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A research team led by The Hong Kong University of Science and Technology (HKUST) unveiled a groundbreaking development in the realm of microprinting technology – a microprinter capable of printing piezoelectric films at an astonishing speed, surpassing existing methods by a factor of 100.
This technology has significant implications for the production of microelectromechanical systems (MEMS), particularly in the domains of sensors, wearable devices, and implantable medical technologies. What sets this microprinter apart is not only its remarkable speed but also its cost-effectiveness compared to other printers on the market.
The microprinter developed by the HKUST research team addresses a critical challenge in the mass production of nanoparticle-based elements, specifically piezoelectric films, which find applications in sensing, actuation, catalysis, and energy harvesting.
As the demand for MEMS, wearable, and implantable electronics, miniaturised portable devices, and the Internet of Things continues to surge, the ability to efficiently produce piezoelectric materials becomes paramount due to their intrinsic property of coupling mechanical and electrical energy.
The technology utilises an electrostatic field to propel streams of ink onto a platform, allowing for the rapid and precise manipulation of thin film patterns. This not only addresses the challenge of mass production but also enhances the control of structures and feature sizes. The printer’s construction is notably cost-effective compared to existing alternatives, making it an attractive option for various applications.
The experiment, spearheaded by Prof. YANG Zhengbao, an Associate Professor at the Department of Mechanical & Aerospace Engineering at HKUST, involved the creation of a 3D microprinting mechanism. This mechanism, featuring a spiny disc connected to a needle and a power supply, generates a powerful electrostatic field that serves as a propellant. The result is streams of ink cone-jetting onto a platform, forming micro patterns reminiscent of the way charged droplets are ejected from the tips of raindrops in a thunderstorm.
The impact of this development is underscored by the team’s achievement in enhancing manufacturing speed by a factor of 100. For example, the printer can fabricate a 10 μm-thick PZT film on a 4-inch Si wafer in just 10 minutes, with minimal material wastage.
This speed is comparable to semiconductor lithography, showcasing the potential for rapid and cost-effective production of piezoelectric components used in various devices, including microphones, clinical ultrasound probes, and thin-film solar panels.
The versatility of the microprinter was stressed. The technology exhibits the ability to print a diverse array of materials, including dielectric ceramics, metal nanoparticles, insulating polymers, and biological molecules. The printer’s speed, precision (features measurable at ~20 μm), and affordability are anticipated to catalyse breakthroughs in scientific research, enabling the production of intricate structures and functionalities that were once deemed impossible.
What adds to the appeal of this microprinter is its affordability. Priced at only HKD 6,000, it stands out as one of the lowest-cost options available on the market. The research team has reached a stage where the microprinter is ready for large-scale production.
Looking ahead, integrating the printer with roll-to-roll substrate receiving systems will be the focus. This is expected to enable potential commercial applications. Furthermore, the team is actively seeking collaborations with commercial partners to enhance the microprinter’s market presence.
There are limitations of current micromanufacturing technologies. Existing micromanufacturing technologies lack the capability to simultaneously achieve high-speed, versatile manufacturing of diverse piezoelectric elements while maintaining control over their dimensions, structures, and functionality.
This underscores the significance of the microprinter’s capabilities in high-speed, versatile manufacturing while maintaining control over dimensions, structures, and functionality—a combination that has been elusive in existing technologies.
The collaborative effort with the City University of Hong Kong underscores the interdisciplinary nature of this research, drawing on expertise from multiple institutions to push the boundaries of microprinting technology. The findings of this research have been published in the prestigious journal Nature Communications, further validating the significance of the microprinter’s contributions to the field.
