of Functional Printing

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1 Prospects and Challenges of Functional Printing Functional Layers and Devices Manufactured by Printing Technologies member of Thomas Blaudeck, Andreas Willert, Reinhard R. Baumann Chemnitz University of Technology Institute for Print and Media Technology Fraunhofer Gesellschaft Institution for Electronic Nanosystems 1

The City Chemnitz City: 243 k inhabitants Chemnitz

6 M inhabitants Stadt der Moderne, Saxon Manchester

technology sectors: automotive and micro engineering

One of the ten fastest growing cities in Germany High

facilities First-class infant, children, and youth

2 The City Chemnitz City: 243 k inhabitants Chemnitz Region: 1.6 M inhabitants Stadt der Moderne, Saxon Manchester Largest closed-packed Art Noveau quarter in Europe Key technology sectors: automotive and micro engineering Leading R&D centre in the field of printed electronics One of the ten fastest growing cities in Germany High quality of life with a wide variety of cultural facilities First-class infant, children, and youth education Beautiful natural surroundings TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

3 The University History 1836 Founded as Royal Mercantile College 1900 Status of Royal Technical Academy (approx. 1,000 students) 1986 Recognised as Technical University (approx. 8,000 students) Situation today 10,500 students / 7 departments / 158 full professors focus on engineering and information technologies center of interdisciplinary research, close links to industry international cooperation with more than 800 higher education institutions 750 international students from 70 countries TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

Faculty of Mechanical Engineering Faculty

Administration Faculty of Humanities and

(closing 2012): Diplom or Magister (5 yrs)

and Master (2 yrs) doctorate (3 6 yrs) 5

4 The University Department Faculty of Natural Sciences Faculty of Mathematics Faculty of Mechanical Engineering Faculty of Electrical Engineering and Information Technology Faculty of Computer Science Faculty of Economics and Business Administration Faculty of Humanities and Social Sciences Degrees monolithic (closing 2012): Diplom or Magister (5 yrs) consecutive (since 2007): Bachelor (3 yrs) and Master (2 yrs) doctorate (3 6 yrs) TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

5 Smart Systems TU Chemnitz photograph: TU Chemnitz/Wolfgang Thieme TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

Smart Systems Campus @ TU Chemnitz http://www.

de/ Fraunhofer Fraunhofer ENAS ENAS Start-Up t Incubator

Smart Systems Campus @ TU Chemnitz Center of Excellence

6 Smart Systems TU Chemnitz Fraunhofer Fraunhofer ENAS ENAS Start-Up t Incubator TU Chemnitz: Institute of Physics and ZfM cleanroom Smart Systems TU Chemnitz Center of Excellence for Micro Systems Integration TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

7 Fraunhofer Institution for Electronic Nanosystems ENAS Focus: Smart Systems Integration using Micro and Nano Technologies MEMS / NEMS Integrati gration & Packaging Electronic Components Communication Unit MEMS/NEMS design Development of MEMS/NEMS MEMS/NEMS test Advanced technology development Back-end-of-line technologies for micro / nano electronics Process and equipment simulation Micro and nano reliability Printed functionalities Advanced system engineering TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

8 The roadmap : Printed smart systems Applica ations Prof. Dr. Arved Hübler printed Key boards & RFID antennas Prof. Dr. Reinhard R. Baumann 2003 all printed transistor [Hübler] 2004 Pi Printed ring oszillator [Hübler] offset printing flexo printing gravure printing inkjet prototyping 100 µm printed membranes adopted antenna design Printed F Cell elements printed flexible batteries further components for smart systems gravure printing screen printing inkjet printing laser processing pilot manufacturing Technologies TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

pmtuc @ TU Chemnitz Institute for Print and Media Technology at Faculty of Mechanical Engineering g founded in 1956 one of the world's leading

Arved Hübler Print Media Technology pmtuc since 1998, before at universities in Heidelberg and Berlin, then Senior R&D Manager at Bertelsmann

Baumann Digital Printing and Imaging g since 2006, before at universities in Leipzig and Bonn, IBM ARC in San Jose / USA, then Senior R&D

