Scholarlink

<p>Conventional screen printing is a versatile material deposition technique widely applied across fields ranging from textiles to biosensors and solar cells. However, the fixed mesh geometry in traditional screens often leads to inaccuracies when printing submillimeter features or non-rectangular patterns. Furthermore, conventional methods are constrained to flat substrates, limiting their broader applicability. To overcome these challenges, this study introduces adaptive screen printing, a novel approach in which screens are fabricated directly through 3D printing. Unlike traditional screen printing, where a separate stencil is placed on top of a mesh to define material deposition, adaptive screen printing integrates the stencil and mesh into a single 3D-printed component. This integration expands design flexibility and allows for fully customizable mesh geometries including triangular or spider-web patterns. These customizable mesh geometries showed improved resolution and fidelity when printing non-prismatic features. In addition, adaptive screen printing demonstrates successful deposition on curved substrates, such as cylindrical and dome-shaped surfaces, addressing a long-standing limitation of the conventional method. With enhanced design freedom and substrate compatibility, adaptive screen printing is expected to open new application opportunities and further extend the versatility of screen-printing technology.</p>

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Adaptive screen printing of conductive materials enabled by 3D-printed screens

  • 期刊论文

  • 发表日期：

    2026年1月11日

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  • Adam Kamal Hussain,
  • Maxwell Judson Kilbourne,
  • Emrah Celik

摘要

Conventional screen printing is a versatile material deposition technique widely applied across fields ranging from textiles to biosensors and solar cells. However, the fixed mesh geometry in traditional screens often leads to inaccuracies when printing submillimeter features or non-rectangular patterns. Furthermore, conventional methods are constrained to flat substrates, limiting their broader applicability. To overcome these challenges, this study introduces adaptive screen printing, a novel approach in which screens are fabricated directly through 3D printing. Unlike traditional screen printing, where a separate stencil is placed on top of a mesh to define material deposition, adaptive screen printing integrates the stencil and mesh into a single 3D-printed component. This integration expands design flexibility and allows for fully customizable mesh geometries including triangular or spider-web patterns. These customizable mesh geometries showed improved resolution and fidelity when printing non-prismatic features. In addition, adaptive screen printing demonstrates successful deposition on curved substrates, such as cylindrical and dome-shaped surfaces, addressing a long-standing limitation of the conventional method. With enhanced design freedom and substrate compatibility, adaptive screen printing is expected to open new application opportunities and further extend the versatility of screen-printing technology.