Frequency limit analysis of drop-on-demand electrohydrodynamic printing with variable meniscus shapes and ink characteristics

• A combined theoretical and experimental approach is used to systematically analyze the frequency limits of drop-on-demand electrohydrodynamic jetting. • The relationship between the characteristic frequency of the meniscus and limiting frequency of drop-on-demand EHD jetting is revealed. • The range of ink parameters suitable for high-frequency drop-on-demand jetting is given. • High-frequency drop-on-demand jetting of ethanol ink at 28 kHz is realized. • This paper provides a theoretical guidance for the design of high-frequency drop-on-demand EHD jetting system. Electrohydrodynamic (EHD) drop-on-demand (DOD) printing has great potential in bioelectronic manufacturing and additive manufacturing due to its high resolution and wide ink compatibility. EHD DOD printing over a certain frequency may appear uneven printing, missing or nonuniform droplets, but the current research on the limiting frequency is unclear, which greatly limits the efficiency and accuracy of printing. This paper aims to systematically study the influence of meniscus shapes and ink characteristics on printing. The numerical model of gas–liquid interface deformation under electric field was established based on the moving grid method, and the motion response of meniscus under different pulse voltage intervals was analyzed to establish the intrinsic connection between the characteristic frequency of meniscus and the limiting stable printing frequency. The effects of meniscus shape parameters and ink characteristics (including viscosity, surface tension and conductivity) on the limiting frequency were systematically investigated through simulation and experimental design. Finally, the optimized design of ink characteristic/meniscus shapes parameters applicable to high-frequency printing was proposed. EHD DOD printing of meniscus shapes ( f ∼ d N -1.5 and f ∼ θ a -2 , where d N and θ a are the meniscus diameter and central angle) and ink characteristics ( Oh 1) were carried out, high-frequency EHD printing at 28 kHz was realized. This paper provides a theoretical basis for the high-frequency EHD printing system design and promotes its application in bioelectronic manufacturing and additive manufacturing.