Digital Twins for Printed Electronics for 3D Packaging, High-performance Sensors, and High-capacity Batteries

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-- printed electronics, feedback, twins, process control, applications ...

Printed electronics has emerged as a versatile technique for on-demand fabrication of passives, interconnects, and active devices. Our group has recently extended this technique to create freeform devices in Three-Dimensional space that have opened exciting application areas for this technology. The manufacturing process for printed electronics, however, can suffer from process drifts and does not have an active feedback loop to fix errors. In this research, we develop a digital twin for aerosol jet 3D printing, a jetting-based method to create printed electronics to address this concern. This work, done in collaboration with an ECE faculty at CMU, matches observations with outcomes expected from a physics-based process model, and continuously updates the hidden variables to minimize this error via probabilistic estimation techniques.
We then use the aerosol jet 3D printing to demonstrate devices with extraordinary performances that cannot be achieved by any other method. Specifically, we show 3D electrodes by this technique that enable detection of pathogens and breast cancer biomarkers in 10-12 seconds at femtomolar levels (fastest detection yet reported). We also show fully customizable brain-computer interfaces (BCIs) that record electrical signals between neurons at densities of thousands of electrodes/cm2, which is 5-10× the current state-of-the-art technologies. We also demonstrated the printing of high-capacity Li-ion batteries and thin flexible robotic skins with embedded sensors.


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  • Date: 18 Sep 2025
  • Time: 07:00 PM UTC to 08:00 PM UTC
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  • Starts 14 April 2025 07:00 AM UTC
  • Ends 18 September 2025 08:00 PM UTC
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  Speakers

Rahul Panat of Carnegie Mellon University

Biography:

Prof. Rahul Panat is Professor of Mechanical Engineering at Carnegie Mellon University (CMU). He is courtesy faculty in the Materials Science and Engineering and the Robotics Institute at CMU. He is also the Associate Director of Research at the Manufacturing Futures Institute at CMU, which is focused on bringing the latest advances in digital technologies to advanced manufacturing.
Prof. Panat completed his PhD in Theoretical and Applied Mechanics from the University of Illinois at Urbana in 2004. He joined Intel Corporation’s packaging R&D unit in Chandler, AZ, where he worked for 10 years on microprocessor materials and manufacturing R&D - specifically on 3D heterogeneous integration. At Intel, Dr. Panat led a team of engineers that developed the fabrication process for world’s first halogen-free IC chip. He returned to academia in 2014 and joined CMU in fall 2017. His research is focused on microscale 3D printing and its applications to biomedical engineering, stretchable electronics, and Li-ion batteries. He has obtained > $7.5 million in research funding from US Intelligence agencies, US Air Force, US Army, ARPA-H, National Institutes of Health (NIH), Department of Energy (DOE), National Science Foundation (NSF), and industry. Prof. Panat is recipient of several awards, including MRS gold medal, Mavis Memorial Award, an award at Intel for his work on the halogen-free chip, Struminger Teaching Fellowship, and the Russell V. Trader chair professorship at CMU.

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