9 TU Chemnitz Institute for Print and Media Technology at Faculty of Mechanical Engineering g founded in 1956 one of the world's leading research and teaching institutions for print processes and machines Prof. Dr. Arved Hübler Print Media Technology pmtuc since 1998, before at universities in Heidelberg and Berlin, then Senior R&D Manager at Bertelsmann AG Prof. Dr. Reinhard R. Baumann Digital Printing and Imaging g since 2006, before at universities in Leipzig and Bonn, IBM ARC in San Jose / USA, then Senior R&D Manager at manroland Druckmaschinen AG The Institute is interdisciplinary Mechanical Engineers, Process Engineers, Physicists, Chemists, Computer Scientists, Electrical Engineers, Technicians, Micro Mechanics, Industrial Engineers, Humanists international TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

10 TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann PRINTING

11 The Three Functional Layers of Media print product typewriter photograph printing 1. Creation of Content author, publisher video product analogue recording tape paper broadcast logistics 2. Management of Information station transportation, selection, storage Bookshop TV station printed paper 3. Interface to the User read, view book, magazine TV radio TV TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

plate PRE MEDIA PRE PRESS PRESS POST PRESS

12 The Traditional Printing Workflow ink product Original data Processed data color separations substrate Collecting Reproduction Graphic Arts Imaging Plate making Printing Binding, Rastert Image Processor intermediate carrier printing plate PRE MEDIA PRE PRESS PRESS POST PRESS TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

13 Pre Press original detail halftone screening Optimised screening methods and colour management to reach the highest subjective quality impression for the human eye for visible information (images, graphics, text) y&sons Company / AccuTone TM on of RR Donnelley Pictures: publicatio frequency modulation screening TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

Traditional Printing Technologies Offset lithography Offset

s) Gravure cold needle Gravure Very high h quality

printing cylinder Low viscosity ink (0.05... 0.2 Pa.

Kipphan, HdM Flexography High quality (Resolution ~20 µm)

14 Traditional Printing Technologies Offset lithography Offset High quality (Resolution ~10 µm) printing and non-printing areas are on one level (oleophilic vs. oleophobic) High viscosity ink ( Pa.s) Gravure cold needle Gravure Very high h quality (Resolution ~5 µm) Printing elements are engraved into printing cylinder Low viscosity ink ( Pa.s) Flexo woodcut H. Kipphan, HdM Flexography High quality (Resolution ~20 µm) Printing elements are raised Low viscosity ink ( Pa.s), higher possible TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

15 Traditional Printing Technologies Offset lithography Offset Offset lithography High quality (Resolution ~10 µm) printing and non-printing areas are on one level (oleophilic vs. oleophobic) High viscosity ink ( Pa.s) Gravure cold needle Gravure Very high h quality (Resolution ~5 µm) Printing elements are engraved into printing cylinder Low viscosity ink ( Pa.s) Flexo woodcut H. Kipphan, HdM Flexography High quality (Resolution ~20 µm) Printing elements are raised Low viscosity ink ( Pa.s), higher possible TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

16 Traditional Printing Technologies Gravure Gravure cold needle cold needle Offset lithography Offset High quality (Resolution ~10 µm) printing and non-printing areas are on one level (oleophilic vs. oleophobic) High viscosity ink ( Pa.s) Gravure cold needle Gravure Very high h quality (Resolution ~5 µm) Printing elements are engraved into printing cylinder Low viscosity ink ( Pa.s) Flexo woodcut H. Kipphan, HdM Flexography High quality (Resolution ~20 µm) Printing elements are raised Low viscosity ink ( Pa.s), higher possible TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

17 Traditional Printing Technologies Flexo woodcut Offset lithography Offset High quality (Resolution ~10 µm) printing and non-printing areas are on one level (oleophilic vs. oleophobic) High viscosity ink ( Pa.s) Gravure cold needle Gravure Very high h quality (Resolution ~5 µm) Printing elements are engraved into printing cylinder Low viscosity ink ( Pa.s) Flexo woodcut H. Kipphan, HdM Flexography High quality (Resolution ~20 µm) Printing elements are raised Low viscosity ink ( Pa.s), higher possible TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

