Simultaneous Patterning of Nanoparticles and Polymers Using an Evaporation Driven Flow in a Vapor Permeable Template

Nanoparticles and polymers have great potential for lowering cost and increasing functionality of printed sensors and electronics. However, creation of practical devices requires that many of these materials be patterned on a single substrate, and many current patterning processes can only handle a single material at a time, necessitating alignment of serial processing steps. Higher throughput and lower cost can be achieved by patterning multiple materials simultaneously. To this end, the microfluidic molding process is adapted to pattern various nanoparticle and polymer inks simultaneously, in a completely additive manner, with three-dimensional control and high relative positional accuracy between the different materials. A differential template distortion observed in channels containing different inks is analyzed and found to result from pressure force in the template due to flow of a highly viscous and highly concentrated ink in small channels. The resulting optimization between patterning speed and dimensional fidelity is discussed.