New mist-based printing method builds precise circuits on complex curved 3D surfaces

A team led by Ethan Secor at Iowa State University is developing aerosol jet printing to apply electronic circuits on complex curved surfaces with 10–100 micron precision. The print head is mounted on a robotic arm, and the process is controlled by software and real-time monitoring. Startup Contour Circuits received a $150,000 NASA contract, and the research is supported by NSF.

• Aerosol printing turns ink into mist and prints patterns 10–100 microns
• The head is mounted on a robotic arm for printing on curved surfaces
• Contour Circuits received a $150,000 NASA STTR contract
• Inks resistant to temperature swings in space are being developed