South Carolina Patent of the Month – November 2025
A major advancement in precision manufacturing technology promises to deliver ultra-fine, high-density features on surfaces, enabling next-generation electronics and sensors. The innovation is detailed in U.S. Patent No. 12458925, titled ‘Membrane devices for filtration and extraction’ (the title on the patent link), but the claims clearly describe a novel aerosol jet printing system. This apparatus, developed by DPX Technologies LLC, refines how materials are deposited with extreme accuracy.
Enhanced Aerosol Printing Accuracy
The core innovation lies in its precise control over the ink aerosol. The system uses an aerosol chamber that generates aerosol-laden transport gas containing ink droplets. This gas moves through a slanted channel, ensuring a direct path to a flow cell.
Inside the flow cell, the aerosol-laden gas gets surrounded by a sheath gas. The sheath gas flows parallel to the aerosol, acting like a precision shroud. This fluid dynamic focusing sharply narrows the aerosol stream. It greatly reduces turbulence. The result is a highly focused beam of ink droplets.
Key Components and Real-World Impact
The apparatus includes an aerosol tube positioned at the sheath gas outlets. This tube guides the flow toward the crucial component: at least one aerodynamic lens. The lens system receives the focused stream. It precisely prints the aerosol droplets onto a substrate surface. The system is engineered to handle tiny aerosol droplets. Their mean diameter can range from $0.5$ to $8$ microns. This level of precision allows for the reliable printing of extremely fine and complex circuits. Optional features like a temperature-controlled platen and a solvent reservoir further enhance control. This technology is critical for advanced applications. It accelerates R&D and manufacturing for microelectronics, printed sensors, and flexible displays.
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The Research & Experimentation Tax Credit (or R&D Tax Credit), is a general business tax credit under Internal Revenue Code section 41 for companies that incur research and development (R&D) costs in the United States. The credits are a tax incentive for performing qualified research in the United States, resulting in a credit to a tax return. For the first three years of R&D claims, 6% of the total qualified research expenses (QRE) form the gross credit. In the 4th year of claims and beyond, a base amount is calculated, and an adjusted expense line is multiplied times 14%. Click here to learn more.
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