Millimeter-wave electromagnetic monitoring for liquid metal droplet-on-demand printing

As new printing approaches emerge, in situ diagnostics to monitor the print quality in real-time become essential for long-term monitoring and feedback control. In this article, we present a millimeter-wave electromagnetic monitoring approach for liquid metal droplet-on-demand printing to support the high-speed and real-time evaluation of droplet ejection. An open-ended rectangular waveguide is placed perpendicular to a jetted droplet stream and operated at a continuous-wave frequency of 40 GHz. Liquid metal droplets with diameters as low as 1.2 mm are characterized, and droplet jetting events on the order of 500  μm are detected at ejection rates up to 80 Hz. The measured results demonstrate that trends at the macro-level (large-scale print variation and anomalies at the nozzle tip) as well as micro-level (droplet size, position, and dynamics) can be detected using this technique.