Fig. 3: Clogging-free printing with a large particle size and higher mass loading printing.

The clogging-free printing was demonstrated based on the ability to print a large particle size and high mass loading suspensions. a The larger particle size printing ability was shown in a linear L/D_p chart with the inset showing a different printed particle size for different L/D_p (scale bar: 100 µm) ratios. L/D_p can be as low as 3.81 for drop-impact printing, which is significantly smaller as compared to inkjet and electrohydrodynamic (EHD) printing. b The percent count to print a single and multiple beads in a drop is demonstrated. The probability of single- bead capturing in a single drop (80-µm diameter) was found to be 32%. The inset shows the number of beads in a single drop (scale bar: 100 µm). c Further, the printed droplet diameter with varying particle size is shown. The droplet diameter was independent of different particle-size suspensions. d The linear chart shows that as high as 71% mass loading suspension solution printing is possible using drop-impact printing as compared to inkjet and EHD printing. The inset shows the scanning electron microscopy (SEM) image of a printed droplet for different mass loading (scale bar: 100 µm). e The printed feature height is shown with varying mass loading (print substrate—glass). The inset shows the printed droplet with 71% mass loading having a base diameter of 990 µm (sieve used—#0.009). f Further, the printed droplet diameter was plotted with varying mass loading (inset image scale bar: 100 µm). The printed drop size was found to be independent with an increase in mass loading. Insets in both figures (e) and (f) show a higher mass loading printed drop.