| Abstract Scope |
Plasma-jet printer (PJP) incorporates a dielectric barrier discharge plasma, to enable simultaneous surface modification, material deposition, and self-sintering in a single step—without the need for multi-step process or cleanroom environment. In this study, we use PJP to enhance surface hydrophilicity, improve adhesion, and directly print conductive, self-sintered metal traces. We further demonstrate PJP’s capability to co-deposit multiple materials, expanding its application potential in multifunctional electronics. A detailed study is conducted to understand the influence of key plasma parameters—including applied voltage, gas flow rate, and nozzle-substrate distance—on surface energy and wettability. Optimized conditions are identified to enhance nanoparticle adhesion and overall print quality. Our results underscore the versatility of PJP as a multifunctional tool for real-time surface engineering, additive metal deposition, and material integration. This work lays the foundation for scalable manufacturing of flexible electronics and space-compatible sensors, where in situ processing and multi-material functionality are essential. |