Jack P. Lombardi

Nanoparticle-Structured Highly Sensitive and Anisotropic Gauge Sensors.

The ability to tune gauge factors in terms of magnitude and orientation is important for wearable and conformal electronics. Herein, a sensor device is described which is fabricated by assembling and printing molecularly linked thin films of gold nanoparticles on flexible microelectrodes with unusually high and anisotropic gauge factors. A sharp difference in gauge factors up to two to three orders of magnitude between bending perpendicular (B(⊥)) and parallel (B(||)) to the current flow directions is observed. The origin of the unusual high and anisotropic gauge factors is analyzed in terms of nanoparticle size, interparticle spacing, interparticle structure, and other parameters, and by considering the theoretical aspects of electron conduction mechanism and percolation pathway. A critical range of resistivity where a very small change in strain and the strain orientation is identified to impact the percolation pathway in a significant way, leading to the high and anisotropic gauge factors. The gauge anisotropy stems from molecular and nanoscale fine tuning of interparticle properties of molecularly linked nanoparticle assembly on flexible microelectrodes, which has important implication for the design of gauge sensors for highly sensitive detection of deformation in complex sensing environment or on complex curved surfaces such as wearable electronics and skin sensors.

Sensor-Based Online Monitoring and Computational Fluid Dynamics (CFD) Modeling of Aerosol Jet Printing (AJP) Process

The objectives of this paper in the context of aerosol jet printing (AJP)—an additive manufacturing (AM) process—are to: (1) realize in situ online monitoring of print quality in terms of line/electronic trace morphology; and (2) explain the causal aerodynamic interactions that govern line morphology based on a two-dimensional computational fluid dynamics (2D-CFD) model. To realize these objectives, an Optomec AJ-300 aerosol jet printer was instrumented with a charge coupled device (CCD) camera mounted coaxial to the nozzle (perpendicular to the platen). Experiments were conducted by varying two process parameters, namely, sheath gas flow rate (ShGFR) and carrier gas flow rate (CGFR). The morphology of the deposited lines was captured from the online CCD images. Subsequently, using a novel digital image processing method proposed in this study, six line morphology attributes were quantified. The quantified line morphology attributes are: (1) line width, (2) line density, (3) line edge quality/smoothness, (4) overspray (OS), (5) line discontinuity, and (6) internal connectivity. The experimentally observed line morphology trends as a function of ShGFR and CGFR were verified with computational fluid dynamics (CFD) simulations. The image-based line morphology quantifiers proposed in this work can be used for online detection of incipient process drifts, while the CFD model is valuable to ascertain the appropriate corrective action to bring the process back in control in case of a drift. [DOI: 10.1115/1.4034591]

Aerosol Jet Printing (AJP) of Flexible Electronic Devices: Online Monitoring of Functional Electrical Properties Using Shape-from-Shading (SfS) Image Analysis

The goal of this research is online monitoring of functional electrical properties, e.g., resistance, of electronic devices made using aerosol jet printing (AJP) additive manufacturing (AM) process. In pursuit of this goal, the objective is to recover the cross-sectional profile of AJP-deposited electronic traces (called lines) through shape-from-shading (SfS) analysis of their online images. The aim is to use the SfS-derived cross-sectional profiles to predict the electrical resistance of the lines. An accurate characterization of the cross section is essential for monitoring the device resistance and other functional properties. For instance, as per Ohm’s law, the electrical resistance of a conductor is inversely proportional to its cross-sectional area (CSA). The central hypothesis is that the electrical resistance of an AJP-deposited line estimated online and in situ from its SfS-derived cross-sectional area is within 20% of its offline measurement. To test this hypothesis, silver nanoparticle lines were deposited using an Optomec AJ-300 printer at varying sheath gas flow rate (ShGFR) conditions. The four-point probes method, known as Kelvin sensing, was used to measure the resistance of the printed structures offline. Images of the lines were acquired online using a charge-coupled device (CCD) camera mounted coaxial to the deposition nozzle of the printer. To recover the cross-sectional profiles from the online images, three different SfS techniques were tested: Horn’s method, Pentland’s method, and Shah’s method. Optical profilometry was used to validate the SfS cross section estimates. Shah’s method was found to have the highest fidelity among the three SfS approaches tested. Line resistance was predicted as a function of ShGFR based on the SfS-estimates of line cross section using Shah’s method. The online SfS-derived line resistance was found to be within 20% of offline resistance measurements done using the Kelvin sensing technique. [DOI: 10.1115/1.4036660]

