Applications and prospects of machine learning for aerosol jet printing: A review

Aerosol Jet Printing (AJP) is an additive manufacturing process that deposits ink-like materials suspended as an aerosol mist. AJP creates three-dimensional (3D) functional structures onto flat or conformal surfaces in complex shapes without the aid of additional tooling, enabling the manufacturing of extremely fine electrical interconnects with freeform structures. Due to the novelty and complexity of AJP, physical understanding is rather limited, hindering physics-based process modeling and analysis. Fortunately, the data resources from AJP applications, e.g., 3D Computer-Aided-Design data, Standard Triangle Language files, in-situ images of part, and nozzle motion records, provide an unparalleled opportunity for developing data-driven, Machine Learning (ML) methods to characterize AJP processes, support process control, and facilitate product improvement. To thoroughly identify the newfound opportunities, this study reviews state-of-the-art ML methods used in AJP applications, investigates open issues in AJP, and outlooks future development of ML-based research topics for AJP. It sheds light on how to maximize the value of ML on AJP data to develop scalable, generalizable decision-making methods. More future works along the direction will be motivated.