| About this Abstract |
| Meeting |
2023 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2023)
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| Symposium
|
2023 Annual International Solid Freeform Fabrication Symposium (SFF Symp 2023)
|
| Presentation Title |
A Hybrid Aerosol Jet Printing and Electrochemical Deposition Process for Manufacturing Multi-layer Inductors and Transformers |
| Author(s) |
Lok-kun Tsui, Yongkun Sui, Thomas Michael Hartmann, Joshua Dye, Judith Maria Lavin |
| On-Site Speaker (Planned) |
Lok-kun Tsui |
| Abstract Scope |
A hybrid additive manufacturing approach combining aerosol jet printing (AJP) and electrochemical deposition process was developed for manufacturing multi-layer inductors and transformers. AJP deposits metals and dielectrics with high resolution for printed electronics applications; however, nanoparticle inks have lower conductivity than bulk. Electrochemical deposition is used to address the low conductivity of the printed metal. An Ag seed layer is aerosol printed followed by the electrochemical deposition of high density, high conductivity Cu and Ni, decreasing the resistance and passivating the inductor surface respectively. We manufactured 8-layer spiral inductors with inductances of 2.5 µH. Flyback transformers consisting of 2-layer primary and 2-layer secondary spiral inductors were manufactured using this hybrid method. These transformers took an input voltage of 17V at 400 kHz and output a voltage of 1250 volts, a gain of 73.5. COMSOL modelling validated the designs. SNL is managed and operated by NTESS under DOE NNSA contract DE-NA0003525. |
| Proceedings Inclusion? |
Definite: Post-meeting proceedings |