Advanced Dielectric Material for PCB Fabrication: Improving Mechanical and Thermal Performance through Additive Manufacturing
Author: Marcel Grooten <m.grooten@domicro.nl>
Introduction
Additive Manufacturing Electronics (AME) and Flexible Hybrid Electronics (FHE) are transforming how electronic devices are designed and produced. Instead of relying on traditional PCB manufacturing processes such as copper etching and multiple lamination steps, electronic circuits can be built layer-by-layer. Using the innovative inkjet printing system ElectroJet™ by ChemCubed (Figure 1), multiple conventional production steps are replaced by depositing only the required material. This turn-key inkjet printing platform enables rapid prototyping, complex geometries, customization, and multi-material printing while protecting your IP (Figure 2).
Figure 1: Block diagram of the setup of the printhead of ElectroJet™ printers (left) and the ElectroJet™ UV3D-3200 printer system (right).
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Figure 2: Demonstrators manufactured by ElectroJet™ printing equipment
Incorporating Carbon nanotubes (CNT) in Dielectric materials
A critical component in printed electronics is the dielectric material. However, improving the mechanical and thermal performance of printed dielectrics without compromising their electrical insulation remains a major challenge. To address this, a novel method for incorporating carbon nanotubes (CNTs) into a UV-curable dielectric material was developed for additive electronics. CNTs are favorable since they can be chemically modified and have exceptional tensile strength and thermal conductivity because of their nanostructure and the strength of the bonds between carbon atoms. Rather than premixing CNTs into a single formulation, the CNT-containing ink and dielectric ink are printed simultaneously and mixed during the printing process before curing. This innovative manufacturing approach creates a reinforced dielectric structure while maintaining excellent printability and electrical performance.
Properties of the CNT incorporated Dielectric material
The performance of the dielectric material was enhanced due to CNT incorporation (Table 1). The mechanical properties significantly increased: the Young's modulus by 123% and the Tensile strength by 112%. Not only the mechanical performance improved, but thermal properties were enhanced as well. One singular glass transition indicated a more uniform material, smaller deformations occurred while heating and the thermal conductivity was increased. Additionally, the CNT-reinforced material retained excellent electrical properties.
Table 1: Mechanical, Thermal and Electrical properties of dielectric material with/without CNT incorporation.
Conclusion and outlook
Multi-layer additive manufacturing offers new opportunities to enhance the performance of printed dielectrics through the combination of materials using the ElectroJet™ printing equipment. Additionally, ElectroJet™ is a supplier of various specialty dielectric and conductive inks, such as inks with bulk silver conductivity. This ElectroJet™ printing platform and its inks change the way circuits are designed and manufactured, enabling creation of complex customizable electronic systems with unparalleled high performance.
Find out more: https://domicro.nl/chemcubed/
About ChemCubed & DoMicro
ChemCubed (US) is a leading supplier of specialty inks and printers in additive printed electronics today. The company combines deep expertise in conductive and dielectic inks, primers and security marking materials with turn-key inkjet printing platforms. The ultimate goal is to optimize printed electronics and 3D printing materials to enhance real-world applications, we prioritize end-use functionality. Our solutions are tailored to meet the unique requirements of diverse applications.
DoMicro (NL), as technology service provider and value-added reseller of Chemcubed in Europe, excels in developing cutting edge inkjet printing processes, micro assembly and 3D packaging technology. Our expertise is in matching the application requirements with material properties and equipment functionalities, creating high-functionality electronic products for the market quickly. Technology development typically relates to the know-how on creating the process for the applications. If you are challenged by the market and looking for a partner to move your ideas into realization, contact us. We really do IMAGINE, CREATE AND ACCOMPLISH.
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