CAREER: Graded and Reliable Aerosol Deposition for Electronics (GRADE): Understanding Multi-Material Aerosol Jet Printing with In-Line Mixing

职业：电子产品的分级且可靠的气溶胶沉积 (GRADE)：了解通过在线混合进行多材料气溶胶喷射打印

• 批准号: 2336356
• 负责人: Ethan Secor
• 金额: $ 62.1万
• 依托单位: Iowa State University
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2024
• 资助国家: 美国
• 起止时间: 2024-07-01 至 2029-06-30
• 项目状态: 未结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2336356&HistoricalAwards=false
• 关键词: CAREER; Graded; Reliable; Aerosol; Deposition

Computer-controlled printing technologies allow manufacturing of precise and complex parts. When these methods are used to print electronic materials, they can produce devices such as sensors and circuits. There is a strong motivation to print parts that contain gradients in material composition and properties, which can mimic biological materials, improve mechanical interfaces, and enable advanced electronic functionality. This Faculty Early Career Development Program (CAREER) award supports fundamental research to understand and control multi-material aerosol jet printing, a technology well suited for manufacturing such material gradients for electronic devices. This printing method can mix micro-scale droplets of different inks during the deposition process to change the material composition, and coordinate this material change with patterning in three dimensions. This technology is relevant to aerospace, biomedical, automotive, energy, and defense applications, thus promoting national prosperity and security. Moreover, the research pursues fundamental advances in manufacturing, aerosol and fluid dynamics, and materials science, thus advancing the progress of science. Alongside the core research objectives of this research, an outreach program will be established to engage 4th-5th grade students with science and engineering concepts via interactive digital printing activities, and game- and project-based learning will be incorporated in undergraduate manufacturing engineering coursework to improve workforce development. The goal of this project is to establish mechanistic knowledge and control of multi-material aerosol jet printing for patterning material gradients. Different materials will be mixed in the aerosol phase within the printhead, allowing digital control of the mixing ratio. Mixing mechanisms for the aerosol, liquid, and colloid phases will be evaluated to understand the effects of materials chemistry, ink formulation, aerosol physics, and print parameters on the mixing efficacy, uniformity, and control using a combination of experiments, simulation, and theory. The ability to fabricate custom gradients in material composition and properties will stimulate broad research of material-processing-structure-property relationships for functionally graded materials in the context of hybrid electronics, including electromagnetic devices, electrochemistry, interfacial mechanics, and biomimetic structures. To guide development of this capability, this project will pursue vertically graded interfaces to reduce failure from thermal expansion mismatch, along with laterally graded conductors to support biocompatible circuits.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

计算机控制的打印技术可以制造精确且复杂的零件。当这些方法用于印刷电子材料时，可以生产传感器和电路等设备。人们有强烈的动机打印包含材料成分和性能梯度的零件，这些零件可以模仿生物材料，改善机械接口并实现先进的电子功能。该学院早期职业发展计划（CAREER）奖项支持基础研究，以了解和控制多材料气溶胶喷射印刷，这是一种非常适合为电子设备制造此类材料梯度的技术。这种打印方法可以在沉积过程中混合不同墨水的微米级液滴来改变材料成分，并协调这种材料的变化与三维图案化。该技术涉及航空航天、生物医学、汽车、能源和国防应用，从而促进国家繁荣和安全。此外，该研究追求制造、气溶胶和流体动力学以及材料科学方面的根本性进展，从而推动科学进步。除了本研究的核心研究目标外，还将建立一个外展计划，通过交互式数字印刷活动让四至五年级的学生了解科学和工程概念，并且基于游戏和项目的学习将纳入本科生制造工程课程，以改善劳动力发展。该项目的目标是建立多材料气溶胶喷射印刷的机械知识和控制，以形成材料梯度图案。不同的材料将在打印头内的气溶胶相中混合，从而可以数字控制混合比例。将结合实验、模拟和理论来评估气溶胶、液体和胶体相的混合机制，以了解材料化学、油墨配方、气溶胶物理和打印参数对混合功效、均匀性和控制的影响。制造材料成分和性能的定制梯度的能力将刺激混合电子领域中功能梯度材料的材料-加工-结构-性能关系的广泛研究，包括电磁器件、电化学、界面力学和仿生结构。为了指导这种能力的开发，该项目将追求垂直分级接口，以减少热膨胀不匹配造成的故障，以及横向分级导体以支持生物相容性电路。该奖项反映了 NSF 的法定使命，并通过使用基金会的评估进行评估，被认为值得支持。智力价值和更广泛的影响审查标准。