| Abstract Scope |
The development of flexible electronics demands scalable, high-resolution manufacturing techniques for robust conductive components. This work optimizes aerosol jet printing (AJP) of PEDOT:PSS, a leading conducting polymer for flexible electronics, using dimethyl sulfoxide (DMSO) as an additive. We systematically examined the effects of key AJP parameters—sheath and carrier gas flow rates, printing speed, atomization power, and ink concentration—on Kapton substrates. Morphological characterization and four-point probe measurements revealed that precisely balanced carrier and sheath gas flows, combined with optimized ink dilution, significantly improve line quality and conductivity by minimizing overspray and edge roughness. Our study defines an optimized AJP processing window for PEDOT:PSS, enabling fabrication of highly conductive, flexible, and well-adhered lines. These results offer practical guidelines for producing scalable printed electronics and highlight the versatility of AJP for polymer-based devices in healthcare, soft robotics, and wearable systems. |