Nanoparticle Based Printed Sensors on Paper for Detecting Chemical Species

There has been an increasing need of technologies to manufacturing chemical and biological sensors for various applications ranging from environmental monitoring to human health monitoring. Currently, manufacturing of most chemical and biological sensors relies on a variety of standard microfabrication techniques, such as physical vapor deposition and photolithography, and materials such as metals and semiconductors. Though functional, they are hampered by high cost materials, rigid substrates, and limited surface area. Paper based sensors offer an intriguing alternative that is low cost, mechanically flexible, has the inherent ability to filter and separate analytes, and offers a high surface area, permeable framework advantageous to liquid and vapor sensing. However, a major drawback is that standard microfabrication techniques cannot be used in paper sensor fabrication. To fabricate sensors on paper, low temperature additive techniques must be used, which will require new manufacturing processes and advanced functional materials. In this work, we focus on using aerosol jet printing as a highresolution additive process for the deposition of ink materials to be used in paper-based sensors. This technique can use a wide variety of materials with different viscosities, including materials with high porosity and particles inherent to paper. One area of our efforts involves creating interdigitated microelectrodes on paper in a one-step process using commercially available silver nanoparticle and carbon black based conductive inks. Another area involves use of specialized filter papers as substrates, such as multi-layered fibrous membrane paper consisting of a poly(acrylonitrile) nanofibrous layer and a nonwoven poly(ethylene terephthalate) layer. The poly(acrylonitrile) nanofibrous layer are dense and smooth enough to allow for high resolution aerosol jet printing. With additively fabricated electrodes on the paper, molecularly-functionalized metal nanoparticles are deposited by molecularly-mediated assembling, drop casting, and printing (sensing and electrode materials), allowing full functionalization of the paper, and producing sensor devices with high surface area. These sensors, depending on the electrode configuration, are used for detection of chemical and biological species in vapor phase, such as water vapor and volatile organic compounds, making them applicable to human performance monitoring. These paper based sensors are shown to display an enhancement in sensitivity, as compared to control devices fabricated on non-porous polyimide substrates. These results have demonstrated the feasibility of paper-based printed devices towards manufacturing of a fully wearable, highly-sensitive, and wireless human performance monitor coupled to flexible electronics with the capability to communicate wirelessly to a smartphone or other electronics for data logging and analysis.

Transparent Antennas for Wireless Systems Based on Patterned Indium Tin Oxide and Flexible Glass

Efficient antennas were achieved at 2.4 GHz and 5.8 GHz in which a transparent conductor, ITO, was deposited on only one side of the glass through sputtering. Antenna structures including grid, loop, and split ring monopoles were also designed and tested. An ITO layer of 650 nm was needed to consistently maintain a sheet resistance of 10 ohms/square or less to reduce antenna losses. A 100 nm aluminum doped silicon dioxide layer was deposited to buffer the ITO from the flexible glass to ensure high conductivity, and photolithography was used to define the antennas followed by an annealing process to improve the ITO conductivity and transparency. A packaging technique using 3D printed frames, Corning® GPPO connectors, and conducting epoxies yielded good antenna performance in terms of radiation efficiency and mismatch loss. Good agreement between simulations and measurements for packaged devices was obtained. Examples of antenna packaging, measurement results, and performance are presented.