Aerosol Jet Printing (AJP) is an innovative and transformative technology poised to revolutionize the fields of printable electronics and additive manufacturing. This research centers on the application of AJP for producing conductive traces and custom strain gauges on printed circuit boards (PCBs), leveraging its non-contact printing capabilities, versatility with various materials, and CNC-driven precision. The ability of AJP to enable rapid circuit prototyping and small-scale production makes it particularly valuable in the electronics industry, where time-to-market is critical.In this study, we introduce the design and characterization of a strain gauge sensor printed using JS-A426 silver ink from NovaCentrix. The use of an ultrasonic atomizer aerosol jet delivery system provides exceptional control over ink deposition, allowing for the creation of intricate designs that would be challenging to achieve with traditional printing methods. Systematic evaluation of the silver ink's conductivity guided the design process, resulting in a strain gauge with a theoretical resistance of 300 Ω. Following the printing, the strain gauges were subjected to sintering using Intense Pulse Light (IPL), a novel technique that promotes rapid curing without the need for high-temperature processing, thereby minimizing substrate damage. Experimental results demonstrated an average resistance of 255 Ω and a gauge factor of 1.81, indicating performance comparable to conventional commercial strain gauges. These findings not only validate the effectiveness of aerosol jet printing but also showcase its potential for a wide array of practical applications across various industries.AJP's precise printing capabilities are particularly advantageous when modifying existing PCBs in a three-dimensional environment. For example, tasks such as adding connections to high-density circuits, which can be labor-intensive and prone to error when performed manually, are streamlined through AJP's ability to navigate complex paths with accuracy. Furthermore, AJP excels in applying electromagnetic shielding to small or irregularly shaped areas, effectively shielding individual components with precision and efficiency.Overall, this study highlights several advantages of aerosol-printed strain gauges over traditional counterparts, including rapid prototyping, conformal printing on diverse surfaces, elimination of adhesive layers, and avoidance of high-temperature sintering processes. The efficiency of the aerosol jet printing approach allows for quick setups and fast production, significantly enhancing overall productivity. Our findings establish a robust case for the viability and superiority of aerosol-printed strain gauges, paving the way for advancements in flexible and efficient electronic components. This research not only contributes to the evolution of printable electronics but also opens new avenues for exploration and innovation in the field of AJP technology, potentially leading to transformative applications in various sectors.