Composite manufacturing technology and application of large-scale and wide-band electromagnetic shielding glass based on electric-field-driven fused deposition micro 3D printing

To address the challenges in achieving high shielding effectiveness and low-cost fabrication of large-area, broadband transparent electromagnetic shielding glass, a broadband transparent shielding structure based on a copper@nickel@iron@nickel heterogeneous multi-layer core–shell grid was designed. A novel large-area composite fabrication process was proposed, integrating height-compensated electric-field-driven fused deposition micro 3D printing, wet etching, and precision electroplating. A series of studies were conducted to reveal the influence of key process parameters on the grid structure. Using a large-sized (650 mm×650 mm×5 mm) uneven glass substrate (height difference of 160 μm)as the substrate, laser rangefinder ranging scanning was employed to compensate for surface irregularities, ensuring consistent printing height (with a maximum printing height up to 0.9 mm). As a result, large-area transparent electromagnetic shielding glass was successfully fabricated (currently the largest size reported), featuring a line width standard deviation of 0.45 μm, sheet resistance fluctuation within ±0.25 Ω/sq, visible light transmittance of 80.4%, and broadband shielding effectiveness ranging from 26.2 to 57 dB over 1 MHz to 10 GHz. This method provides a novel solution for the high-performance, low-cost manufacturing of large-area broadband transparent electromagnetic shielding glass.