High-definition aerosol printing using an optimized aerosol distribution and aerodynamic lens system

An apparatus for printing discrete high-resolution high-density features on a surface using an aerosol stream, the apparatus comprising;

• an aerosol chamber adapted for a transport gas to enter through a port and entrain aerosol containing droplets in the aerosol chamber to form an aerosol-laden transport gas;
• a flow cell having a flow cell channel bounded by sheath gas ports in fluid communication with a source of a sheath gas, the sheath gas ports adapted to convey the sheath gas to the flow cell channel via sheath gas outlets connected to the sheath gas ports via sheath gas conduits bounding the flow cell channel and through which the aerosol-laden transport gas is passed, and the aerosol-laden transport gas is surrounded by sheath gas passed through the sheath gas conduits substantially parallel in flow direction to the flow cell channel;
• and
• an aerosol tube positioned within the flow cell channel at the sheath gas outlets, the aerosol tube having a first end at a first end of the flow cell channel and a second end below the sheath gas outlets, and the aerosol tube having one or more of an internal restrictor that reduces an internal diameter of the aerosol tube at least one point along a length of the aerosol tube;
• wherein the aerosol chamber is in direct communication with the flow cell via a slanted channel so that aerosol-laden transport gas is transported directly from the aerosol chamber to the aerosol tube through the slanted channel;
• wherein at least one aerodynamic lens is adapted to receive the aerosol-laden transport gas surrounded by sheath gas and print the aerosol droplets from the aerosol-laden transport gas onto the surface of a substrate.