Numerical analysis of electrohydrodynamic printing under electric field focusing mode

Abstract As an emerging micro/nanoscale 3D printing technology, Electrohydrodynamic (EHD) printing has undergone rapid development in recent years. However, in most EHD printing processes, voltage is directly applied to both the nozzle and the substrate, resulting in the electric field being influenced by the printing height. This poses challenges for printing three-dimensional curved surface structures. This study presents a comprehensive investigation into the EHD jetting process, utilizing a novel voltage loading method that separates electrodes from both the nozzle and the substrate. Through experimental setups and numerical simulations, this research was conducted to examine the effects of printing height, voltage, and electrode diameter on jetting behavior. The results show that compared to the traditional electrode form, the new voltage loading method will increase the electric field intensity of the liquid surface before ejection by 37.1% and is more conducive to the formation of Taylor cones. It can ensure that the printing fluctuation is less than 2.4% when the printing height varies between 1.5-2.5 times the nozzle diameter, which is more favorable for printing multi-layer structures. The threshold voltage for ejection is provided in this model. When the electrode is reduced, the efficiency of electric field utilization will be further improved, but the acceleration of the jet velocity will cause an increase in droplet size. The findings highlight the method's capability to maintain consistent droplet sizes and electric field intensities across varying conditions, thereby enhancing printing stability and efficiency. The study's innovations provide valuable insights for advancing micro/nano 3D printing technologies, emphasizing the potential for improved EHD printing processes in practical engineering applications.