Inkjet Technology for Digital Fabrication E-Book

• Herausgeber: John Wiley & Sons
• Kategorie: Fachliteratur
• Sprache: Englisch

Seitenzahl: 691

Veröffentlichungsjahr: 2012

Beschreibung

Whilst inkjet technology is well-established on home and small office desktops and is now having increasing impact in commercial printing, it can also be used to deposit materials other than ink as individual droplets at a microscopic scale. This allows metals, ceramics, polymers and biological materials (including living cells) to be patterned on to substrates under precise digital control. This approach offers huge potential advantages for manufacturing, since inkjet methods can be used to generate structures and functions which cannot be attained in other ways.

Beginning with an overview of the fundamentals, this bookcovers the key components, for example piezoelectric print-heads and fluids for inkjet printing, and the processes involved. It goes on to describe specific applications, e.g. MEMS, printed circuits, active and passive electronics, biopolymers and living cells, and additive manufacturing. Detailed case studies are included on flat-panel OLED displays, RFID (radio-frequency identification) manufacturing and tissue engineering, while a comprehensive examination of the current technologies and future directions of inkjet technology completes the coverage. 

With contributions from both academic researchers and leading names in the industry, Inkjet Technology for Digital Fabrication is a comprehensive resource for technical development engineers, researchers and students in inkjet technology and system development, and will also appeal to researchers in chemistry, physics, engineering, materials science and electronics.

Leseprobe

Table of Contents

Title Page

Copyright

About the Editors

List of Contributors

Preface

Chapter 1: Introduction to Inkjet Printing for Manufacturing

1.1 Introduction

1.2 Materials and Their Deposition by Inkjet Printing

1.3 Applications to Manufacturing

1.4 Potential and Limitations

References

Chapter 2: Fundamentals of Inkjet Technology

2.1 Introduction

2.2 Surface Tension and Viscosity

2.3 Dimensionless Groups in Inkjet Printing

2.4 Methods of Drop Generation

2.5 Resolution and Print Quality

2.6 Grey-Scale Printing

2.7 Reliability

2.8 Satellite Drops

2.9 Print-Head and Substrate Motion

2.10 Inkjet Complexity

References

Chapter 3: Dynamics of Piezoelectric Print-Heads

3.1 Introduction

3.2 Basic Designs of Piezo-Driven Print-Heads

3.3 Basic Dynamics of a Piezo-Driven Inkjet Print-Head (Single-Degree-of-Freedom Analysis)

3.4 Design Considerations for Droplet Emission from Piezo-Driven Print-Heads

3.5 Multi-Cavity Helmholtz Resonator Theory

3.6 Long Duct Theory

3.7 Concluding Remarks

References

Chapter 4: Fluids for Inkjet Printing

4.1 Introduction

4.2 Print-Head Considerations

4.3 Physical Considerations in DOD Droplet Formation

4.4 Ink Design Considerations

4.5 Ink Classification

4.6 Applications in Electronic Devices

References

Chapter 5: When the Drop Hits the Substrate

5.1 Introduction

5.2 Stable Droplet Deposition

5.3 Unstable Droplet Deposition

5.4 Capillarity-Driven Spreading

5.5 Coalescence

5.6 Phase Change

5.7 Summary

References

Chapter 6: Manufacturing of Micro-Electro-Mechanical Systems (MEMS)

