Method and apparatus for fine feature spray deposition

A system for fine feature spray deposition comprising:

• a substrate platform for supporting a substrate;
• spray assembly comprising:
• a spray source for providing a stream of material to be deposited on a substrate;
• a collimator, said collimator being positioned in a path of the stream from said spray source;
• and
• a dynamic aperture assembly, said dynamic aperture assembly being positioned downstream of said collimator with respect to said spray source and above said substrate platform, the dynamic aperture assembly defining at least one opening therein to pass at least a portion of the stream of material onto a surface of the substrate;
• a drive mechanism, the drive mechanism being operatively coupled to at least one of the spray assembly and the substrate platform for inducing relative motion there between;
• and
• a controller, the controller being operably coupled to said spray assembly and said drive mechanism to control said relative motion and said stream of material.

A method for depositing a fine feature on a substrate using spray deposition comprising:

• generating a stream of material from a spray source;
• passing a portion of the stream through a collimator spaced from the spray source;
• passing the portion of the stream through an opening in a dynamic aperture member spaced from the collimator and supported above the surface of the substrate;
• moving one of the substrate or dynamic aperture member while generating the stream of material from the spray source to define the feature on the surface of the substrate.

A method for directly printing a multilayer electrical component on a substrate comprising:

• generating a stream of conductive material from a spray source;
• passing a portion of the stream through a collimator spaced from the spray source;
• passing the portion of the stream through an opening in a dynamic aperture member spaced from the collimator and supported above the surface of the substrate;
• moving one of the substrate or dynamic aperture member to define a first conductive feature on the surface of the substrate;
• generating a stream of an insulative material from a second spray source;
• passing a portion of the stream through a collimator spaced from the second spray source;
• passing the portion of the stream through an opening in a dynamic aperture member spaced from the collimator and supported above the surface of the substrate;
• and
• moving one of the substrate or dynamic aperture member to define an insulative feature on the surface of the substrate at least partially covering the first conductive feature.