer, avoiding the overheating of the substrate. To validate the manufacturing process, we printed strain gauges with conventional geometry on polyvinyl chloride (PVC) conduits. The entire manufacturing process, included sensor wiring and optional encapsulation, is performed at room temperature, compatible with the plastic surface. At the end of the process, the measured thickness of the printed sensor was 8.72 µm on average, the volume resistivity was evaluated 40 µΩ∙cm, and the thermal coefficient resistance was measured 0.150 %/°C. The average resistance was (71 ± 7) Ω and the gauge factor was found to be 2.42 on average.

Printable Stretchable Silver Ink and Application to Printed RFID Tags for Wearable Electronics.

A printable elastic silver ink has been developed, which was made of silver flakes, dispersant, and a fluorine rubber and could be sintered at a low temperature. The printed elastic conductors showed low resistivity at 21 µΩ·cm, which is about 13.2 times of bulk silver (1.59 µΩ·cm). Their mechanical properties were investigated by bending, stretching, and cyclic endurance tests. It was found that upon stretching the resistance of printed conductors increased due to deformation and small cracks appeared in the conductor, but was almost reversible when the strain was removed, and the recovery of conductivity was found to be time dependent. Radio-frequency identification (RFID) tags were fabricated by screen printing the stretchable silver ink on a stretchable fabric (lycra). High performance of tag was maintained even with 1000 cycles of stretching. As a practical example of wearable electronics, an RFID tag was printed directly onto a T-shirt, which demonstrated its normal working order in a wearing state.

Interface Modified Flexible Printed Conductive Films via Ag2O Nanoparticle Decorated Ag Flake Inks.

A new approach to stable, low resistance inexpensive printed flexible conductive inks is proposed. Silver inks have been extensively studied and commercialized for applications in printed electronics due to the inherent high conductivity and stability of silver, even in particulate-based percolation networks processed at temperatures compatible with low-cost polymer films such as poly(ethylene terephthalate) (PET). Recent interest in flexible and even stretchable circuits, however, has presented new challenges for particle-based inks as mechanical strains can result in the opening of critical particle-to-particle contacts. Here we report a facile, low-cost method for the single-step synthesis of stable, printable nanoscale Ag2O decorated Ag flake inks which can be converted to highly conductive Ag films at 150 °C curing temperature without the use of limited shelf life organometallics or low metal loading nanoparticles to modify the interface between silver flakes. Analysis indicates that decoration of Ag flakes with Ag2O nanoparticles (NPs) during ink synthesis improves the conductivity and flexibility of printed silver films by forming bridging interconnections between Ag flakes after low temperature reduction of the Ag2O NPs. In this work, printed nanodecorated silver conductors with starting oxide to metal weight ratios of 5:95 exhibited lateral resistivities lower than 1.5 × 10-5 Ω·cm, which was 35% less than films derived from undecorated Ag flake inks of the same total Ag loading and binder system. This resistivity difference increased to 45% after cyclic bend testing showing increased resilience to repeated flexing for the nanodecorated inks. Through detailed compositional and morphological characterizations, we demonstrate that such improved conductivity and flexibility are due to a more effective bridging afforded by the in situ synthesized Ag NPs on the surface of Ag flakes. These properties, combined with the simplified syntheses method of the nanoink, make the material a viable, advantageous alternative to the limited number of stretchable conductors currently available.

Direct Inkjet Printing of Silver Source/Drain Electrodes on an Amorphous InGaZnO Layer for Thin-Film Transistors.

Printing technologies for thin-film transistors (TFTs) have recently attracted much interest owing to their eco-friendliness, direct patterning, low cost, and roll-to-roll manufacturing processes. Lower production costs could result if electrodes fabricated by vacuum processes could be replaced by inkjet printing. However, poor interfacial contacts and/or serious diffusion between the active layer and the silver electrodes are still problematic for achieving amorphous indium-gallium-zinc-oxide (a-IGZO) TFTs with good electrical performance. In this paper, silver (Ag) source/drain electrodes were directly inkjet-printed on an amorphous a-IGZO layer to fabricate TFTs that exhibited a mobility of 0.29 cm²·V-1·s-1 and an on/off current ratio of over 105. To the best of our knowledge, this is a major improvement for bottom-gate top-contact a-IGZO TFTs with directly printed silver electrodes on a substrate with no pretreatment. This study presents a promising alternative method of fabricating electrodes of a-IGZO TFTs with desirable device performance.

Gigahertz Electromagnetic Structures via Direct Ink Writing for Radio-Frequency Oscillator and Transmitter Applications.

Radio-frequency (RF) electronics, which combine passive electromagnetic devices and active transistors to generate and process gigahertz (GHz) signals, provide a critical basis of ever-pervasive wireless networks. While transistors are best realized by top-down fabrication, relatively larger electromagnetic passives are within the reach of printing techniques. Here, direct writing of viscoelastic silver-nanoparticle inks is used to produce a broad array of RF passives operating up to 45 GHz. These include lumped devices such as inductors and capacitors, and wave-based devices such as transmission lines, their resonant networks, and antennas. Moreover, to demonstrate the utility of these printed RF passive structures in active RF electronic circuits, they are combined with discrete transistors to fabricate GHz self-sustained oscillators and synchronized oscillator arrays that provide RF references, and wireless transmitters clocked by the oscillators. This work demonstrates the synergy of direct ink writing and RF electronics for wireless applications.

Development of a Flexible Non-Metal Electrode for Cell Stimulation and Recording.

