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  • 1. Inkjetprinten op groot formaat een koud kunstje? Mikrocentrum Themadag Thermomechanica 16 maart 2010 Jos Gunsing NTS Mechatronics
  • 2. Overview • Intro Jos Gunsing • Inkjetprinting – NTS Mechatronics – Print quality/accuracy – Examples of IJ printers – Thermal effects/remedies • Conclusions/trends • Appendix: – General info NTS Group
  • 3. Track record Inkjet Equipment & Markets Continuous inkjet & drop on demand 1990 2004 Graphical Graphical 20 years experience in Inkjet Equipment !! 1995 2006 2007-now Textile Electronics other applications Continuous inkjet Océ hotmelt inkhead/ drop on demand
  • 4. Stork Digital Imaging colorproofing inkjet printer Sensitivity curve human perception (indicative) Size of deviation in mu 2 1 10 20 30 Periodicity of deviations in mm
  • 5. Banding in inkjet printers Courtesy of Jos Notermans Stork Digital Imaging/prints
  • 6. Banding in inkjet printers • Perfect drop positioning → no banding
  • 7. Banding in inkjet printers • Errors in drop positioning → banding
  • 8. Banding in inkjet printers • Positioning errors also cause color shifts
  • 9. Printing • Printer configurations: – General: • Printing motion and substrate handling combined e.g. – Single pass » Roll-to roll – Multi pass: » Shuttle/printheads motion » Substrate motion/handling combined • Printing motion and substrate handling separated e.g. – Single pass » Drum/shuttle – Multi-pass » Shuttle/printheads motion and/or » Table motion
  • 10. Stork Digital Imaging colorproofing inkjet printer Inkjetprinter drive system (proofing printer/paper-foil-textile) - Accuracy: - 2 to 3 µm line-to-line; 600 dpi - < 20 µm over 36 mm (4-colour) - ±0.5 mm; start of print/print width - Productivity: - 1 tot 2 m2/hour - Time for 1 print: 5 to 20 min. Drum up to 300rpm Printhead motion Drops
  • 11. Agfa - Thieme
  • 12. M-press Tiger AGFA M-press Tiger Inkjet Printer 550 up to 770 m2 /hour Photo quality; 720dpi, <5 micron scanning/point-to-point accuracy 64 printheads (Xaar);drop-on-demand Combinations with 1 or more screenprint stations (white,spot/metallic colour,varnish etc.) Print format 2.6*1.6m 64 printheads Fast scan: acceleration 6 m/s2 speed (max) 1.3 m/s Series product Functions: Force frame/metro frame 2 slave/2 master drive long stroke (hybrid belt/linear motor) 1 short stroke drive Maintenance unit print heads Calibration camera (NTS Optel) Calibration robot Total 9 PCB’s; distributed motion control (DSP-based)
  • 13. Reference side M-press Tiger Table Reference side Fast Gripper Gripper scan motion Table Gripper motion Substrate transport direction Shuttle with 64 printheads 2 colours/head Short scan Screenprinting system motion (stepping) Inkjet system
  • 14. Thermal effects • Required accuracies: – Overall dot positioning accuracy approx. 20 µm – Motion errors <8 µm (5 µm) 40 35 X-accuracy 3 sigma [mu] Y-accuracy 3 sigma [mu] – Overlay: 30 25 20 • approx. 50-100 µm ; 15 10 – screen-print/retro-verso 5 0 M a y -0 5 J a n -0 4 O c t-0 6 J u l- 0 9 F e b -0 8 N o v -1 0
  • 15. Thermal effects • Heat sources – Printheads: • Max. 30W/head; 64 heads/shuttle • Typical UV ink temperature: 45 to 65° C – UV-sources • 2 times 12kW pin curing (not continuous power) – Linear motors: • Fast scan direction/scanning • Slow scan direction/stepping
  • 16. Thermal effects • Shuttle: – Fast scan direction: • Failure: – Mispositioning of dots/colours • Remedy: – “Pre-/postignition” (SW/HW); T known – Temperature control – Slow scan scan direction • Failure – Mispositioning of dots (also unicolour) • Remedy: – Temp control ± 0.1° during 1 print cycle C – ± 1°C over longer periods – Defined references of head positioning devices/printheads – Remark: SW correction in this direction not possible
  • 17. Thermal effects • Substrate table: – Overlay inkjet print/screen print: Reference side for table, gripper, shuttle • Temperature known; – compensation start print position » Reference side/line; Gripper (steel) motion » Table thermal center of gravity » Gripper position Gripper – Expansion length/width during print Substrate motion • Within print duration: ± 0.1° overall C through printing system • Ambient temperature controlled – table and substrate Table (alu) – Jetting distance 1.5 mm t.c.o.g. • Landing distance/drop speed/drop angle – Height tolerance table 0.15 mm overall – Equal temperature over alu table/table shape
