Description: Plasma jet printing is a promising method to address many unique challenges in printed electronics. The plasma jet technique converts an ink solution and a carrier gas into a low temperature atmospheric pressure plasma jet that is subsequently printed to the substrate. Plasma is the main driving force for printing and the plasma is generated by applying electromagnetic field. So the ink flow to the substrate is dictated by the electromagnetic field which is not affected by microgravity environment. Also, all other printing technologies for printed electronics rely heavily on ink quality/supply chain and post processing. Eliminating post processing and reducing the dependency on ink supply chain will enable fabrication of a wide range of devices enabling on demand manufacturing of electronics. Developing a process for dry printing of multi-materials including conductors and dielectrics can be a game changing development for an industry that relies heavily on the quality of ink. The plasma process provides a unique set of variables that can be independently controlled to tune the material properties by mixing and matching of materials and gases and varying the plasma process parameters. Sterilization is another key aspect. Plasma jet technology can successfully be used to sterilize surfaces, science tools, objects that are re-used by astronauts onboard the ISS. By demonstrating the sterilization capability of the technology, Space Foundry will provide a cross cutting technology for in-space manufacturing. Plasma jet will help in re-using any tools that the crew uses routinely and prevent any biofilm formation like that of a 3D printed spoon (with crevices where food particles can settle resulting in fungus growth) or any science tools. This will enable more re-using and recycling of parts thus reducing resource consumption and sustained space exploration.

Benefits: On demand manufacturing of electronics (ODME) and NASA’s Multimaterial fabrication facility “Fablab” relies on integrating multiple technologies into one singe additive manufacturing facility. Plasma jet printing This will help for the future missions to moon and mars and accelerate low earth orbit (LEO) commercialization. Integration of this novel plasma jet printing technology with other additive manufacturing tools would provide tremendous value for ODME. Sterilization of science tools and reusable objects brings additional value.

Printed electronic devices including flexible electronics and flexible hybrid electronics are next generation smart devices that have applications in both consumer and industrial segments. Some of the direct applications involve wearable monitoring devices, printed antenna, printed battery, printed sensors (gas and bio), in-mold electronics for automotive industries etc.,