Additive manufacturing of improved thermo-mechanical composite material

A method of fabricating a reinforced three dimensional (3D) dielectric section of an additively manufactured electronics (AME) using inkjet printing, the method comprising:

• a. providing an ink jet printing system comprising:
• i. a first print head, operable to dispense a first dielectric ink composition;
• ii. a second print head, operable to dispense a second dielectric ink composition comprising organically modified, silicate-based ceramic (ORMODS) co-monomers, having a ceramic constituent, wherein the second dielectric ink composition has a different thermo-mechanical characteristic parameter than the first dielectric ink composition;
• iii. a conveyor, coupled to the first, and the second print heads operable to convey a substrate to each of the first, and the second print heads;
• and
• iv. a computer aided manufacturing (“CAM”) module including a central processing module (CPM), in communication with at least the conveyor and each of the first, and second print heads, the CPM further comprising at least one processor in communication with a non-transitory processor-readable storage medium storing thereon a set of executable instructions that, when executed by the at least one processor cause the CPM to control the ink-jet printing system, by carrying out steps that comprise:
• I. receiving a 3D visualization file representing the AME;
• and
• II. generating a file library comprising a plurality of files, each file representing a substantially 2D layer for printing the reinforced three dimensional (3D) dielectric section of the AME, and a metafile representing at least the printing order;
• b. providing the first dielectric ink composition, and the second dielectric ink composition;
• c. using the CAM module, obtaining from the library a first file representative of the first layer for printing the reinforced three dimensional (3D) dielectric section of the AME, wherein the first file comprises printing instructions for a pattern corresponding to the first dielectric ink, and printing instruction for a pattern corresponding to the second dielectric ink;
• d. using the first print head, forming the pattern corresponding to the first dielectric ink;
• e. curing the pattern corresponding to the first dielectric ink representation in the first layer;
• f. using the second print head, forming the pattern corresponding to the second dielectric ink;
• g. curing the pattern corresponding to the second dielectric ink representation in the first layer;
• h. using the CAM module, obtaining from the library, a subsequent file representative of a subsequent layer for printing the reinforced three dimensional (3D) dielectric section of the AME, the subsequent file comprising printing instructions for a pattern corresponding to the first dielectric ink, and printing instructions for a pattern corresponding to the second dielectric ink, in each subsequent layer;
• i. repeating the steps of:
• using the first print head, forming the pattern corresponding to the first dielectric ink, to the step of using the CAM module, obtaining from the 2D file library the subsequent, substantially 2D layer, whereupon curing of the pattern corresponding to the second ink composition in the final layer, the reinforced three dimensional (3D) dielectric section of the AME comprises at least one of:
• an array of a plurality of reinforced forms of the second dielectric ink composition within a continuous matrix of the first dielectric ink composition, and alternating layers of the first dielectric ink compositions and the second dielectric ink composition;
• and
• j. removing the substrate.