Precision Control of Aerosol Jet Printing for Conformal Electronics Fabrication with Ultra‐Fine and Wide‐Range Resolution

Abstract Aerosol jet printing (AJP) is a cutting‐edge additive manufacturing technique, ideal for fabricating conformal electronics due to its extended working distance, simplicity, and environmental sustainability. However, achieving optimal resolution is hindered by complex interactions between aerosol droplets and substrates, as well as the influence of various process parameters. This study focuses on precise AJP control to enable high‐resolution conformal electronics fabrication. Through randomized single‐factor experiments, the effects of gas flow rates, focusing ratio, and print speed, highlighting the role of back pressure on focusing limits are examined. A computational fluid dynamics model, incorporating accurate particle size data, predicts aerosol stream width to expedite operating window identification. The interaction mechanisms between aerosol droplets and substrates are elucidated, achieving a resolution of 5 µm. A precision manufacturing protocol is developed, ensuring high‐quality features with resolutions ranging from 10 to 300 µm across diverse 3D substrates without overspray. The successful integration of a heater, temperature sensor, and display demonstrates AJP's potential for multi‐functional conformal electronics.