In-situ monitoring of aerosol jet printing

• Main Author: Oh, Alexis Xian Yang
• Other Authors: Moon Seung Ki
• Format: Final Year Project
• Language: English
• Published: Nanyang Technological University 2024
• Subjects: Engineering; Aerosol jet printing; Acoustic monitoring for DED; Thermal mass flow sensor
• Online Access: https://hdl.handle.net/10356/177250
• Institution: Nanyang Technological University

The advent of Aerosol Jet Printing (AJP) marks a transformative phase in the additive manufacturing sector, introducing a paradigm where precision and versatility in printing functional materials on diverse substrates are paramount. This research report meticulously investigates the intricate dynamics of AJP, with a special focus on enhancing process control and monitoring to address the inherent challenges that accompany this novel manufacturing technology. As AJP emerges as a cornerstone for applications ranging from electronics to biomedicine, the imperative for sophisticated in-situ monitoring techniques becomes increasingly pronounced, underscoring the essence of this study. Embarking on an exploratory journey through the existing corpus of additive manufacturing literature, the research identifies a critical void in the domain of real-time process oversight within AJP operations. The crux of the study revolves around the conceptualization and empirical assessment of various in-situ monitoring methodologies, notably encompassing optical, acoustic, and thermal strategies. These techniques are meticulously tailored to align with the unique environmental conditions and operational nuances characteristic of AJP, aiming to surmount prevalent challenges such as nozzle clogging, uneven aerosol deposition, and inconsistent substrate adhesion—factors that critically impact the quality and integrity of printed structures. With an innovative approach, the research delves into the adaptation and integration of advanced monitoring technologies from parallel domains, rigorously evaluating their efficacy within the AJP landscape. The methodology embraces a holistic perspective, incorporating a blend of theoretical analysis, experimental validation, and computational modelling to offer a granular understanding of the underlying mechanisms that govern material flow, deposition dynamics, and defect formation within the AJP process. The findings of this comprehensive study illuminate the potential of integrated in-situ monitoring systems to significantly elevate the precision, efficiency, and reliability of AJP outputs. Through a nuanced dissection of the experimental results, the report not only charts a path toward mitigating the technical obstacles inherent to AJP but also unfolds the broader implications for additive manufacturing at large. The research underscores the pivotal role of real-time monitoring in catalysing innovation, optimizing operational methodologies, and expanding the applicability of AJP across a spectrum of industrial and research domains. This research report transcends the conventional boundaries of additive manufacturing investigations, offering profound insights into the optimization of Aerosol Jet Printing through advanced in-situ monitoring techniques. By charting unexplored territories and laying down the groundwork for future explorations, the study stands as a beacon for researchers, engineers, and technologists poised on the brink of the next industrial revolution, propelled by the advancements in additive manufacturing technologies.