Hydrostatic optimization of inkjet-printed films

In this work, we study the optimization of the geometry of inkjet-printed polymer films and develop a simple analytic framework to understand our results and establish limitations on inkjet-printed patterns. We show how drop spacing and ink concentration affect the thickness of a printed film and how hydrostatic conditions with contact angle hysteresis have to be considered to print optimized rectangular features. If advancing and receding contact angle are not taken into account, printed features will either bulge or break up into smaller beads. Thus, we provide a comprehensive analysis of the limits of film formation using regular assemblies of droplets.