Planar laser imaging and modeling of matrix-assisted pulsed-laser evaporation direct write in the bubble regime

A combination of planar laser imaging and theoretical modeling has been used to examine matrix-assisted pulsed-laser evaporation direct write MAPLE-DW in the bubble regime. MAPLE-DW is a method for patterning substrates via laser-initiated forward transfer of an organic fluid containing metallic particles and coated on a transparent support. For our conditions, best deposition of a silver-based, thick-film ink was found to occur when laser-initiated vaporization forces the ink outward as a bubble. Planar laser imaging was used to monitor bubble growth as a function of time for three different ink films with nominal thicknesses of 12, 25, and 50 m and two laser beam diameters of 30 and 60 m. From these measurements, correlations were developed for predicting the maximum height and velocity of bubbles via three known process variables: laser energy, ink thickness, and beam diameter. Further insight on the physics of the MAPLE-DW process was obtained by developing a theoretical model for bubble growth based on a simple force balance associating vapor-pocket pressure and viscous forces. Primary parameters specifying the subsequent differential equation were related to the above process variables. Numerical solutions to the differential equation were used to predict successfully bubble growth versus time for the conditions analyzed in the imaging experiments. © 2006 American Institute of Physics. DOI: 10.1063/1.2234542