Optomec’s Aerosol Jet Technology can enable 3D polymer and composite structures to be printed at the micron scale with embedded electronics. This breakthrough could potentially reduce the cost and size of next-generation products used in the electronics and bio-medical industries.

This new capability is the result of the Aerosol Jet’s ability to print fine features and a proprietary in-situ curing capability for rapid on-the-fly solidification.

The Optomec method relies on local deposition and local curing. This makes the process economical, in terms of material consumption, but is also key to enabling high resolution features.

“This breakthrough in 3D printing technology extends additive manufacturing to the creation of micron scale, free-form polymer structures and smart devices,” said Mike O’Reilly, Optomec Director Aerosol Jet Product Management.  Early adopter customers have already developed innovative applications for smart devices and micro-fluidic applications.

Using this process high aspect ratio, free-form 3D structures can be printed at the micron-scale, without the need for support structures, from materials including photopolymers and certain composites.  Additionally, the resulting structures can be metallized with conformal 3D conductive traces and printed functional components, such as antennas and sensors, to create fully functional 3D components all in one manufacturing machine.  This direct digital approach optimizes the fabrication process, reducing manufacturing steps and material usage making Aerosol Jet 3D micro-structure printing a cost-effective, green technology.

Aerosol Jet 3D micro-structure printing is capable of resolutions with lateral feature sizes down to 10 microns, and lateral and vertical build resolutions from 1 micron to 100 nanometers respectively.  Aspect ratios of more than 100:1 have been achieved.  Additionally, such 3D micro-structures can be printed onto existing components and products, such as semiconductor chips, medical devices or industrial parts. Optomec offers a white paper on Aerosol Jet 3D micro-structure printing.

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