Direct ink writing (DIW) is an additive manufacturing technology that has been widely used in many fields, including soft electronics, ceramic structures, and flexible biomedical applications. In DIW process, writing a trace with desired geometry is of fundamental importance to fabricate a three-dimensional model. In this article, a normalized geometry modeling method with bulge-free analysis for process planning in DIW is presented. The geometry prediction model is developed by converting conventional dispensing parameters to a dimensionless variable, speed ratio v*. The developed model is independent of tip gauge and feeding mechanism. To address the common bulge issue in DIW of low-viscosity fluids, the critical bulge-free printing range has been identified by characterizing the bulge formation process. The developed geometry prediction model and the identified bulge-free printing range are validated by experimental data of several different tips and inks. Finally, a DIW process planning method based on the developed geometry prediction model is demonstrated.
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