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Sensors 2020, 20, 6087 4 of 13 2.2. Inkjet Fabrication Protocol Inkjet printing is an additive manufacturing technique that utilizes commercially available products when compared with MEMS microfabrication techniques necessitating a cleanroom. However, inkjet printing was not selected as the first choice for the cochlear arrays. While inkjet printing is suitable for flexible surfaces such as paper and polymers, the technique is limited in two ways for the cochlear application. First, feature sizes are limited to hundreds of microns. Second, traditional cochlear implant arrays are tailored upon a silicone substrate that has been optimized over decades for atraumatic, and appropriately positioned insertion. Thus, larger-scale inkjet-printed coils were used to validate the simulation generated using FEM in COMSOL software, as described in the previous section. The Epson Stylus C88+ Inkjet Printer (Epson America, Inc., Long Beach, CA, USA), was used to print upon a polymeric substrate of Novele IJ-200 PET-based (NovaCentrix, Austin, TX, USA). A silver ink comprised of the Metalon JS-B25P nano-silver ink by NovaCentrix with a 75 nm diameter particle size, produced the conductive traces, creating the microcoils. The printer was prepared using NovaCentrix protocol to fully utilize conductive silver ink, rather than the intended commercial printer ink. A basic coil pattern is designed and saved as a .png or .dwg file. The coil has a 0.81 μm thickness and was allowed a 24 h resting period at 25 ◦C prior to any handling for best trace continuity and substrate adhesion. 2.3. FEM-Injet Coil Testing Radiation pattern comparison between the FEM model and the fabricated coils was performed to validate functionality of the fabricated coils and provide insight on radiation patterns generated from miniaturized coils. Two fabricated coils were positioned 20 cm apart, one acting as the transmitter while the other acts as the receiver, while one coil, provided a 500 mVPP, 1.6 GHz sinusoidal input voltage, was rotated at 10 degree increments as radiated field intensities were captured from the stationary receiver coil. The testing environment described in previous experimentation [16] was performed on an acrylonitrile-butadiene-styrene (ABS)-based support structure within a Faraday cage to prevent interference. Miniaturization via AJP was initiated once validation of the coils was demonstrated from this experimentation. 2.4. Aerosol Jet Printing Protocol As mentioned in the introduction, AJP is an additive manufacturing technique capable of printing on planar and non-planar substrates. The Optomec Aerosol Jet 200 Series System (ANIWAA, Singapore), including the control software, KEWA, and a vial of UTDOTS AgX40 silver nanoparticles (UTDOTS, Champaign, IL, USA) were used in the creation of the coils. A process flow diagram was designed to determine the print order of the AutoCAD coil layers which include the coil, interface pads, and an insulation bridge, all shown in Figure 3. The coil and interface pads were created via program file loaded onto the Optomec Aerosol Jet 200. The silver nanoparticle vial is exposed to an ultrasonic atomizer (UA) set to 30 ◦C. The attached platen heater is set to 80 ◦C. A glass slide is cleaned with isopropyl alcohol and is blow dried with nitrogen gas. After cleaning, the glass slide is secured to the platen heater. Blue painter’s tape was used to fasten the glass to the platen heater. Additional assembly is necessary to construct the nozzle with a specific tip size. A 150 μm nozzle tip is used to create the 1800 μm coils, shown in Figure 6. The sheath gas rate was set to 24 CCM and the UA gas rate is set to 12 CCM. After the printer has been prepared, the AutoCAD file, converted into a .prg program file via VMTOOLS extension, is loaded to the control software, KEWA. Fiducials are manually entered into the program file to dictate boundaries of the printing area. Process speed and rapid speed can be selected; 0.2 mm/s and 20 mm/s are used, respectively. Once the system is positioned to the origin/home location, the program file is initiated. As thePDF Image | Silver-Nanoparticle Microcoil via Aerosol Jet Printing
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