Experimental insights into aerosol jet printing on 3D curved surfaces: line morphology and resistivity

Aerosol Jet Printing (AJP) is a versatile, non-contact technique for fabricating fine-feature electronics on various substrates, yet its application to complex 3D geometries remains underexplored. Here, we investigate how substrate curvature affects line morphology and electrical performance in AJP-printed lines. By printing on concave and convex surfaces with systematically varied slope magnitudes, and characterizing line width, thickness, overspray, and resistivity, we reveal trends in these parameters. Our findings provide one of the first quantitative insights into conformal AJP deposition, laying the groundwork for process optimization on non-planar surfaces and opening new avenues for directly integrating printed electronics on 3D parts.