Numerical simulation of stable electrohydrodynamic cone-jet formation and printing on flexible substrate

This study aimed to regulate the stability of electrohydrodynamic cone-jet morphology by modifying the needle structure and conical point electrode by drawing upon high AC voltage and low flow velocity values. Accordingly, stability is achieved by the electrohydrodynamic jet (E-Jet) printing, considered an effective tool in micro and nanofabrication for flexible electronic systems. In the present study, 2-phase-field method was employed to draw a comparison of the volume of fraction method to optimize parameters for stable cone-jet on a PET substrate surface by exploiting a range of copper control electrodes. With COMSOL Multiphysics software, the equations of electric potential and electrical body forces were successfully solved. The validation study was compared with ensure the optimization parameters of cone-jet morphology, as retained in the boundaries of Melcher-leaky dielectric model. Moreover, the simulation parameters were directly adopted to print continuous line patterns on the PET substrate, which are considered prominent and promising E-Jet printing methods for flexible electronic systems. [Display omitted] •The 2-Phase field method develops stable cone-jet morphology on flexible substrate.•AC voltage 6.6 kV & 2 kV and flow velocity 200 mm/s are optimal parameters.•The Parameters generate fast decay of residue charges on the substrate surface.•The parameters conclude that phase field method is more capable compared to VOF.•Continuous microstructures are directly printed on PET substrate in experiments.