Multiphysics Analysis and Verification of Jet Flight in Electrohydrodynamic Printing for Near-Field Electrospinning Applications

Electrohydrodynamic (EHD) printing is a versatile process that can be used to pattern high-resolution droplets and fibers through the deposition of an electrified jet. This highly complex process utilizes a coupled hydrodynamic and electrostatic mechanism to drive the fluid flow. While it has many biomedical, electronic, and filtration applications, its widescale usage is hampered by a lack of detailed understanding of the jetting physics that enables this process. In this paper, a numerical model is developed and validated to explore the design space of the EHD jetting process, from Taylor cone formation to jet impingement onto the substrate, and analyze the key geometrical and process parameters that yield high-resolution structures. This numerical model applies to various process parameters, material properties, and environmental factors and can accurately capture jet evolution, radius, and flight time. It can be used to better inform design decisions when using EHD processes with distinct resolution requirements.