Printing Electronic Parts for Next-Generation Technologies at Argonne

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Tiny electronic devices, called microelectronics, may one day be printed as easily as words on a page, thanks to new research from scientists at the U.S. Department of Energy’s (DOE) Argonne National Laboratory. Building on years of progress in printed electronics, the team has shown how to create durable, low-power electronic switches, called transistors, by combining custom inks and a specialized printing process. These switches, which control the flow of electrical current to turn circuits on and off, use very little power, are built to last and show new behaviors not seen in earlier printed devices. This research could help create flexible sensors, smart windows and other new technologies that need reliable, energy-saving electronics.

The scientists used a method called aerosol jet printing, which works like an inkjet printer. But instead of regular ink, it uses specially formulated ink made from nanoparticles. The printer turns the ink into a fine mist and sprays it onto a surface, building up layers to form electronic parts.

A key ingredient in these printed devices is vanadium dioxide. This material is special because it can act like a wire, letting electricity flow, or like an insulator, blocking electricity. This switching ability is important for making electronic circuits and memory devices, which store and process information.

To control the flow of electricity in the transistors, the team used a process called redox gating. In simple terms, this means they use a chemical reaction to add or remove electrons from the vanadium dioxide. By applying a small voltage — less than what is used in a typical battery — they can turn the transistor on or off. This method is less harsh than other techniques, which could damage the material and make devices wear out quickly.

“We chose printing methods for two main reasons,” said Argonne Materials Scientist Yuepeng Zhang. “First, printing enables rapid prototyping and iterative design, which helps us optimize materials and device structures quickly. Second, printed electronics have benefits for device functionality, especially since our devices show a well-modulated current response to voltage, making them suitable for printed logic devices and niche applications.”

Wei Chen, a chemist from Argonne and the University of Chicago, emphasized the durability of the new devices. “Redox gating is robust and does not damage the materials, so we can run thousands of cycles without issues,” he said. “In previous methods, devices could only run a few times — sometimes just 10 cycles — before failing. Our devices can run thousands of cycles with no problem.”