6.1 Introduction

6.2 Limitations and Opportunities in MEMS Fabrication

6.3 Benefits of Inkjet in MEMS Fabrication

6.4 Chemical Sensors

6.5 Optical MEMS Devices

6.6 Bio-MEMS Devices

6.7 Assembly and Packaging

6.8 Conclusions

Acknowledgements

References

Chapter 7: Conductive Tracks and Passive Electronics

7.1 Introduction

7.2 Vision

7.3 Drivers

7.4 Incumbent Technologies

7.5 Conductive Tracks and Contacts

7.6 Raw Materials: Ink

7.7 Raw Materials: Conductive Polymers

7.8 Raw Materials: Substrates

7.9 Printing Processes

7.10 Post Deposition Processing

7.11 Resistors

7.12 Capacitors

7.13 Other Passive Electronic Devices

7.14 Outlook

References

Chapter 8: Printed Circuit Board Fabrication

8.1 Introduction

8.2 What Is a PCB?

8.3 How Is a PCB Manufactured Conventionally?

8.4 Imaging

8.5 PCB Design Formats

8.6 Inkjet Applications in PCB Manufacturing

8.7 Future Possibilities

References

Chapter 9: Active Electronics

9.1 Introduction

9.2 Applications of Inkjet Printing to Active Devices

9.3 Future Outlook

References

Chapter 10: Flat Panel Organic Light-Emitting Diode (OLED) Displays: A Case Study

10.1 Introduction

10.2 Development of Inkjet Printing for OLED Displays

10.3 Inkjet Requirements for OLED Applications

10.4 Ink Formulation and Process Control

10.5 Print Defects and Control

10.6 Conclusions and Outlook

Acknowledgements

References

Chapter 11: Radiofrequency Identification (RFID) Manufacturing: A Case Study

11.1 Introduction

11.2 Conventional RFID Technology

11.3 Applications of Printing to RFID

11.4 Printed Antenna Structures for RFID

11.5 Printed RFID Tags

11.6 Conclusions

References

Chapter 12: Biopolymers and Cells

12.1 Introduction

12.2 Printers for Biopolymers and Cells

12.3 Ink Formulation

12.4 Printing Cells

12.5 Reactive Inks

12.6 Substrates for Printing

12.7 Applications

12.8 Conclusions

References

Chapter 13: Tissue Engineering: A Case Study

13.1 Introduction

13.2 A Feasibility Study of Live Cell Printing by Inkjet

13.3 3D Biofabrication by Gelation of Inkjet Droplets

13.4 2D and 3D Biofabrication by a 3D Bioprinter

13.5 Use of Inkjet Technology for 3D Tissue Manufacturing

13.6 Summary and Future Prospects

Acknowledgements

References

Chapter 14: Three-Dimensional Digital Fabrication

14.1 Introduction

14.2 Background to Digital Fabrication

14.3 Digital Fabrication and Jetted Material Delivery

14.4 Liquid-Based Fabrication Techniques

14.5 Powder-Based Fabrication Techniques

14.6 Research Challenges

14.7 Future Trends

References

Chapter 15: Current Inkjet Technology and Future Directions

15.1 The Inkjet Print-Head as a Delivery Device

15.2 Limitations of Inkjet Technology

15.3 Today's Dominant Technologies and Limitations

15.4 Other Current Technologies

15.5 Emerging Technologies

15.6 Future Trends for Print-Head Manufacturing

15.7 Future Requirements and Directions

15.8 Summary of Status of Inkjet Technology for Digital Fabrication

References

Index

This edition first published 2013

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Library of Congress Cataloging-in-Publication Data

Inkjet technology for digital fabrication / edited by Ian M Hutchings, Graham D. Martin.

pages cm

Includes index.

ISBN 978-0-470-68198-5 (cloth)

1. Microfluidics. 2. Microfabrication. 3. Ink-jet printing. 4. Three-dimensional printing. 5. Coating processes.

I. Hutchings, Ian M. II. Martin, Graham D. (Graham Dagnall)

TJ853.4.M53I545 2013

620.1′06– dc23

2012029022

A catalogue record for this book is available from the British Library.

Cloth ISBN: 978-0-470-68198-5

About the Editors

Ian M. Hutchings has been GKN Professor of Manufacturing Engineering at the University of Cambridge since 2001, working in the Institute for Manufacturing which is part of the Department of Engineering. Previously, he was Reader in Tribology at the Department of Materials Science and Metallurgy. His research interests are interdisciplinary, crossing the boundaries between engineering, materials science and applied physics. He established the Inkjet Research Centre at Cambridge in 2005 with support from the UK Engineering and Physical Sciences Research Council and several academic and industrial collaborators.

Graham D. Martin has been Director of the Inkjet Research Centre at the Institute for Manufacturing, University of Cambridge since 2005. He has a PhD in solid state physics and has worked in inkjet-related research, consultancy and product development for many years. The companies he has worked for include Cambridge Consultants Ltd (Non Impact Printing Systems group leader), Elmjet (Technical Director) and Videojet (Director of Technology).

