Aerosol jet printing of PEDOT:PSS for large area flexible electronics

We investigate and optimize the Aerosol Jet Printing of PEDOT:PSS by studying the role of the parameters determining the final quality of the printed features. In fact, printing thin films of organic materials requires a high control in the deposition process to control the morphology/structure of the films that determine the electrical and functional performance of organic devices. We studied aerosol jet printed lines of the PEDOT:PSS semiconductive polymer on flexible Kapton substrates. We choose the focus ratio, defined as the ratio between the sheath and carrier gas flow rates, as the main parameter that best characterizes the process and hence the characteristics of printed lines. A detailed analysis of the line width and thickness, as a function of the focus ratio and carrier gas flow for different nozzle sizes and sheath gas flow rates, is reported. The edge profile definition of printed PEDOT:PSS lines has been found to be affected by a combination of overspray, typical of aerosol deposition, and pinholes due to the Kapton/PEDOT:PSS interaction, while their core profile results to be almost defects free. An optimal printing window for different nozzle sizes has been determined in terms of a minimization of overspray/pinholes effects with respect to the whole line width. Finally, an array of whole-plastic, planar Organic Electrochemical Transistors, having both the channel and the gate electrode made of PEDOT:PSS, has been manufactured using the best combination of process parameters. Transistors have been characterized for different channel/gate area ratios and the transconductance analysed as a function of channel to gate area.