Continuous ink-jet printing electronic components using novel conductive inks

To reduce the cost of electronics fabrication and to take advantage of numerous potential specialized applications, a novel process of manufacturing three-dimensional electronic products is introduced in the present investigation. This process, which is currently being patented by the University of Pittsburgh, utilizes specialized continuous ink jet (CIJ) printing technology and innovative conductive inks that are capable of producing high-resolution conductive traces. Unlike drop-on-demand (DOD) techniques that are aimed at more precise features sizes (1 micron or less) and smaller scale applications, the present investigation demonstrates that the new process can be used in mass production applications where larger feature sizes (~50 microns) are sufficient. It has been found that the traces produced by the process have excellent adherence and have an electrical resistivity of only 2.9 times of bulk silver after curing. The major advantage of the proposed CIJ process is that it not only provides a fast and cost-effective method for applying electronic components (conductors, diodes, capacitors and resistors) on existing products, but it also allows the printing of conductive traces in three-dimensional space. With a throw distance that exceeds 10 cm, it demonstrates how the new fabrication process is not only suitable for desktop microfabrication, but also for large volume applications such as automotive glass.