Cold spray-based rapid and scalable production of printed flexible electronics

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dc.authorid0000-0002-3644-7133
dc.contributor.authorAkin, Semih
dc.contributor.authorLee, Seungjun
dc.contributor.authorJo, Seunghwan
dc.contributor.authorRuzgar, Duygu Gazioglu
dc.contributor.authorSubramaniam, Karthick
dc.contributor.authorTsai, Jung -Ting
dc.contributor.authorJun, Martin Byung-Guk
dc.date.accessioned2026-02-12T21:04:58Z
dc.date.available2026-02-12T21:04:58Z
dc.date.issued2022
dc.departmentBursa Teknik Üniversitesi
dc.description.abstractFlexible electronics (FE) is attracting great attention from both scientific and industrial communities, and plays a crucial role in smart device applications. Despite great promise, traditional printing approaches (e.g., screen printing, ink-jet printing, etc.) often need a high-temperature post-sintering process to produce FE with desired electrical conductivity and adhesion strength. The post-sintering processes, however, often lead to fast oxidation of the functional coating while limiting the use of low-thermal budget substrates. Exponential advance of FE in a large-scale and energy-efficient manner relies on rationally eliminating the post-sintering processes. To this end, with the aim of uncovering process-structure-properties relationships, we employ the emerging cold spray (CS) technique for rapid and scalable production of FE without a need for high-temperature post-sintering. In this regard, micron-scale Tin (Sn) particles are directly written on a flexible polymer substrate (PET) by cold spraying under ambient conditions. The effect of CS process parameters on the resultant coatings is comprehensively characterized in terms of microstructure, film thickness, electrical conductivity, linewidth, and adhesion strength. The resulting electrodes show excellent electrical conductivity (6.98 x 105 S m-1), adhesion strength, long-term stability, and flexibility without significant conductivity loss after 1000 bending cycles. By leveraging the CS operational settings, a resistive macro-heater (12 x 15 cm2) and an LED circuit (2.5 cm x 18 cm) are fabricated to demonstrate the applicability of the CS in printed FE. Moreover, to address the low-spatial reso-lution of CS writing, a case study on sequential CS and femtosecond laser machining is performed, which further led to ultra-high resolution (i.e., 30 mu m linewidth) custom-designed flexible electrodes. Thus, the present study reveals the immense potential of the CS technique for rapid and scalable production of FE without the need for post-sintering.
dc.description.sponsorshipOffice of Overseas Scholarship Programs from the Republic of Turkey Ministry of National Education; Purdue University, School of Mechanical Engineering; Institute of Information & Communications Technology Planning & Evaluation (IITP) - Korea Government (MSIT) [2021-0-01577]; Scientific and Technological Research Council of Turkey (TUBITAK); DST, Government of India [SB/S9/Z-03/2017-X (2019-20)]
dc.description.sponsorshipThe first author of this study, S.A, acknowledges a scholarship through the Office of Overseas Scholarship Programs from the Republic of Turkey Ministry of National Education. S.A also acknowledges a fellowship (Lambert Fellowship) support from Purdue University, School of Mechanical Engineering. S.L acknowledges a scholarship support by Institute of Information & Communications Technology Planning & Evaluation (IITP) grant funded by the Korea Government (MSIT) (No.2021-0-01577) . D.G.R acknowledges a fellowship (2219-International Postdoctoral Fellowship Program) by the Scientific and Technological Research Council of Turkey (TUBITAK) . K.S acknowl-edges DST, Government of India for the SERB Purdue University OVDF project grant (No. SB/S9/Z-03/2017-X (2019-20) ) .
dc.identifier.doi10.1016/j.addma.2022.103244
dc.identifier.issn2214-8604
dc.identifier.issn2214-7810
dc.identifier.scopus2-s2.0-85141230816
dc.identifier.scopusqualityQ1
dc.identifier.urihttps://doi.org/10.1016/j.addma.2022.103244
dc.identifier.urihttps://hdl.handle.net/20.500.12885/6743
dc.identifier.volume60
dc.identifier.wosWOS:000883785800002
dc.identifier.wosqualityQ1
dc.indekslendigikaynakWeb of Science
dc.indekslendigikaynakScopus
dc.language.isoen
dc.publisherElsevier
dc.relation.ispartofAdditive Manufacturing
dc.relation.publicationcategoryMakale - Uluslararası Hakemli Dergi - Kurum Öğretim Elemanı
dc.rightsinfo:eu-repo/semantics/closedAccess
dc.snmzKA_WoS_20260212
dc.subjectAdditive manufacturing
dc.subjectCold spray
dc.subjectPrinted electronics
dc.subjectFlexible electronics
dc.subjectDirect writing
dc.subjectSustainable repairing
dc.subjectLaser machining
dc.titleCold spray-based rapid and scalable production of printed flexible electronics
dc.typeArticle

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