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Electrohydrodynamic (EHD) processes were used for direct writing of bead arrays with controllable bead sizes. Experiments were conducted to align layers of bead-on-string structures in an effort to create three-dimensional patterns. The results show that the jet focuses on previously deposited droplets allowing for the selective deposition of material over already deposited patterns. Jet attraction to already deposited solutions on the substrate is attributed to the charge transport at the liquid ink–metal collector interface and the dielectric properties of the water/poly(ethylene oxide) (PEO) solution under an electric field. The deposition process consists of three steps: (1) deposition of a layer of bead-on-string structures, (2) addition of extra volume to the beads by subsequent passes of the jet, and (3) evaporation of the solvent resulting in an array of beads with varying sizes. Patterns with up to 20 passes were experimentally obtained. The beads' height was seen to be independent of the number of passes. The process reported is a simple, fast, and low-cost method for deposition of bead arrays with varying diameters.

Deposition of Variable Bead Diameter Arrays by Self-Focusing Electrohydrodynamic Jets