Aerosol Jet® printing of HF RFID antennas on fiber-based paper substrates for smart packaging

The use of fiber-based papers as substrates for the smart packaging industry holds great promise for future green and sustainable electronics. However, this area has not been extensively explored so far, and the manufacturing of paper-based electronics is still at its early stages. In this work, 16 different paper-based substrates were characterized based on their properties, including surface roughness, ink–substrate response, and ability to withstand thermal sintering. The best paper-based substrate was further selected for Aerosol Jet® Printing (AJ®P) using a silver nanoparticle ink. The electrical performance of the printed lines was evaluated to assess the AJ printability of the investigated substrates, while their reliability and durability were further characterized through accelerated aging tests (including climate and light exposure) and resistance to water and rubbing. Finally, a high-frequency radio frequency identification antenna tag was AJ printed as a case study of a smart and flexible electronics for packaging, and its frequency response was successfully validated. This study demonstrates the use of AJP on sustainable fiber-based substrates as an effective printing technique to serve the needs of a sustainable, smart packaging industry.