This study presents a method of producing flexible electrodes for potentially simultaneously stimulating and measuring cellular signals in retinal cells. Currently, most multi-electrode applications rely primarily on etching, but the metals involved have a certain degree of brittleness, leaving them prone to cracking under prolonged pressure. This study proposes using silver chloride ink as a conductive metal, and polydimethysiloxane (PDMS) as the substrate to provide electrodes with an increased degree of flexibility to allow them to bend. This structure is divided into the electrode layer made of PDMS and silver chloride ink, and a PDMS film coating layer. PDMS can be mixed in different proportions to modify the degree of rigidity. The proposed method involved three steps. The first segment entailed the manufacturing of the electrode, using silver chloride ink as the conductive material, and using computer software to define the electrode size and micro-engraving mechanisms to produce the electrode pattern. The resulting uniform PDMS pattern was then baked onto the model, and the flow channel was filled with the conductive material before air drying to produce the required electrode. In the second stage, we tested the electrode, using an impedance analyzer to measure electrode cyclic voltammetry and impedance. In the third phase, mechanical and biocompatibility tests were conducted to determine electrode properties. This study aims to produce a flexible, non-metallic sensing electrode which fits snugly for use in a range of measurement applications.

Regulation of the Deposition Morphology of Inkjet-Printed Crystalline Materials via Polydopamine Functional Coatings for Highly Uniform and Electrically Conductive Patterns.

We report a method to achieve highly uniform inkjet-printed silver nitrate (AgNO3) and a reactive silver precursor patterns on rigid and flexible substrates functionalized with polydopamine (PDA) coatings. The printed AgNO3 patterns on PDA-coated substrates (glass and polyethylene terephthalate (PET)) exhibit a narrow thickness distribution ranging between 0.9 and 1 µm in the line transverse direction and uniform deposition profiles in the line axial direction. The deposited reactive silver precursor patterns on PDA-functionalized substrates also show "dome-shaped" morphology without "edge-thickened" structure due to "coffee-stain" effect. We posit that the highly uniform functional ink deposits formed on PDA-coated substrates are attributable to the strong binding interaction between the abundant catecholamine moieties at the PDA surface and the metallic silver cations (Ag(+) or Ag(NH3)(2+)) in the solutal inks. During printing of the ink rivulet and solvent evaporation, the substrate-liquid ink (S-L) interface is enriched with the silver-based cations and a solidification at the S/L interface is induced. The preferential solidification initiated at the S-L interface is further verified by the in situ visualization of the dynamic solidification process during solvent evaporation, and results suggest an enhanced crystal nucleation and growth localized at the S-L interface on PDA functionalized substrates. This interfacial interaction mediates solute transport in the liquid phase, resulting in the controlled enrichment of solute at the S-L interface and mitigated solute precipitation in both the contact line region and the liquid ink-vapor (L-V) interface due to evaporation. This mediated transport contributes to the final uniform solid deposition for both types of ink systems. This technique provides a complementary strategy for achieving highly uniform inkjet-printed crystalline structures, and can serve as an innovative foundation for high-precision additive delivery of functional materials.

Laser-assisted direct ink writing of planar and 3D metal architectures.

The ability to pattern planar and freestanding 3D metallic architectures at the microscale would enable myriad applications, including flexible electronics, displays, sensors, and electrically small antennas. A 3D printing method is introduced that combines direct ink writing with a focused laser that locally anneals printed metallic features "on-the-fly." To optimize the nozzle-to-laser separation distance, the heat transfer along the printed silver wire is modeled as a function of printing speed, laser intensity, and pulse duration. Laser-assisted direct ink writing is used to pattern highly conductive, ductile metallic interconnects, springs, and freestanding spiral architectures on flexible and rigid substrates.

The Coupled Photothermal Reaction and Transport in a Laser Additive Metal Nanolayer Simultaneous Synthesis and Pattering for Flexible Electronics.

The Laser Direct Synthesis and Patterning (LDSP) technology has advantages in terms of processing time and cost compared to nanomaterials-based laser additive microfabrication processes. In LDSP, a scanning laser on the substrate surface induces chemical reactions in the reactive liquid solution and selectively deposits target material in a preselected pattern on the substrate. In this study, we experimentally investigated the effect of the processing parameters and type and concentration of the additive solvent on the properties and growth rate of the resulting metal film fabricated by this LDSP technology. It was shown that reactive metal ion solutions with substantial viscosity yield metal films with superior physical properties. A numerical analysis was also carried out the first time to investigate the coupled opto-thermo-fluidic transport phenomena and the effects on the metal film growth rate. To complete the simulation, the optical properties of the LDSP deposited metal film with a variety of thicknesses were measured. The characteristics of the temperature field and the thermally induced flow associated with the moving heat source are discussed. It was shown that the processing temperature range of the LDSP is from 330 to 390 K. A semi-empirical model for estimating the metal film growth rate using this process was developed based on these results. From the experimental and numerical results, it is seen that, owing to the increased reflectivity of the silver film as its thickness increases, the growth rate decreases gradually from about 40 nm at initial to 10 nm per laser scan after ten scans. This self-controlling effect of LDSP process controls the thickness and improves the uniformity of the fabricated metal film. The growth rate and resulting thickness of the metal film can also be regulated by adjustment of the processing parameters, and thus can be utilized for controllable additive nano/microfabrication.

Screen Printing of Highly Loaded Silver Inks on Plastic Substrates Using Silicon Stencils.

Screen printing is a potential technique for mass-production of printed electronics; however, improvement in printing resolution is needed for high integration and performance. In this study, screen printing of highly loaded silver ink (77 wt %) on polyimide films is studied using fine-scale silicon stencils with openings ranging from 5 to 50 µm wide. This approach enables printing of high-resolution silver lines with widths as small as 22 µm. The printed silver lines on polyimide exhibit good electrical properties with a resistivity of 5.5×10(-6) Ω cm and excellent bending tolerance for bending radii greater than 5 mm (tensile strains less than 0.75%).