Macroformaat printen + Micrometers nauwkeurig
             p                              g
                       =
     ...
Overview
• Intro Jos Gunsing
  – NTS M h t i
        Mechatronics
  – Avans Hogeschool; research group mechatronics


• In...
Track record
Inkjet Equipment & Markets




            Continuous inkjet &
            drop on demand



        1990    ...
Inkjet Printing

• First choice:   “Golden Triangle”:
      • H d b t t i k combination chosen
        Head-substrate-ink ...
Inkjet Printing

       Sensitivity curve h
       S   iti it        human perception (i di ti )
                         ...
Inkjet Printing
                                   j          g
                 Sources of printing inaccuracy (a.o.)
•  ...
Banding in inkjet printers




                    Courtesy of Jos Notermans
                    Stork Digital Imaging
Banding in inkjet printers

• Perfect drop positioning  no banding
Banding in inkjet printers

• Errors in drop positioning  banding
Banding in inkjet printers

• Positioning errors also cause color shifts
IJ Printing
• Printer configurations:
   – General:
      • Printing motion and substrate handling combined e g
          ...
Layout considerations
– Choices:
   • Motion concept
       – Print heads vs substrates
   • Substrate transport
   • Ink ...
Layout considerations
– Motion concept:
   • Endproduct/print: required productivity/quality
   • Heads:
       –   Type o...
Stork Digital Imaging
                                  g        g g
                                   colorproofing inkj...
Stork Digital Imaging
                    colorproofing inkjet printer



• Printhead drive:
  –   Price: max. Euro 800,- ...
Stork Digital Imaging
  colorproofing inkjet printer
Stork Digital Imaging
           colorproofing inkjet printer

Simulation Print Head Capstan Drive System




            ...
Stork Digital Imaging
                   colorproofing inkjet printer

• Simulation print head drive system:
  – Capstan c...
Stork Digital Imaging
                      colorproofing inkjet printer



• Remarkable:
  –   stepping during printing n...
Stork Digital Imaging
       colorproofing inkjet printer


       Scanning accuracy

                              +/- 2 ...
Stork Digital Imaging
        g        g g
   colorproofing inkjet printer


                 •   Functions:
             ...
Stork Digital Imaging
                          production inkjet printer for textile

•   Production Inkjet Printer for T...
Stork Digital Imaging
                g        g g
         production inkjet printer for textile



                     ...
AGFA
M-press Tiger
AGFA
                                                      M-press Tiger


   AGFA M-press Tiger Inkjet Printer
        ...
Reference side
      R f        id
                                          AGFA
                                      M-...
AGFA
                         M-press Tiger




• Accuracy:
  – Overall dot positioning accuracy approx. 20 μm
     • Moti...
AGFA
M-press Tiger



       •   Requirements:
           –    Automated substrate transport
                through machi...
AGFA
                       M-press Tiger



• Heat sources
  – Printheads:
     • Max. 30W/head; 64 heads/shuttle
     • ...
AGFA
                               M-press Tiger


• Shuttle:
  – Fast scan direction:
     • Master/slave linear motor/b...
AGFA
                            M-press Tiger

• Substrate table:
  – Jetting distance 1.5 mm
     • Landing distance/dro...
Etchresist printing
                          p      g
                       Inkjet versus Lithography




Photoplot   La...
Etchresist printing
                            tc es st p t g
                               Application requirements



...
Etchresist printing
    tc es st p t g
Layout considerations functional model


                    •   PAINT/redundancy
 ...
Conclusions
                 Accuracy versus Cost


• Cost driven:
  – What must be accurate??
  – What can be inaccurate?!
Trends printing/jetting
                        Graphical/Functional IJ printing
•   Layout trends:
      y
    – Graphica...
Appendix

