Design and fabrication of a modular, low-cost aerosol jet printer

Abstract

Flexible electronics that conform to non-planar surfaces represent an important frontier in device engineering, with applications spanning wearable systems, biomedical interfaces, and structural monitoring. Fabrication of these systems requires manufacturing approaches that can precisely pattern functional materials onto diverse substrates. Aerosol jet printing (AJP) offers distinctive capabilities in this domain, using aerodynamic focusing to direct aerosolized functional inks with high spatial precision onto both planar and non-planar surfaces. We report the development of a modular, low-cost aerosol jet printer (LC-AJP) constructed from commercial off-the-shelf components, open-source software, and custom 3D-printed elements. Despite its modest cost (<$1,200), the system achieves sub-50 µm resolution in printed features. We demonstrate material versatility by successfully printing with silver nanoparticle inks, PEDOT conducting polymer, and carbon black composites, enabling fabrication of functional temperature sensors. The modular architecture facilitates rapid innovation, exemplified by our implementation of a 4-in-1 multi-nozzle configuration that quadruples production throughput by simultaneously printing four identical structures. This accessible platform establishes a foundation for broader adoption of advanced manufacturing techniques for flexible electronics, with opportunities for further refinement in resolution, materials compatibility, and integration with complementary fabrication methods.