A Review of Aerosol Printing With Emphasis on Shuttering Methods

Abstract

Aerosol printing (AP) has emerged as a versatile direct-write additive manufacturing technique capable of depositing fine-resolution features on planar and non-planar substrates. While widely adopted for applications ranging from electronic interconnects to sensors and 3D microstructures, its continuous jetting nature necessitates reliable shuttering mechanisms for discrete feature fabrication. This review highlights the evolution of shuttering strategies in AP, spanning mechanical external shutters, pneumatic shutters, internal rotary valve systems, and advanced internal pneumatic shutters. Each approach is examined with respect to its operating principle, advantages, and limitations. By critically analyzing prior work alongside recent advances, this review provides insights into the role of shuttering in overcoming process challenges and advancing the capability of AP for next-generation manufacturing.