A laboratory-scale inkjet printing system was designed for printing polymeric inks with the focus on PEDOT:PSS, a transparent, electrically conductive polymer. PEDOT:PSS inks with 0 and 1 wt. % Surfynol were tested rheologically in elongational and shear flows. A process model is presented and validated for the prediction of flow boundary after the ink exits the nozzle, including drop formation. Process optimization involved establishing a process window related to the voltage waveform, substrate temperature, speed and printed line-overlap, aiming at avoiding satellite drops, “coffee cup” rings, the Rayleigh instability, “stacked printed lines,” and discontinuities in the printed lines or films.

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