TP 6: Simulation and Optimization of the Aerosol-Jet-Printing Process

• Applicant: Professor Dr. Jens Harting
• Subject Area: Electronic Semiconductors, Components and Circuits, Integrated Systems, Sensor Technology, Theoretical Electrical Engineering ; Chemical and Thermal Process Engineering ; Fluid Mechanics
• Term: since 2025
• Project identifier: Deutsche Forschungsgemeinschaft (DFG) - Project number 528402728

The quality of the structures produced by aerosol jet printing (AJP) depends heavily on the choice of inks and the selected process parameters. These include, on the one hand, the jet and nozzle guidance and, on the other, the rheology of the inks, flow dynamic instabilities at jet and droplet level and the interaction of the droplets with the substrate. The drying and subsequent sintering process, in particular, have a major influence on the quality of the printed structures. To optimize the HF properties of printed structures, it is necessary to find the best possible parameters for the ink formulation and to understand the parameters of the printing and layer formation process on the scale of individual droplets. In this project, mesoscale computer simulations will be used to gain an in-depth understanding of the influence of the individual parameters, to vary them independently of each other, and ultimately to contribute to the development of optimized functional RF structures. In particular, these simulations make it possible to understand how surface roughness can be minimized, and the best possible surface profiles can be produced. Furthermore, parameters can be identified that allow for the minimization of defects and an adjustable porosity of the printed and sintered structures. In close cooperation with the other sub-projects of this research group, the simulation results will be validated and lead to proposals for improved processes and optimized RF components.

• DFG Programme: Research Units
• Subproject of: FOR 5727: 3D functionalization for radio frequency applications