Modular motion control software development to support a versatile, low-cost aerosol jet platform for printed electronics

A wide variety of digital fabrication methods rely on computer numerical control motion systems for positioning and synchronization of complex functions. Although low-cost microcontrollers have supported widespread adoption of 3D printing and greatly reduced barriers to market entry, higher precision printing methods such as aerosol jet printing continue to rely on expensive, purpose-built motion control platforms. Advances in low-cost and versatile microcontrollers present a compelling opportunity for the design of inexpensive, simple, and modular motion control applications suitable for precision printing modalities that require multitasking. Here, an aerosol jet printer is developed with an inexpensive 32-bit microcontroller using real-time operating system features. Multitasking enables robust synchronization of the motion system with a variety of peripheral hardware devices necessary for functional patterning. This is demonstrated for electronic inks with competitive performance compared to high-end commercial printing platforms, while maintaining a modular, accessible, and versatile framework to support portability for hybrid manufacturing capabilities.

Automated summary

This paper presents the development of an aerosol jet printer using a low-cost 32-bit microcontroller with real-time operating system features, enabling robust synchronization of the motion system with various peripheral hardware devices for functional patterning. The printer demonstrates competitive performance with high-end commercial printing platforms for electronic inks, while maintaining a portable, modular, and versatile framework to support hybrid manufacturing capabilities.