Composite ultrasonic material applicators with individually addressable micro-applicators and methods of use thereof

A material applicator for controlling application of at least one material on a substrate, the material applicator comprising:

• a housing attached to a robotic arm configured to move the housing across a surface;
• and
• an array plate with an applicator array positioned within the housing, the applicator array comprising a plurality of micro-applicators, each of the plurality of micro-applicators comprising an ultrasonic transducer, a material inlet, a reservoir, and a micro-applicator plate with a plurality of apertures, wherein the micro-applicator plate is in mechanical communication with the ultrasonic transducer such that at least one material is ejected in an election direction through the plurality of apertures as atomized droplets when the ultrasonic transducer vibrates the micro-applicator plate,
• wherein the plurality of micro-applicators comprises a first subset of micro-applicators and a second subset of micro-applicators, wherein the micro-applicator plates of the first subset of micro-applicators are arranged on a first plane that is perpendicular to the ejection direction and the micro-applicator plates of the second subset of micro-applicators are arranged on a second plane parallel to and offset in the ejection direction from the first plane.

A material applicator for controlling application of at least one material on a substrate, the material applicator comprising:

• a housing;
• and
• an array plate with an applicator array positioned within the housing, the applicator array comprising a plurality of micro-applicators, each of the plurality of micro-applicators comprising an ultrasonic transducer, a material inlet, a reservoir, and a micro-applicator plate with a plurality of apertures, wherein the micro-applicator plate is in mechanical communication with the ultrasonic transducer such that at least one material is ejected through the plurality of apertures as atomized droplets when the ultrasonic transducer vibrates the micro-applicator plate,
• wherein the plurality of micro-applicators comprises a first subset of micro-applicators and a second subset of micro-applicators, wherein the micro-applicator plates of the first subset of micro-applicators are arranged on a first plane to elect the at least one material in a first ejection direction perpendicular to the first plane and the micro-applicator plates of the second subset of micro-applicators are arranged on a second plane non-parallel to the first plane to eject the at least one material in a second election direction that is perpendicular to the second plane.