Optomec showcased its Aerosol Jet technology for 3D Printed Electronics applications at the LOPEC International Conference and Exhibition in Munich earlier in March.  Aerosol Jet Printers are used to directly print functional electronic circuitry and components onto low-temperature, non-planar substrates, without the need for masks, screens, or plating.  The company’s newest printer- the Aerosol Jet 5X system for printing conformal electronics onto 3D structures delivers the precision and flexibility required to produce high-resolution 3D printed electronic devices such as conformal antennas, sensors, and other components for applications in consumer electronics, automotive, aerospace and the Internet of Things.

Noted Dr. Mike Renn, CTO and Director of Optomec’s Advanced Applications Lab, Aerosol Jet is a non-contact printing technique capable of patterning a variety of electronic and polymeric materials at the micrometer size scale. The UV light exposure during the printing can substantially cure polymeric materials in-flight, allowing structures to be built up in three dimensions. Aspect ratios of more than 20:1 are achieved with micrometer-scale posts, cylinders, and cones.

With robotic manipulation of the print head and target substrate, the 3D features can be fabricated in nearly any orientation including the fabrication of hollow structures such as microbubbles. By co-depositing electronic and polymeric materials it is possible to fabricate hybrid structures. In this case the polymeric materials serve as the mechanical support for nano-metal conductors and other electronic materials. The printing process accurately controls the location, geometry and thickness of the deposit and produces a smooth mirror-like surface finish to insure optimum antenna performance. No plating or environmentally harmful materials are used in the process.

This process works with standard injection molded plastics–no special additives or coatings are needed.

Mobile device antennas including LTE, NFC, GPS, Wifi, WLAN, and BT have been printed using the Aerosol Jet process and independently tested by a leading cell phone component supplier. Measured antenna performance is comparable to other production methods. The Aerosol Jet printing process is scalable – antennas can be printed on up to 4 cases simultaneously on a single machine. Machine throughput for a typical antenna pattern measuring ~300 mm2 averages 30,000 units per week.

Optomec
www.optomec.com