18 Inkjet: Technology Map Inkjet (IJ) Continuous IJ (CIJ) Drop on Demand IJ (DoD) Deflection Binary Deflection Multiple Deflection Drop generation Piezo (PIJ) Thermal (TIJ) Electro- Acoustic (AIJ) Piezo static ti (EIJ).. Roof Shooter Push Mode Print head design Edge Shooter Squeeze Tube Bend Mode Shear Mode Inks liquid pigments (particles) aqueous hotmelt dyes (molecules) non-aqueous TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

19 DoD Piezo Inkjet Technology Principle Deformation of a piezo crystal which leads to a volume alternation in the ink chamber and finally to a drop ejection No squeezing! TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

Printability Facts: ρ Ink density [g/cm³] γ Surface tension [mn/m] rheology of the ink system η Ink viscosity [mpas] a Nozzle diameter [µm] ν Drop velocity [m/s] drop break-up at the nozzle drop

20 Printability Facts: ρ Ink density [g/cm³] γ Surface tension [mn/m] rheology of the ink system η Ink viscosity [mpas] a Nozzle diameter [µm] ν Drop velocity [m/s] drop break-up at the nozzle drop formation and ejection energy ink supply within the printhead interaction ti with substrate bt t Z = 2,17 Z = 7,32 Z = 17,32 D. Jang, D. Kim, J. Moon: Influence of Fluid Physical Properties on Ink-Jet Printability. Langmuir 2009, 25, TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

21 Determination of the Surface Energy Young s Equation σ lg Material σ s/l-g [J/m²] σ Metals sl σ sg Ceramic Glass 300 φ = 0 σ lg cos φ = σ sg σ sl PVC 45.2 POM 42.1 PTFE < φ < 90 Mercury 476 φ = 180 Water < φ < 180 Ethanol Pentane TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

22 Post Press Printing PRESS Binding, POST PRESS Process steps in Post Press : folding cutting collecting binding working and turning product H. Kipphan, HdM TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

23 Post Press Printing PRESS Binding, POST PRESS Process steps in Post Press : folding cutting collecting binding working and turning product H. Kipphan, HdM TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

24 FUNCTIONAL PRINTING TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

25 From Color Separations to Functionality Separations screen dot patterns contone elements this is the printers k h minimum diameter of a screen dot is 5-10 µm reproducible dot positioning < 100 µm for 1 Mio. copies know-how: back-to-front registering < 200 µm improvement potential using single cylinder drives printing speed up to 15 2m paper width printing on endless paper web or paper sheets broad variety of stock to be printed TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

26 From Color Separations to Functionality Separations Laser Manufacturing applica ation circuitry, antennae, transistors, diodes, batteries Text and Images recognized by the eye Ambient Electronics Si Chip Supply Chain Management System radio frequency finishing Chip Applicator write / read functi ionality con nductivity semicon nductivity in nsulation CYAN MA AGANTA Y ELLOW BLACK ad hesives intel lligence pro otection printed functionalities TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

27 Printing Functionality Separations, traditional & future ones Color Cyan Color Magenta Color Yellow Color Black Gloss & Protection Electrical Conductivity Adapted Dielectric Properties Electrical Semi-Conductivity Electric Power Electro-Luminescence / Light Emission Sensing Environment Surface Modification Surface Protection Catalysis Intelligence via Chip and / or Supplemental Electronics Process Colorso Coating Circuitry Sensors Process Support Chips Geometric Shape / Laser Cutting TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

28 Functional Printing Workflow Materials Functional Inks Functional substrates Inkjet Characterisation Confocal Microscopy SEM Profilometry AFM Conductivity PrePress Functionality management Functionality halftoning Xero Screen Gravure PostPress Layer drying Thermal annealing UV annealing Process and Workflow Integration TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

29 Functional Printing Workflow Rheology Adjustors Substrate Ingr 1 in soln. Ingr 2 in soln. Formulation Deposition Wet Layer Ingr n in soln. functional precursor material predefines functionality predefines functionality Classical workflow for micro patterning Aim: for functional printing, the deposition process including drying and post-production process (functionality forming) must be understood Drying Solid Layer Functionality Forming Functional cto Layer (pre)defines functionality defines functionality Scheme modified after R. W. Vest: Electronic Films from Metal-Organic Precursors, Purdue University (1988) TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

