Deposition of Microscale Coatings by Self-Limiting Electrospray

a. Overview of thickness-limited electrospray deposition (ESD). Electrostatically-driven spray creates a charged film which redirects charged incident droplets. b. and c. SEM images of spray results, illustrating the wide range of morphologies and particle size which can be obtained with this method(b: nanowires, c: hollow spheres).

Invention Summary:

Researchers at Rutgers University have developed a scalable, cost-effective method for depositing microscale coatings of a wide variety of materials and composites compatible with complex additive manufactured or micromachined structures.

The newly-developed method utilizes a self-limiting spray which, once deposited on the surface of a target material, generates a charged film that repels incident spray and redirects it to uncoated portions of the target material. Deposition of functional coatings often results in unused and ultimately wasted material; when coatings incorporate advanced materials this waste may incur a significant cost. The self-limiting property of the electrospray results in thickness-limited coatings with unprecedented uniformity while minimizing waste material. Further, this method can be performed in ambient conditions without requiring a vacuum or bath immersion.

Market Applications:

- Deposition of functional microscale coatings, barriers, and thin films utilizing advanced and/or nanomaterials

- Repair of microscale defects without necessitating coating reapplication



- Cost-effective; reduces material waste

- Adaptable for use with a range of coating materials

- Scalable, compatible with ambient processing

- Generates a thickness-limited and highly uniform coating

- Compatible with complex 3D structures


Intellectual Property & Development Status:

Patent pending. Available for licensing and/or research collaboration.

Related Research Articles:

Patent Information:
For Information, Contact:
Shu Wang
Licensing Manager
Rutgers University
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