List of Contributors

Khalid A. Alamry, Organic Materials Innovation Centre, School of Chemistry, University of Manchester, United Kingdom

Thomas Boland, Department of Biomedical Engineering, University of Texas at El Paso, USA

Paul Calvert, College of Engineering, University of Massachusetts Dartmouth, USA

Dolores Caras-Quintero, Organic Materials Innovation Centre, School of Chemistry, University of Manchester, United Kingdom

Julian Carter, Technology Consultant, United Kingdom

Neil Chilton, Printed Electronics Ltd., United Kingdom

Mark Crankshaw, R&D—Engineering, Xaar PLC, United Kingdom

Brian Derby, School of Materials, University of Manchester, United Kingdom

J. Frits Dijksman, Philips Research Europe, High Tech Campus 11, The Netherlands

Hanna M. Haverinen, Solar and Alternative Energy Engineering Research Center, King Abdullah University of Science and Technology (KAUST), Saudi Arabia

Ian M. Hutchings, Inkjet Research Centre, University of Cambridge, United Kingdom

Ghassan E. Jabbour, Department of Electrical Engineering, Department of Materials Science and Engineering, Solar and Alternative Energy Engineering Research Center, King Abdullah University of Science and Technology (KAUST), Saudi Arabia

Sungjune Jung, Department of Physics, University of Cambridge, United Kingdom

Marie-Beatrice Madec, Organic Materials Innovation Centre, School of Chemistry, University of Manchester, United Kingdom

Andromachi Malandraki, Organic Materials Innovation Centre, School of Chemistry, University of Manchester, United Kingdom

Graham D. Martin, Inkjet Research Centre, University of Cambridge, United Kingdom

Makoto Nakamura, Graduate School of Science and Engineering for Research, University of Toyama, Japan

Bill O'Neill, Department of Engineering, University of Cambridge, United Kingdom

Anke Pierik, University of Twente, Faculty of Science and Technology, Physics of Fluids, The Netherlands

Jake Reder, Celdara Medical, LLC, USA

Veronica Sanchez-Romaguera, Organic Materials Innovation Centre, School of Chemistry, University of Manchester, United Kingdom

Madhusudan Singh, Department of Materials Science and Engineering, University of Texas at Dallas, USA

Jonathan Stringer, Department of Mechanical Engineering, University of Sheffield, United Kingdom

Vivek Subramanian, Department of Electrical Engineering and Computer Sciences, University of California, USA

David B. Wallace, MicroFab Technologies, Inc., USA

Mike Willis, Pivotal Resources Ltd, United Kingdom

Desheng Xu, Organic Materials Innovation Centre, School of Chemistry, University of Manchester, United Kingdom

Stephen G. Yeates, Organic Materials Innovation Centre, School of Chemistry, University of Manchester, United Kingdom

Yuka Yoshioka, Heraeus Materials Technology, USA

Preface

From its initial use for product marking and date coding in the 1980s, and its development and widespread adoption for the desktop printing of text and images in the following two decades, inkjet technology is now having an increasing impact on commercial printing for many applications including labels, print-on-demand books and even newspapers. With great intrinsic flexibility and very short set-up times, inkjet printing is also challenging conventional methods for more specialised uses such as ceramic tile decoration and textile printing.

Exactly the same processes by which individual drops of liquid are produced and directed onto a substrate under digital control can be used to deposit materials other than the coloured ‘inks’ used for text and graphics. Metals, ceramics and polymers, with a wide range of functionality, can all be printed by inkjet methods, and exciting possibilities are also raised by the ability to print biological materials, including living cells. We are at the dawn of a digital age for printing, and it is the aim of this book to show how the changes which are happening in that world will lead to equally revolutionary changes in the ways in which we can manufacture products. Digital fabrication offers the possibilities of tailoring materials at a microscopic level, and positioning them exactly where they are required, with exactly the right properties. It has the potential to generate structures and functions which cannot be attained by other methods, and which are limited only by the creativity and ingenuity of the designer. It forms a new and powerful addition to the portfolio of methods available for manufacturing.