  • 18. Conclusions • Thermal aspects: – Depending on printer layout/image-buildup – Shuttle; T conditioning: • Size in combination with transient temperature • Perpendicular to fast scan – Table; T conditioning: • Size in combination with transient temperature • Shape; Constant landing (printing) distance – Other measures; T known: • SW-related; timing of nozzle firing;
  • 19. Trends Printing/jetting Graphical/Semicon – Graphical: • Productivity; > m2 /h (’94->’99->2006->2009 resp. 2->20->400->770 m2 /h) • One-off cost (offset/screenprint) vs. flexibility) • Formats > • Range of materials > • Accuracy fixed (image quality) – Semicon: • Productivity: – Cost/m2 – Accuracy: » Moore’s law; also on PCB-level
  • 20. Trends Printing/jetting Graphical/Semicon – Spin off graphical/jetting • 3 D structures/Rapid Prototyping/Manufacturing: – Productivity > – Accuracy > (Shape/size/surface structure) • Manufacture based on jettechnology – Replacement lithography; PCB/Display-manufacture; » Productivity > » Accuracy > (resolution for PCB manufacture >>) » Reliability (missing or malpositioned droplet) – Development print head specific for functional jetting
  • 21. Appendix General info NTS Group
  • 22. NTS Group June 2009 January, 2010
  • 23. Snap shot information NTS • Privately owned, created in 2005 in a merger of Nebato (est. 1954) and Te Strake (est. 1947) • Head office in Eindhoven (NL), manufacturing locations in NL, P.R. of China, Czech Republic and Israel • 700 employees, turnover >100 M Euro • Focussed on full life cycle support in manufacturing of opto- mechatronic systems and components for world wide operating OEM’s
  • 24. NTS-Group Companies Development System Suppliers Component & Part making Finishing Engineering Mechatronics Machining Sheet Metal Surface Treatment NTS Optel NTS Mechatronics NTS Mans (25%) NTS NTS Finish Nijmegen Eindhoven Deurne Metaalbewerking Bergeijk Bergeijk NTS Systence NTS Mechatronics NTS Prometal NTS Hermus NTS Prometal Wijchen Shanghai Slavičín, CZ Venray Slavičín, CZ Shanghai, China MI Partners (10%) NTS Shemer NTS Combimetaal Eindhoven Bar Mislav, Israel (50%) Bergeijk MA3 (10%) NTS Prometal Eindhoven Slavičín, CZ
  • 25. NTS Competences • Engineering & Making Competences: • Specialised platforms for accurate positioning and handling; • Optics and laser technology; • Sheet metal frames and coverings; • Machined parts in combination with above; • Life cycle management: focus on the total life cycle of the module: (integration of) design, engineering, prototyping, industrialisation, value engineering and - if useful - transfer to low cost country; • Operational excellence: Lean thinking and acting in the organisation and the supply chain.
  • 26. International organization NTS-group g System akin ies Cap Eng. Supplier M abil it abi litie C ap s -NL -NL -NL -IL -CZ -CN -IL -IL * -CN -CZ
  • 27. Markets 40% 35% 35% 30% 25% 25% 20% 18% 15% 10% 9% 10% 5% 3% 0% Analytical Semicon Printing Medical Solar Other Markets served in 2008
  • 28. Semicon products overview ASSEMBLEON MANIA ASME ASML DEK
  • 29. Analytical products overview Phenom-World SPECTRO
  • 30. Medical products overview Elekta Philips Medical Systems Zimmer MVM DORC
  • 31. Printing products overview Punch Graphix Buhrs Stork Prints Heidelberg GOSS Océ Agfa - Thieme
  • 32. Technology competence : Integrator • Mechatronics • Manufacturing – Positioning & handling – Lowcost concepts & system – Motion building blocks architecture – Machine dynamics – Calibration & test in production – Precision mechanics – Reproducebility knowledge – Power electronics – Embedded software • Optics & vision • Inkjet specific • Physics – Handling of substrate (roll to roll , sheet to sheet, xy) • Environment – Interaction with ink, inkhead – Cleanroom and substrate – Temperature – Intelligent synchronisation with – Vacuum jetting-system • Calibration knowledge – Cleaning
  • 33. Motion Controlled systems : synergy by reuse of proven solutions(technology) m/s Velocity - Accuracy 100 10 Textile Electronics/ Semiconductor Packaging. 1 Agro CDr/DVDr Printing CD/DVD Medical mastering 0.1 Textile Graphical 0.01 0.001 mm 1 0.1 0.01 0.001
  • 34. Track record Inkjet Equipment & Markets Continuous inkjet & drop on demand 1990 2004 Graphical Graphical 20 years experience in Inkjet Equipment !! 1995 2006 2007-now Textile Electronics other applications Continuous inkjet Océ hotmelt inkhead/ drop on demand
  • 35. Our core competence : complex system integration Motion controlled Inkjet Equipment area Jetting System area Application area Ink, Inkhead & substrate Processes & environment

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