Aerosol jet printing polymer dispersed liquid crystals on highly curved optical surfaces and edges.

We demonstrate a new technique for producing Polymer Dispersed Liquid Crystal (PDLC) devices utilising aerosol jet printing (AJP). PDLCs require two substrates to act as scaffold for the Indium Tin Oxide electrodes, which restricts the device geometries. Our approach precludes the requirement for the second substrate by printing the electrode directly onto the surface of the PDLC, which is also printed. The process has the potential to be precursory to the implementation of non-contact printing techniques for a variety of liquid crystal-based devices on non-planar substrates. We report the demonstration of direct deposition of PDLC films onto non-planar optical surfaces, including a functional device printed over the 90° edge of a prism. Scanning Electron Microscopy is used to inspect surface features of the polymer electrodes and the liquid crystal domains in the host polymer. The minimum relaxation time of the PDLC was measured at 1.3 ms with an 800 Hz, 90 V, peak-to-peak (Vpp) applied AC field. Cross-polarised transmission is reduced by up to a factor of 3.9. A transparent/scattering contrast ratio of 1.4 is reported between 0 and 140 V at 100 Hz.