SAMPE Journal - July/August 2017 - 51
Article
Figure 7. PSKIN printed on 3D printed ABS wing section.
print small/large features, etc. With
varying sizes of print-head nozzles,
feature sizes as small as 10mm (<10
µm with optimization) are possible,
even with high viscosity (up to 2500
cP), high solids content (≥60 wt%)
inks, which is well beyond the range
of conventional inkjet writing. The
process is non-contact, enabling
traces to be printed over steps,
curved surfaces, and conformally on
non-planar objects, while printing
with a standoff distance of up to 5
mm. Line widths of printed features
are controlled by various parameters
such as gas flow ratios, temperature,
and substrate velocity. In principle,
virtually any substrate can be used,
provided it is compatible with
the ink. The AJ printing system is
also equipped with an 833 nm NIR
laser for sintering nanoparticle
inks on substrates sensitive to high
temperatures (>120°C). For laser
curing processes, the jetted features
are subjected to the same toolpath as
for deposition, yet under a controlled
focused laser beam. The laser can be
adjusted by controlling power output
(50-1000 mW) and velocity. By using
multiple printing heads, the AJ thruput can be increased considerably
and can be integrated with roll-toroll printing technologies for mass
production. Aerosol Jet printing is a
breakthrough technology that is an
emerging replacement for traditional
SAMPE Journal, Volume 53, No. 4, July/August 2017
thick-film processes like screenprinting, photolithography and
micro-dispensing, and is far more
robust than emerging inkjet printing
solutions. The AJ machine at Qi2,
as well as an example of a printed
Structural Health Monitoring (SHM)
system on a composite part, are
shown in Figure 4.
PSKIN Systems on 3D Models
To assess different printed pSKIN
sensors, a multi-material NACA4412
wing model was designed for testing
at the University of Washington
3'x3' Kirsten Wind Tunnel. This is a
modular model with a total length
of 914mm (36") and consists of
three exchangeable aerodynamic
sections of 304mm (12") each. The
two end sections were 3D printed
polycarbonate parts. Two middle
sections were fabricated too: one
was made of aluminum 2024-T3
and the other was 3D printed using
polycarbonate. The parts can be
observed in Figure 5. The goal of
this multi-material model was to
assess the feasibility of different
printed sensors deposited on
different substrate materials. Thus,
the instrumented section was placed
in the middle of the wing model.
This approach allowed us to reduce
manufacturing and assembly time as
well as cost while providing a flexible
platform to assess performance
of printed sensors over different
substrate materials in the wind
tunnel.
Figure 8. Printing of pSKIN on 3D printed polycarbonate wing section.
51
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