Transitioning Inkjet Technology from Research to Production
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- Harriet Bridges
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1 Transitioning Inkjet Technology from Research to Production FROM RESEARCH TO PRODUCTION Dipl.-Ing. Daniel Fechtig, PhD Profactor GmbH - Functional Surfaces and Nanostructures Group
2 Profactor - Numbers and Facts 2 LOCATIONS: STEYR and VIENNA SINCE EMPLOYEES PROFACTOR GmbH
3 Our Profile Research Solutions Image Processing Flexible Robotics Industrial Assistance Systems Simulation based Optimization Digitalization Rapid Prototyping/Tooling Functional Surfaces Additive Micro/Nano-Fabrication Nano/Microstructures PROFACTOR GmbH 3
4 Additive Micro/Nano-Fabrication 3D Printing Individualized Products Competitive small lot size production (nearly) endless freedom of design and material combinations More (new) functions as competitive advantage Scalability for mass fabrication PROFACTOR GmbH 4
5 Additive Micro/Nano-Fabrication Additive Inkjet Printing Individualized Products Competitive small lot size production (nearly) endless freedom of design and material combinations Printing on finished 3D Object More (new) functions as competitive advantage Scalability for mass fabrication PROFACTOR GmbH 5
6 Additive Micro/Nano-Fabrication Additive Nanoimprint Lithography High Resolution Large Area 2.5D patterns in a single step On curved surfaces (independent of DOF) Material flexibility Scalability for mass fabrication PROFACTOR GmbH 6
7 Micro/Nanostructures Nanoimprinting on curved surfaces Multilayer, Multimaterial Nanoimprinting NIL large area PROFACTOR GmbH 7
8 NIL large area Roll-to-Plate Applications Microfluidic Lab-on-a-Chip Safety Features Solar Cells (OPVs) Smart Windows Optics, Microelectronics Functional Surfaces PROFACTOR GmbH 8
9 Project e-paper PROFACTOR GmbH 9
10 Nanoimprinting on curved surfaces Applications Optical, Haptic effects Magic color impressions Anti-Reflection Coating for Lenses Aberration Correction for Lenses/Contact Lenses Digital Tampon Printing PROFACTOR GmbH 10
11 Having Inkjet-printable Nanoimprint Materials MD C Ormostamp 25 C Diluted UV-curable stamp materials viscosity < 30 mpas (printhead dependent) temperature range of the printhead!! PROFACTOR GmbH 11
12 Having Inkjet-printable Nanoimprint Materials Inkjet printing of functional nanoimprintable materials Modification of existing UV-curable materials Reactive diluents image width = 1.62mm OS v1 OS v2 OS v3 OS v4 Dots size 40µm MD700 v1 54µm MD700 v4 45µm OC v1 48µm OC v2 65µm 115µm PROFACTOR GmbH 12
13 Inkjet and NIL combined area definition Step 1 Inkjet printing Step 2 UV-NIL 4 cm PROFACTOR GmbH 13
14 Preparation of masters using on single stamp Inkjet printing for each facet Rotation of the same stamp PROFACTOR GmbH 14
15 Digital PAD printing Requirements Solution Digital printing on curved Substrates Printable Inks Small and large lot sizes Migration behaviour Digital PAD printing: Process Development Adjustment of Materials, Ink, Substrate Curved substrates Optical and graphical elements PROFACTOR GmbH 15
16 inkpad Project Idea Analog Pad Printing Digital Inkjet Printing (only planar surfaces) Digital Pad Printing of curved surfaces Inkjet-Druck Substrat Substrat Going Digital PROFACTOR GmbH 16
17 Digital multimaterial reversal NIL on curved surfaces Inkjet Printing of pattern on the membrane Transferring the material to the substrate digital multimaterial reversal NIL on curved surface PROFACTOR GmbH 17
18 Functional Surfaces robot Assisted Inkjet Printing Digital PAD Printing Functional Elements on Curved Surfaces and Textiles PROFACTOR GmbH 18
19 MEM4WIN - Inkjet Graphene and P3HT:PCBM for OPV EU project MEM4WIN ( ): Printed Graphene Windows, which exhibit higher energy efficiency (quadruple glazing) lower weight (frameless window, ultra-thin glass membranes) micro mirror arrays for control of solar radiation and light guidance possibility to generate energy (OPV) 11 international project partners LISEC, PROFACTOR GmbH, OPVius GmbH, Energy Glas GmbH, Durst Phototechnik AG, TIGER Coatings GmbH & Co.KG, CNR, JKU, Univ. Kassel, Cambridge Graphene Center, Korea University Module: Active area: ~ 134 cm 2, Efficiency: 1.8 % PROFACTOR GmbH 19
20 DIMAP - Inks for 3D Inkjet Printing Development of novel ink materials for 3D multi-material printing by PolyJet technology Mainly using nanoscale material enhanced inks to broaden the range of current available AM materials New functionalities for 3D printed objects Not only for rapid prototyping also for the use in production processes. PROFACTOR GmbH 20
21 DIMAP - PolyJet Printing and New materials Inkjet based 3D printing Layers of curable liquid photopolymers Curing via UV-radiation Soluble support material 100 s nozzles per head Advantages High level of detail, smooth surfaces and high precision ± 10 microns drop accuracy ± 5% drop to drop uniformity 3D printing of complex shapes Digital materials (DM) Inks: improvements of Mechanical Properties Ceramic enhanced and high strength polymeric inks (polyimide) Electrical conductivity Metal enhanced inks Weightiness Foams: light weight polymeric materials PROFACTOR GmbH 21
22 inkjetpcb PCB inkjet Complex, multi-stage, material intensive, costly, high waste production, environmentally aggressive, SUBTRACTIVE. PROFACTOR GmbH
23 inkjetpcb - Research Program Overview PROFACTOR GmbH
24 Robot Assisted Inkjet Printing Applications Individualized Shoes Digital Printing on finished Textiles Airplanes Cars PROFACTOR GmbH 24
25 Using a Robot For Inkjet Printing PROFACTOR GmbH 25
26 Inkjet Profactor Inkjet Dimatix DMP Ardeje Origin D100 Ricoh Gen 4 Toshiba CF1 Fujifilm Spectra Polaris Possibility to mount Ricoh Gen4 on robot Toshiba CF1 on xyz system Curing-Sintering Systems UV Phoseon Firejet 16W/cm² 395nm UV-conveyor system 120W/cm² broadband UV-LEDs 365nm and 395nm IR Heraeus IR Quattro Broadband Heraeus Flash System max 2kJ pulse energy PROFACTOR GmbH 26
27 Our Team Außerhuber Helene Fachberger Hannes Di Pietro Vito Matteo Wagner Annika Fischinger Thomas Tina Mitteramskogler Guillen Ellen Haslinger Michael Kastner Julia Fechtig Daniel Kopp Sonja Kurzmann Julia Leichtfried Hans Martin Mühlberger Michael Musikar Verena Rostami Nazila Schranzhofer Leo Schuster Sebastian Voglhuber Thomas Amiya Moharana Masters + Interns PROFACTOR GmbH 27
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