General info NTS Group
NTS Group

   June 2009



   January, 2010
   J
Snap shot information NTS
        p
• Privately owned, created in 2005 in a merger of Nebato
            owned
  (est. 195...
NTS-Group Companies
                        p    p
 Development        System Suppliers                  Component & Part ...
NTS Competences
                  p
•   Engineering & Making Competences:
    • Specialised platforms for accurate positio...
International organization
                g


         NTS-group
Markets
40%
         35%
         3 %
35%

30%
                                                               25%
25%

20%...
Semicon products overview




     ASSEMBLEON

                         MANIA




   ASME


                  ASML        ...
Analytical products overview




  Phenom-World
                      SPECTRO
Medical products overview

                                  Elekta




Philips Medical
   Systems


                   Zi...
Printing products overview
Punch Graphix
                               Buhrs




                Stork Prints
           ...
Technology competence : Integrator
        gy    p             g

 •   Mechatronics                 •   Manufacturing
    ...
Motion Controlled systems : synergy by
reuse of proven solutions(technology)
           m/s                               ...
Track record
Inkjet Equipment & Markets




            Continuous inkjet &
            drop on demand



        1990    ...
PowerPoint heeft het automatisch downloaden v an deze externe afbeelding niet toegestaan om te v oork omen dat uw priv acy...
16.00 hr Gunsing - NTS Mechatronics BV
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16.00 hr Gunsing - NTS Mechatronics BV

