In-process orientation of particles in a direct-write ink to control electrical characteristics of an electrical component being fabricated

A system for in-process orientation of particles used in direct-write inks for fabricating an electrical component, the system comprising:

• a holding chamber for retaining an aerosol, wherein the aerosol includes direct-write particles;
• a structure to generate an electric field in the holding chamber to cause electrostatic induction of the aerosol to polarize the direct-write particles in the aerosol;
• an exit nozzle to direct the aerosol including the polarized direct-write particles on a substrate to form an electrical component;
• and
• another structure to generate another electric field, wherein the aerosol including the polarized direct-write particles is directed through the other electric field toward the substrate and wherein the other electric field causes the polarized direct-write particles to be aligned in a selected orientation to form the electrical component with predetermined electrical characteristics when deposited on the substrate.

A method to make an electrical component, comprising:

• providing a substrate;
• producing an aerosol comprising a plurality of direct-write particles;
• placing the aerosol comprising the plurality of direct-write particles in a first electric field to cause electrostatic induction of the aerosol to polarize the direct-write particles in the aerosol;
• directing the aerosol comprising the polarized direct-write particles in a deposition column on a substrate to form an electrical component;
• and
• directing the deposition column through a second electric field to align the polarized direct-write particles in a selected orientation to form the electrical component with a predetermined electrical characteristic.