30 PROSPECTS FUNCTIONAL PRINTING TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

31 Medium Internet Internet of Things TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

32 The Vision: Printed Smart Objects TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

33 The Vision: Printed Smart Objects organic memory power source organic sensor communication with a computer system printed signage element RFID technology near field technology printed keyboard TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

34 PROSPECTS AND CHALLENGES FUNCTIONAL PRINTING TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

Industrial Printing Beyond Color The Topics

print heads to increase productivity Metal

substrates cations Micro Technologies RFID

Packaging Digital UV-Varnishing 54 2009 TU

35 Industrial Printing Beyond Color The Topics of R&D Inkjet Technology ganging g g of print heads to increase productivity Metal Precursors Image wise micro metallization of substrates cations Micro Technologies RFID antenna integration Appli Device Prototyping Printing of Organic Conductors and Semiconductors source drain Traditional Packaging Digital UV-Varnishing TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

36 Equipment tegration kjet Int Ink TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

37 Equipment Webpress Integration for Printing Functionalities TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

38 Inkjet Laboratory Dimatix Materials Printer (DMP) Xaar XUSB & XJ-126/50 Microdrop single nozzle system iti with Spectra Piezo IJ heads TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

39 Inkjet Laboratory Parameters IJ-System DMP 2831 XAAR 126/50 Microdrop iti / Spectra # nozzles / 256 nozzle distance (µm) / resolution (dpi) 254 / / 185 / (25400) 254 / 100 drop volume (pl) 1 / nozzle Ø (µm) 10 / 21, print frequency (khz) ,001 7,5 0, , T max head ( C) T max substrate ( C) 60 ( ) max. substrate bt t vel (m/s) ka k.a , ,1 10 1,0 shot repetition / positioning (µm) max. sheet substrates (BxHxT in mm) printable fluids 15 / k.a. 1 / 4,5 1 / 5 1 / x 210 x x 300 x x 200 x x 300 x 50 org./solv., UV, org./solv., UV, org./solv., UV, org./solv., UV, oil, aqu. oil oil, aqu. oil, aqu TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

Silver Precursor Printing Inkjet-Printed Metal Patterns Funding:

R. Baumann O Ag O O O O O O Ag O O + + 140 C

water) Molecule structure dried printed droplet (not sintered)

ring effect) Metal-organic complex (solid state) Silver content

5% Inkjet ink: 23% solution in water 9% silver content in ink M.

Lang: Silica supported silver nanoparticles from a silver(i)

hydrogenation, Catal. Commun. 2009. D. R.

40 Silver Precursor Printing Inkjet-Printed Metal Patterns Funding: O S. Jahn, A. Jakob, H. Lang, R. R. Baumann O Ag O O O O O O Ag O O C Silver(I)-2-[2-(2-metoxyethoxy)ethoxy]acetate (dissolved in water) Molecule structure dried printed droplet (not sintered) Diameter: 50µm Maximum height: 1µm Distinct donut shape (coffee ring effect) Metal-organic complex (solid state) Silver content in salt: 39.5% Inkjet ink: 23% solution in water 9% silver content in ink M. Steffan, A. Jakob, P. Claus, H. Lang: Silica supported silver nanoparticles from a silver(i) carboxylate: highly active catalyst for regioselective hydrogenation, Catal. Commun D. R. Whitcomb, (Minnesota Mining and Manufacturing Company), Silver carboxylate compounds as silver sources in photothermographic and thermographic elements. US Patent 5,491,059, TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

Strap mounting characterization Low-cost

41 Low-Cost RFID antennas applying Silver Inks: Principle M. Dinter, R. Zichner, A. Willert, R. R. Baumann Antenna printing Simulation Strap mounting characterization Low-cost RFID means... inexpensive materials high efficient technologies maximal performance maximal reliability single item-level tagging 2008 profitable! funded by FMER TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