We are very grateful to the authors who have contributed to this volume, which we hope will help to define this rapidly moving field of research and provide a valuable resource for those who want to explore it further. It is impossible to forecast how it will develop, even over the next 10 years. What appears certain to us is that it will not stand still.

Ian M. Hutchings and Graham D. Martin Cambridge April 2012

Chapter 1

Introduction to Inkjet Printing for Manufacturing

Ian M. Hutchings, and Graham D. Martin

Inkjet Research Centre, University of Cambridge, United Kingdom

1.1 Introduction

The basic principles of conventional printing have remained the same for hundreds of years: the various different printing processes which we take for granted all involve the repeated reproduction of the same image or text many times. Usually, this is achieved by transferring a pattern of liquid or semi-liquid ink from some master pattern to the paper or other substrate through direct contact. Changes to the printed product can be achieved only by changing the master pattern, which involves making physical changes within the printing machine.

In contrast, the inkjet printer which is now ubiquitous in the modern home and office works on a fundamentally different principle. Each small droplet of ink, typically 10–100 µm in diameter, is created and deposited under digital control, so that each pattern printed in a sequence can just as readily be different from the others as it can be the same. The principles of inkjet printing were first developed commercially during the 1970s and 1980s, with the practical applications of marking products with dates and bar codes, and addressing bulk mail. As indicated in Figure 1.1, the technology used for these purposes, which demand high operating speeds but can tolerate quite low resolution in the printed text, is now fully mature: these printers, which use continuous inkjet (CIJ) technology, are widely used as standard equipment on production lines worldwide. The next development, from the mid-1980s onwards, involved drop-on-demand (DOD) printing which is capable of much higher resolution than the early coders and placed the capability for digital reproduction of text and images, at low cost, into the domestic and small office environment. The principles of both the CIJ and DOD printing technologies are described in Chapter 2.

Figure 1.1 The applications of inkjet technology have developed in three waves: initially for marking and coding, followed by desktop printing of text and graphics in the home and small office environment and, currently, increasing use in commercial printing and manufacturing.

The subject of this book is the third wave of technology development shown in Figure 1.1; the use of inkjet printing as a manufacturing process. This advance, which is occurring in parallel with the use of inkjet for commercial printing in direct competition with such processes as offset lithography, employs the same basic principles of drop generation as the earlier applications, but with an emphasis on the features of reliability, accuracy, flexibility and robustness which are essential for successful industrial application. Many of the applications discussed in this volume are still under development, and there is undoubted scope for further innovation. Several features of inkjet printing make it particularly attractive for manufacturing.

Firstly, it is a digital process. The location of each droplet of ‘ink’ (i.e. the material being deposited) can be predetermined on a two-dimensional grid. If necessary the location can be changed in real time, for example to adjust for distortion or misalignment of the substrate, or to ensure that a certain height of final deposit is achieved. Because it is a digital process, each product in a sequence can easily be made different from every other, in small or even in major ways; bespoke products are generated just as readily as multiple replicas of the same design. Since the pattern to be printed is held in the form of digital data, there may be significant cost savings over processes which involve the use of a physical mask or template.

Secondly, it is a non-contact method; the only forces which are applied to the substrate result from the impact of very small liquid drops. Thus fragile substrates can be processed which would not survive more conventional printing methods. The substrate need not even be solid: we shall see examples in Chapter 13 where materials are printed into a liquid bath, and in Chapter 14 where the substrate is a bed of powder. Material can be deposited onto non-planar (rough or textured) substrates, since the process can be operated with a stand-off distance between the print-head and substrate of at least 1 mm. In conventional contact-based printing, the printed material may also be transferred by accidental contact, potentially causing poor quality or contamination; such problems are avoided in a non-contact process.

Thirdly, a wide range of materials can be deposited. By selection of an appropriate print-head, liquids with viscosities from 1 to 50 mPa s or higher can be printed. Several different methods can be used to generate printed structures. Multiple combinations of materials can be used, and inkjet printing can also be combined with other process steps, so that in principle complex heterogeneous and composite structures can be produced, with different materials distributed in all three dimensions.