Abstract
Aerosol Jet Printing (AJP) is an emerging non-contact, high-resolution additive manufacturing technique that holds great promise for addressing diverse and complex manufacturing demands. However, inherent trade-offs persist among its core capabilities-flexibility, resolution, and throughput-while further progress is hindered by insufficient collaboration between ink formulation and process optimization. This review provides a comprehensive synthesis of recent progress in both AJP-compatible material innovations and critical process advancements. From a global perspective, we systematically explore material-process integrated innovation pathways aimed at achieving synergistic improvements in performance. In addition, representative applications of AJP are summarized across domains such as printed electronics, flexible sensors, energy storage and harvesting devices, and bioelectronics. Looking ahead, AJP is expected to spearhead the next-generation of advanced manufacturing technologies, playing a pivotal role in the convergence of flexible and intelligent production systems.