42 Low-Cost RFID antennas Antenna printing evaluation of appropriate silver pigment inks flexo printing directly into emballage strap Integration by Booster concept development of business cases optimization of materials and processes cost calculation manufacturing of demonstrators ROLAND 700 (c) printed silver antenna booster concept TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

43 Low-Cost RFID antennas Strap Mounting Slow SMT s liquid conductive adhesive solder (Surface-Mount Technologies) Manual applicator Rapid SMT s (< 1 sec) paste over tape anisotropic adhesive foil TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

44 Low-Cost RFID antennas Characterization mobile reader RFID bulk reading on item-level shelves implicate: dense transponders - data collisions moving transponders motion captures inventory at the push of a button optimized logistics... steady reader TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

45 Inkjet-Based Prototyping of Devices S. Jahn, M. Bartzsch, H. Kempa, R. R. Baumann, A. C. Hübler layout for electrode structures source gate drain insulator semiconductor offset printed PEDOT:PSS on plastic L substrate inkjet printed PEDOT:PSS on paper source drain -1.4E E E-06 Vgs=10V Vgs=0V Vgs=-10V Vgs=-20V Vgs=-30V Vgs=-40V Funding: Ids / A -8.0E E E E-07 Vgs=-50V Vgs=-60V EU-FP6 PolyApply ( ) 0.0E U ds / V TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

Printed Electronics require Power Everywhere!

high flexibility R2R-processable direct product integration possible

variability Displays Smart Cards semi-active RFID-Label Medicine (

46 Printed Electronics require Power Everywhere! Further development of battery technology low price low thickness high flexibility R2R-processable direct product integration possible environmentally friendly (metal-free possible) high layout variability Displays Smart Cards semi-active RFID-Label Medicine ( smart patches ) Data logger TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

47 Printed Flexible Batteries A. Willert, A. Kreutzer, U. Geyer, R. R. Baumann manganese oxide-zinc-system printable electrode materials break-proof layers easy recycling low price integration in printed products power everywhere flexible 1,5 V 3 V capacity 2 mah/cm TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

48 Hierarchically Structured Membranes S. Jahn, S. Ebert, L. Engisch, W. A. Goedel, R. R. Baumann Principle of digital membrane manufacturing 1 temporary substrate 2 inkjet print head 3 mold liquid 4 printed droplets as molds 5 solved polymer 6 glazed polymer 7 micro sieve S. F. Jahn, L. Engisch, R. R. Baumann, S. Ebert, W. A. Goedel: Inkjet fabrication method for polymer microsieves. Langmuir, 2009, 25 (1), Adjusting the diameter of the pores by varying polymer layer thickness German Patent DE TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

49 Digital UV-Varnishing / Spot Varnishing using Inkjet technology offset printed substrate inkjet varnishing with UV ink: New Opportunities: free positioning of the varnish spots fine varnish patterns soft contour texture haptic effects TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

50 Conclusion Printing of new functionalities by an appropriate combination of different printing technologies will pave the way for printed products with integrated functionalities more than color. Prof. Dr. Reinhard R. Baumann phone +49 (0) Chemnitz University of Technology, Germany Institute for Print and Media Technology Digital Printing and Imaging Group Dr. Thomas Blaudeck phone +49 (0) Thank you for your attention TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

51 team assistant The Baumann Group Principal investigator: Prof. Dr. Reinhard R. Baumann Fraunhofer ENAS Printed Functionalities Imaging Institute for Print and Media Technology Digital Printing and I i PhD student PhD student PhD student PhD student PhD stu tudent Post Doc lab engineer lab engineer senior senior scientist scientist PhD stu tudent technician Andreas Willert TU Chemnitz Institute for Print and Media Technology Reinhard R. Baumann

Printing Beyond Color. Printed Smart Objects on Advanced Paper Substrates. Reinhard R. Baumann

Printing Beyond Color. Printed Smart Objects on Advanced Paper Substrates. Reinhard R. Baumann Printing Beyond Color Printed Smart Objects on Advanced Paper Substrates June 17, 2009 member of Reinhard R. Baumann member of Chemnitz University of Technology Institute for Print and Media Technology