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We report the design, fabrication, and characterization of the first 3D-printed, monolithic corona ionizer arrays (CIAs) in the literature. The CIAs are binder inkjet-printed in stainless steel 316L and have 5, 9, or 32 emitters (emitter pitch equal to 6 mm, 4 mm, or 2 mm, respectively); each emitter is 5 mm tall, with 1.7 mm diameter at the base and 300 μm diameter at the tip. Current-voltage data were collected in air with the emitter array biased negatively with respect to a counter-electrode for varying inter-electrode separation; the current divided by the bias voltage has a linear dependence with respect to the bias voltage minus the onset voltage –in agreement with the Townsend current-voltage law. 3D finite element simulation of the electrostatics of the densest CIA using the COMSOL Multiphysics evidences that the emitters at the periphery of the array have the highest electrical field, while a 1D electrohydrodynamic model implemented in the same software predicts a 400 μm-thick corona region surrounding the corona tip.

Miniature, 3D-Printed, Monolithic Arrays of Corona Ionizers