In-situ qualification and physics-based process design for aerosol jet printing via spatially correlated light scattering measurements

Aerosol jet printing is a contactless, digital, and additive technique broadly used for manufacturing flexible, hybrid, and conformal electronics. However, both intra-batch and batch-to-batch variability have hindered widespread industry adoption and scaling to production volumes. Recently, light scattering measurements have emerged as a tool to measure aerosol volume fraction – a key parameter determining deposition rate – and have proven an effective feedback source for closed-loop control on timescales ranging from tens of minutes to hours. While this is a promising capability to mitigate long-term process drift, it lacks the temporal resolution to validate print quality for complex and precise electronic circuits. Here, real-time process monitoring with