Understanding Spray Coating Process: Visual Observation of Impingement of Multiple Droplets on a Substrate

Design and development of a coating device: Multiple-droplet drop-casting (MDDC-Alpha)

We report the development of a coating device (multiple-droplet drop-casting), which releases multiple droplets simultaneously or with a short time-lag (<10 ms) using a multi-channel syringe pump to achieve deposition of large-area (up to ∼100 cm²) and patterned coatings. The device exhibits the following features and characteristics: simple, low-cost, and scalable; adaptive to various solution-processed materials; insensitive to small contaminations/impurities; minimizes material waste; and can create patterns (printing). The demonstration of the device performance was carried out by fabricating coatings using four strategic model solutions, namely, carbon nanotube ink, graphene oxide ink, [poly(3,4-ethylenedioxythiophene):poly(styrene sulfonate)] PEDOT:PSS solution, and n-methyl-2-pyrrolidone diluted methylammonium lead iodide (CH₃NH₃PbI₃)-based light harvesting perovskite. We investigated the effect of release height (droplet velocity or Weber number) and the film area on the film characteristics. The results show that the device yields reproducible and uniform films on the order of micrometers in thickness and ∼1 μm in roughness.