<p>Electric field-assisted droplet deposition presents a promising strategy for overcoming inherent challenges in engineering manufacturing and demonstrates potential for high-quality, sustainable manufacturing. This article provides a systematic review of the physical principles and engineering applications of this technology. First, it comprehensively elaborates on two typical charging modes—induction and polarization—as well as their coupled mechanisms, highlighting how droplet deposition dynamics can be finely tuned through the regulation of charge distribution, electrical stress, and effective surface tension. Next, the article analyzes the stage-wise control of droplet behavior by electric fields: during initial contact, electrical stress pierces the air film to suppress air entrainment and achieve central touchdown; during spreading, charge accumulation enhances wetting and suppresses splashing; during retraction, enhanced viscous dissipation in induction charging droplets inhibits bouncing and jetting. The technology has been applied in key industrial processes such as droplet-based 3D printing, spraying, and cutting lubrication, enabling the elimination of pore defects, high-precision printing on non-planar surfaces, simulation of microgravity droplet deposition, improved transfer efficiency and reduced overspray in spraying, and enhanced lubrication and cooling in machining—thereby increasing material utilization, reducing energy consumption, and minimizing waste, which reflects its advantages in sustainable, low-energy manufacturing.</p>

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Droplet Deposition Behaviors in Electric Fields: From Foundations to Engineering Manufacturing

  • Hao Yi,
  • Jiayi Xiong,
  • Zenan Niu,
  • Le Cao,
  • Huajun Cao

摘要

Electric field-assisted droplet deposition presents a promising strategy for overcoming inherent challenges in engineering manufacturing and demonstrates potential for high-quality, sustainable manufacturing. This article provides a systematic review of the physical principles and engineering applications of this technology. First, it comprehensively elaborates on two typical charging modes—induction and polarization—as well as their coupled mechanisms, highlighting how droplet deposition dynamics can be finely tuned through the regulation of charge distribution, electrical stress, and effective surface tension. Next, the article analyzes the stage-wise control of droplet behavior by electric fields: during initial contact, electrical stress pierces the air film to suppress air entrainment and achieve central touchdown; during spreading, charge accumulation enhances wetting and suppresses splashing; during retraction, enhanced viscous dissipation in induction charging droplets inhibits bouncing and jetting. The technology has been applied in key industrial processes such as droplet-based 3D printing, spraying, and cutting lubrication, enabling the elimination of pore defects, high-precision printing on non-planar surfaces, simulation of microgravity droplet deposition, improved transfer efficiency and reduced overspray in spraying, and enhanced lubrication and cooling in machining—thereby increasing material utilization, reducing energy consumption, and minimizing waste, which reflects its advantages in sustainable, low-energy manufacturing.