As nano-sized silver particles are prohibitively expensive, lower cost materials (e.g., micro-sized aluminum) are sought for the manufacture of conducting electrodes. Inks containing various aluminum weight percentages are dot-printed onto a stainless-steel substrate with an electrohydrodynamic (EHD) inkjet, which is superior to thermal and piezoelectric inkjets for inks containing larger particles because it ejects drops smaller than the nozzle diameter. Various ink solvents (ethanol, octanol, and diethylene glycol) are formulated with aluminum particles from 1 to 10 wt%. EHD inkjet characteristics such as drop-separation distance, drop size, drop-to-substrate impact velocity, and required voltage are reported. The ink's thermo-fluid properties are the primary factors controlling drop characteristics and printing quality. (C) 2011 Elsevier Ltd. All rights reserved.