Parametric Optimization of PEDOT:PSS Aerosol Jet Printing for Enhanced Line Morphology in Flexible Electronics

ABSTRACT Aerosol Jet Printing (AJP) is an advanced, maskless fabrication technique for flexible electronics, enabling precise patterning of functional materials on diverse substrates. In this study, we systematically optimize AJP parameters to achieve superior line morphology and printing fidelity of PEDOT:PSS conductive polymer on flexible Kapton substrates. Key printing parameters—including carrier gas flow rate (CGF), sheath gas flow rate (SGF), printing speed, and ink formulation (PEDOT:PSS/DMSO ratio)—are varied to elucidate their effects primarily on line uniformity, edge definition, thickness, and defect minimization. Through comprehensive experimental analysis, we identify optimal conditions consisting of a CGF of 15–18 sccm, a SGF of 60 sccm, a printing speed of 2 mm/s, and a DMSO concentration of 10%, resulting in continuous, uniform, and defect‐free printed lines with well‐defined morphology and minimal overspray. These findings provide clear quantitative guidelines for reliably achieving high‐quality PEDOT:PSS lines, laying a critical foundation for scalable manufacturing of flexible electronics, energy devices, and other related applications.