Neil Chilton | Printed Electronics Limited: Can we scale inkjet printing to sub-micron drops by simply shrinking nozzle diameters?
00:11:58.524 - 00:14:14.904
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Summary of the clip:
How do we bridge the gap between high-viscosity screen-printable inks and non-contact deposition on complex, non-planar geometries?
Direct-write additive manufacturing on curved surfaces requires deposition technologies that bypass the physical constraints of traditional screen printing while maintaining high material loading. Piezo jetting emerges as a highly viable non-contact alternative, capable of depositing nanoparticle inks from a distance of several millimeters. This approach enables the precise patterning of functional components, such as conformal antennas, directly onto singly curved substrates with performance characteristics that closely match theoretical electromagnetic predictions.
The rheological behavior of functional inks is critical to this process, relying on shear-thinning properties to enable the dispensing of highly viscous materials. In piezo jetting systems, pneumatic pressure applied to a syringe reservoir ensures continuous fluid replenishment to prevent voids within the chamber. A high-speed mechanical valve action then generates intense localized shear forces, temporarily lowering the ink's viscosity to eject controlled droplets of materials that would otherwise be too viscous for standard inkjet heads.
This non-contact jetting mechanism expands the material envelope for printed electronics, facilitating the multi-layer deposition of advanced copper inks and dielectrics to construct fully functional circuits. By partnering with leading material innovators, developers can leverage these high-shear dispensing heads to process challenging formulations, such as copper nanoparticle inks, enabling robust metallization and insulating layers on complex, three-dimensional surfaces where screen printing is impossible.
In this short video, you can learn:
* How piezo jetting enables non-contact deposition of nanoparticle inks onto curved surfaces.
* The role of shear-thinning rheology and high-speed valve mechanics in jetting high-viscosity fluids.
* The application of copper and dielectric inks for direct-write circuit fabrication.
π **Clip Abstract** The speaker discusses the use of piezo jetting as a non-contact printing method to deposit nanoparticle copper inks and dielectrics onto curved surfaces, highlighting a successful conformal antenna project. He explains the mechanical and rheological principles of the jetting head, detailing how syringe pressure and rapid valve closure exploit shear-thinning properties to dispense high-viscosity fluids.
π€ Speaker: Neil Chilton
π’ Company: Printed Electronics Limited
π
Event: Future of Electronics RESHAPED USA 2026
π Location: Computer History Museum, Mountain View, California, USA
π Learn more at the next TechBlick event: https://www.techblick.com
#HagenPoiseuille, #Microfluidics, #ShearThinning, #SubMicronInkjet, #PrintedElectronics, #MicroLEDDisplays
This is a highlight of the presentation:
Printing with High Viscosity Fluids
Future of Electronics RESHAPED USA 2026
10-11 June 2026
Computer History Museum, Mountain View, California, USA
Organised By:
TechBlick
More Highlights from the same talk.
00:09:23 - 00:10:54
How does Electro Hydrodynamic Jetting defy conventional fluid dynamics to print 3D structures mid-air?
How does Electro Hydrodynamic Jetting defy conventional fluid dynamics to print 3D structures mid-air?
Traditional inkjet deposition faces limitations in droplet size and solvent evaporation control, often restricted by the physical properties of piezo or thermal printheads. Superfine inkjet (SIJ) technology bypasses these boundaries by utilizing electro hydrodynamics (EHD) to trigger droplet ejection, resulting in dramatically smaller droplet sizes and accelerated emission rates compared to conventional processes.
The true magic of EHD jetting lies in the physical behavior of sub-micron and low-picoliter droplets. Because the droplet size is so small, the surface-area-to-volume ratio increases exponentially, making the droplet mostly surface; this allows the solvent to evaporate rapidly during flight, even when using high-boiling-point solvents such as those rated up to 254 degrees Celsius.
This rapid in-flight drying mechanism alters how the material behaves upon hitting the substrate. Instead of forming a spreading liquid pool that requires post-cure stabilization, the partially dried nanomaterial stacks predictably, enabling the high-precision printing of 2.5D and fully 3D microscopic features such as vertical pillars and fine conductive lines.
In this short video, you can learn:
* The core mechanics of Electro Hydrodynamic (EHD) jetting versus piezo and thermal printheads.
