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Molybdenum electrical interconnects for thermoelectric modules were produced by air plasma spraying a 30µm size molybdenum powder through a laser-cut Kapton tape mask. Initial feasibility demonstrations showed that the molybdenum coating exhibited excellent feature and spacing retention (~170µm), adhered to bismuth-telluride, and exhibited electrical conductivity appropriate for use as a thermoelectric module interconnect. A design of experiments approach was used to optimize air plasma spraydoi:10.2172/1096514 fatcat:uxyjpassbjaexmpkzot4h34diy