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<p>Additive manufacturing of aluminum (Al) micro-conductor is highly sought after due to its cost-effectiveness and excellent electrical properties. However, sintering Al particles poses significant challenges. The low viscosity of molten Al, combined with high thermal conductivity, rapid oxidation, and poor inter-particle bonding, typically results in instantaneous melt drop and excessive thermal damage, making it difficult to use in additive manufacturing of microelectronics. To overcome these obstacles, this work proposes an intermittent laser selective sintering method that temporally controls the sintering process through pulsed laser irradiation. The progressive and intermittent sintering of Al microparticles significantly reduces the issues of viscosity drop, thermal diffusion, and oxidation. The resulting Al micro-conductors exhibit a high-resolution pattern of 12&#xa0;µm with good conductivity, surpassing conventional Al printing methods. The research validated the versatility of the ILSS process by fabricating flexible microheater and LED panels, successfully applying it to both glass and flexible substrates. </p>

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Intermittent Laser Selective Sintering of Aluminum Particles for Cost-Effective One-Step Manufacturing of Alternative Micro-Conductors

  • 期刊论文

  • 发表日期：

    2025年6月8日

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  • Seunghyun Back,
  • Huiae Park,
  • Bongchul Kang

摘要

Additive manufacturing of aluminum (Al) micro-conductor is highly sought after due to its cost-effectiveness and excellent electrical properties. However, sintering Al particles poses significant challenges. The low viscosity of molten Al, combined with high thermal conductivity, rapid oxidation, and poor inter-particle bonding, typically results in instantaneous melt drop and excessive thermal damage, making it difficult to use in additive manufacturing of microelectronics. To overcome these obstacles, this work proposes an intermittent laser selective sintering method that temporally controls the sintering process through pulsed laser irradiation. The progressive and intermittent sintering of Al microparticles significantly reduces the issues of viscosity drop, thermal diffusion, and oxidation. The resulting Al micro-conductors exhibit a high-resolution pattern of 12 µm with good conductivity, surpassing conventional Al printing methods. The research validated the versatility of the ILSS process by fabricating flexible microheater and LED panels, successfully applying it to both glass and flexible substrates.