Systems and methods for controlling the morphology and porosity of printed reactive inks for high precision printing

A system of optimizing morphology and electrical properties of a reactive metal ink printed on a substrate, the system comprising:

• a printer jet head having a nozzle to dispense droplets comprising a reactive metal ink and a solvent onto the substrate to produce a dense film in the absence of sintering;
• a temperature-controlled stage configured to hold the substrate during dispensing of the droplets onto the substrate and to control a temperature of the substrate, wherein the temperature-controlled stage is configured to maintain the temperature of the substrate at a temperature between about 60° C. and about 80° C. during deposition of the reactive metal ink onto the substrate,
• wherein a contact angle of a dispensed droplet relative to the substrate is less than 15°,
• wherein a concentration of the solvent to reactive metal ink ranges between 1:1 and 10:1,
• such that the dense film provides media resistivity less than 2 μΩcm with an optimized morphology with a porosity less than 60%.