* How high surface-area-to-volume ratios in micro-droplets enable rapid in-flight solvent evaporation.
* Techniques for utilizing pre-dried droplets to construct micro-scale 2.5D and 3D structures.
π **Clip Abstract** This clip explains the physics behind Superfine Inkjet (SIJ) technology and its use of electro hydrodynamics to achieve sub-picoliter droplet volumes. It highlights how rapid in-flight solvent evaporation allows developers to print complex 3D microstructures directly onto non-absorbent substrates.
#ElectrohydrodynamicJetting, #SuperfineInkjet, #InFlightEvaporation, #Micro3DPrinting, #PrintedElectronics, #MicroLEDManufacturing
00:04:40 - 00:06:10
Why does low-tech screen printing remain the high-yield king of industrial printed electronics over digital inkjet?
Why does low-tech screen printing remain the high-yield king of industrial printed electronics over digital inkjet?
In the printed electronics landscape, choosing the correct deposition method requires balancing throughput, substrate compatibility, and material viscosity. While digital methods like inkjet receive significant attention, industrial production lines still heavily rely on traditional screen printing as their primary daily workhorse.
Screen printing excels in mass production because it accommodates high-viscosity pastes with highly predictable, well-characterized substrate interactions. This allows manufacturers to control wet-out behaviors and construct high-value, highly complex non-consumer components without the wetting and pooling risks associated with low-viscosity inkjets.
Even as technology pushes toward sub-micron features, modern screen printing systems can reliably deliver features down to 30 microns, with 200 microns being highly repeatable in daily production. It remains the most commercially viable starting point for high-reliability medical, sensor, and industrial electronic components.
In this short video, you can learn:
* The strategic criteria for selecting screen printing over flexographic, gravure, or digital inkjet methods.
* How utilizing high-viscosity pastes stabilizes substrate interactions to prevent trace deformation.
* The resolution limits of modern production-scale screen printing for complex, high-value components.
π **Clip Abstract** This clip analyzes why screen printing remains the dominant manufacturing method in commercial printed electronics despite the rise of digital alternatives. It discusses the critical relationship between ink viscosity, substrate interaction, and long-term production reliability.
#IndustrialScreenPrinting, #HighViscosityPastes, #SubstrateWetting, #FineLinePrinting, #PrintedElectronics, #FlexibleElectronics
00:14:14 - 00:16:15
Can Electro Hydrodynamic printing scale up from single-nozzle R&D to high-throughput Quantum Dot display manufacturing?
Can Electro Hydrodynamic printing scale up from single-nozzle R&D to high-throughput Quantum Dot display manufacturing?
While electro hydrodynamic jetting is highly effective for micro-scale printing, transitioning the process from single-nozzle academic systems to industrial production has historically been a significant bottleneck. Addressing this scale-up challenge requires moving beyond single or dual nozzle arrays into massively parallel architectures designed for industrial high-volume applications.
The development of a multi-nozzle EHD head represents a major leap forward for display manufacturing, particularly in high-precision quantum dot patterning for color conversion layers. By integrating hundreds or potentially thousands of parallel nozzles, the system can rapidly deposit sub-20 micron droplets across a precise grid array in a single pass.
Operating with a stable pitch, such as 168 microns, this multi-nozzle configuration offers positioning accuracy and drop size control that conventional inkjet printing cannot replicate. This advancement bridges the gap between ultra-fine digital deposition and high-throughput semiconductor or display packaging lines.
In this short video, you can learn:
* The engineering hurdles of scaling up electro hydrodynamic jetting from R&D to mass production.
* How multi-nozzle arrays achieve high-throughput quantum dot patterning for advanced display color conversion.
* The spatial and volumetric advantages of EHD multi-nozzle systems over traditional industrial inkjet heads.
π **Clip Abstract** This clip details the industrial scale-up of Superfine Inkjet (SIJ) technology using advanced multi-nozzle printing heads. It focuses on the strategic deployment of these multi-nozzle arrays for high-speed quantum dot patterning in display manufacturing.
#ElectrohydrodynamicPrinting, #MultiNozzleArrays, #QuantumDotPatterning, #SuperfineInkjet, #PrintedElectronics, #MicroLEDDisplays