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This study aims to characterize the evolution of droplet-size distributions in aerosol jet printing and its impact on print quality.

Unveiling droplet size evolution in aerosol jet printing processing via numerical simulation

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This study aims to characterize the evolution of droplet-size distributions in aerosol jet printing and its impact on print quality.
Integrated laser particle-size analysis with CFD modelling to assess droplet transformations.
Investigated various gas-flow conditions and their effects on droplet size with a 300 μm nozzle.
Analyzed the interactions of coalescence and evaporation on droplet dynamics.
Median droplet diameter varied by up to 45.4% under tested conditions.
Changes in gas flow resulted in a 76.4% difference in median diameter.
Droplets smaller than ∼3 μm were easily entrained, while larger droplets contributed to jet collimation.

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Randomized trial reveals droplet size evolution in aerosol jet printing, suggesting enhanced print quality understanding.

Zhang et al. (2026) studied this question.

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