Predicting multi-nodal in-nozzle particle interactions in high-viscosity fluid mediums for acoustophoretic direct-ink writing of line-patterned composites
Year: 2025
Type: article
Abstract: Patterned functional materials offer improved properties (electrical, thermal, etc.) over their bulk counterparts in many applications, including energy storage, flexible electronics, and sensors. However, manufacturing approaches for patterning materials over large areas with features on the order of hundreds of microns or less are limited. Acoustophoresis, which uses acoustic forces to control particle arrangement in a fluid medium, is a pathway to address this challenge. This process is dependent on particle and fluid properties and enables patterning of a broad range of materials. Herein, a model with experimental validation is presented to demonstrate that acoustophoresis can be combined with direct-ink writing (DIW) to fabricate line patterns over large cm-scale areas. An in-nozzle particle interaction model was developed to investigate the impact of processing conditions on multi-nodal acoustophoretic DIW. The model predicts patterned line widths within a factor of two relative to experimental results for a high-viscosity case study. The model was used to investigate the impact of frequency, particle loading, particle radius, and acoustic pressure on line width and patterning time, providing critical feedback regarding the processing conditions suitable for a target application. Model results illustrate that frequency had the greatest impact on line patterns: increasing from 1 to 3 MHz resulted in a greater than 65% reduction in line width and a greater than 85% reduction in patterning time. Additionally, experiments were conducted with an alumina-epoxy ink, and a ∼21 cm 2 area pattern was rastered in ∼5.5 minutes, demonstrating a path towards large-area line-patterned composite fabrication.
Source: Additive manufacturing
Authors: Emilee N. Armstrong, Keith E. Johnson, Kyle A. Herbruger, Austin K. Sanchez, Matthew R. Begley, Corie L. Cobb
Language: English
Subfield: Automotive Engineering
Field: Engineering
Domain: Physical Sciences
Open Access status: hybrid
Estimated APC paid: $4,430
Funders: National Science Foundation, U.S. Department of Energy, University of Washington, Office of Energy Efficiency and Renewable Energy, University of California, Santa Barbara, Materials Research Science and Engineering Center, Harvard University, Office of the President, University of California, Division of Materials Research, Office of Energy Efficiency, California NanoSystems Institute, Advanced Materials and Manufacturing Technologies Office
OpenAlex ID: W4409246767