Laser Sintering of Aerosol Jet Printed Hexagonal Boron Nitride Coatings
Faculty Mentor Information
Dr. Brian Jaques, Boise State University; Dr. Joshua Eixenberger, Boise State University; and Dr. Dave Estrada, Boise State University
Presentation Date
7-16-2026
Abstract
Additively manufactured electronics (AME) have garnered significant attention over the last decade due to the capability to produce lightweight, flexible, and conformal electronic devices. For next-generation extreme-environment applications, these devices require protective coatings capable of withstanding extreme temperatures, radiation exposure, and chemically harsh conditions while maintaining reliable performance. Hexagonal boron nitride (h-BN) is a promising coating material due to its high thermal stability, electrical insulation, and chemical inertness. Producing high-quality h-BN coatings requires developing printable ink for aerosol jet printing (AJP), optimizing AJP parameters, and sintering the printed films into dense coatings. However, the intrinsic layered structure of h-BN makes printed coatings difficult to densify. This work investigates the development of printable h-BN inks and evaluates laser sintering as a rapid processing technique for consolidating printed films. Optical microscopy, scanning electron microscopy, and optical profilometry were used to assess coating morphology, microstructure, densification, and surface quality. Evidence of film consolidation was observed after multiple passes were lased below the focal plane, indicating the feasibility of laser sintering for AJP h-BN coatings. These results provide insight into the processing-structure relationships governing laser-sintered AJP h-BN coatings and establish a foundation for the development of robust ceramic coatings for extreme-environment electronic applications.
Laser Sintering of Aerosol Jet Printed Hexagonal Boron Nitride Coatings
Additively manufactured electronics (AME) have garnered significant attention over the last decade due to the capability to produce lightweight, flexible, and conformal electronic devices. For next-generation extreme-environment applications, these devices require protective coatings capable of withstanding extreme temperatures, radiation exposure, and chemically harsh conditions while maintaining reliable performance. Hexagonal boron nitride (h-BN) is a promising coating material due to its high thermal stability, electrical insulation, and chemical inertness. Producing high-quality h-BN coatings requires developing printable ink for aerosol jet printing (AJP), optimizing AJP parameters, and sintering the printed films into dense coatings. However, the intrinsic layered structure of h-BN makes printed coatings difficult to densify. This work investigates the development of printable h-BN inks and evaluates laser sintering as a rapid processing technique for consolidating printed films. Optical microscopy, scanning electron microscopy, and optical profilometry were used to assess coating morphology, microstructure, densification, and surface quality. Evidence of film consolidation was observed after multiple passes were lased below the focal plane, indicating the feasibility of laser sintering for AJP h-BN coatings. These results provide insight into the processing-structure relationships governing laser-sintered AJP h-BN coatings and establish a foundation for the development of robust ceramic coatings for extreme-environment electronic applications.