  1. 1. Macroformaat printen + Micrometers nauwkeurig p g = Macrokosten? Mikrocentrum Themadag Actief positioneren in het micrometergebied 8 juni 2010 Jos Gunsing NTS Mechatronics/Avans Hogeschool
  2. 2. Overview • Intro Jos Gunsing – NTS M h t i Mechatronics – Avans Hogeschool; research group mechatronics • Inkjetprinting – NTS Mechatronics; cooperation in IJ S – Print quality/accuracy; banding in IJ printers – IJ printers; examples i t – Conclusions; accuracy versus cost – Trends; Graphical/Functional IJ printing • Appendi Appendix: – NTS Group; General info
  3. 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. 4. Inkjet Printing • First choice: “Golden Triangle”: • H d b t t i k combination chosen Head-substrate-ink bi ti h Ink Printhead Substrate
  5. 5. Inkjet Printing Sensitivity curve h S iti it human perception (i di ti ) ti (indicative) Size of deviation in mu 2 1 10 20 30 Periodicity of deviations in mm
  6. 6. Inkjet Printing j g Sources of printing inaccuracy (a.o.) • Printhead: – Drop speed/angle – Drop size – Missing drops – Position: rotation/perpendicular to print scanning motion direction – ………………. • Ink: – Bi-directional printing: drop shape; gloss; colour overlay – Coalescence; colour effects – …………. • Motion: – Scanning motion – Stepping motion – ……………….. • Substrate – Flatness Fl t – Thermal stability – Dry/wet stability (e.g. paper/textile) – …………….. • General – Static electricity – …………………
  7. 7. Banding in inkjet printers Courtesy of Jos Notermans Stork Digital Imaging
  8. 8. Banding in inkjet printers • Perfect drop positioning  no banding
  9. 9. Banding in inkjet printers • Errors in drop positioning  banding
  10. 10. Banding in inkjet printers • Positioning errors also cause color shifts
  11. 11. IJ Printing • Printer configurations: – General: • Printing motion and substrate handling combined e g 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
  12. 12. Layout considerations – Choices: • Motion concept – Print heads vs substrates • Substrate transport • Ink curing • Printhead controls • Overall controls • HMI/MMI; operator/service • Ink supply system; pressure, degassing, pressure fluctuations • A ili Auxiliary f functionality i li – Printhead maintenance: capping/wiping/brushing/flushing – Printhead calibration: camera system and head adjustment y j
  13. 13. Layout considerations – Motion concept: • Endproduct/print: required productivity/quality • Heads: – Type of print process; DOD, CIJ, other – Max. speed/acceleration/jerk/temperature/temp. gradient M d/ l ti /j k/t t /t di t – Redundancy (head reliability) – Dropsize, accuracy speed/angle • Substrate: – flexible/rigid/sizes (length, width, thickness, flatness) automated/manual change; temperature/temp. gradient; • Integration of: – Maintenance of printheads – Calibration of printheads
  14. 14. Stork Digital Imaging g g g colorproofing inkjet printer Inkjetprinter drive system (proofing printer/paper-foil-textile) - Accuracy: A - 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 p Printhead motion Drops
  15. 15. Stork Digital Imaging colorproofing inkjet printer • Printhead drive: – Price: max. Euro 800,- incl. controls/linear guiding – Step size:1/10, 1/12, 1/24 mm line to line resp. 240, 300, 600 dpi – Accuracy: +/- 3 μm line to line – Accuracy : +/- 20 μm over 36 mm – Accuracy : +/- 0.5 mm home position – Temp. range: 17 tot 60 deg C (operating) – Scalability approx. 300 up to 2000 mm
  16. 16. Stork Digital Imaging colorproofing inkjet printer
  17. 17. Stork Digital Imaging colorproofing inkjet printer Simulation Print Head Capstan Drive System i
  18. 18. Stork Digital Imaging colorproofing inkjet printer • Simulation print head drive system: – Capstan concept with dc-motor/encoder • Results: • Sample-frequency: 3000 Hz (processor choice) • Control l ith C t l algorithm; proportional + velocity f db k ti l l it feedback • Motor choice: Maxon 6 Watt • Encoder choice: Hengstler 10k lines/rev ( g (40k p pulses/rev). ) • Tacho on motor • i motor/capstan shaft: 10 • Jmax reduction motor/capstan shaft • a max: necessary F normal on capstan shaft (friction)
  19. 19. Stork Digital Imaging colorproofing inkjet printer • Remarkable: – stepping during printing not in between substrate edges printing, – tacho required – friction; seals linera guide to be left out – a max approx. 10 times “a nom” – stiffness motor shaft dominant
  20. 20. Stork Digital Imaging colorproofing inkjet printer Scanning accuracy +/- 2 μm b / boundaries d i s nominal curve s(t) t
  21. 21. Stork Digital Imaging g g g colorproofing inkjet printer • Functions: – Substrate change • Automated/separate function – Substrate: • Drum/DC motor/rotary encoder – Printhead: • Friction wheel drive/rotary encoder – Stepping during printing • Continuous IJ; S-curve • Drop On Demand; vhead constant • Transition from CIJ -> DOD: – Flying distance smaller 3 mm ->1/1.5 with higher accuracy – Changes in design necessary; • adjustments
  22. 22. Stork Digital Imaging production inkjet printer for textile • Production Inkjet Printer for Textile j – Continuous Inkjet – Substrate motion • Direct drive – Printhead motion; 20 kg mass shuttle • Linear motor – Accuracy: 30/40 micron (substratetransport) – Print width 1600 mm – productivity: 15/20 m2/hour
  23. 23. Stork Digital Imaging g g g production inkjet printer for textile • Substrate transport: – A Accurate textile transport t t til t t – Textile freehanging; ink through textile (e.g. silk) – Operator view of printed textile Front from front – Easy roll change
  24. 24. AGFA M-press Tiger
  25. 25. AGFA 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.) p )  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)
  26. 26. Reference side R f id AGFA 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
  27. 27. AGFA M-press Tiger • Accuracy: – Overall dot positioning accuracy approx. 20 μm • Motion errors <8 μm (5 to 6 μm) 40 X-accuracy 3 sigma [mu] 35 Y-accuracy 3 sigma [[mu]] Y i • Overlay: 30 25 – approx. 50-100 μm ; 20 15 » screen print/retro verso screen-print/retro-verso 10 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
  28. 28. AGFA M-press Tiger • Requirements: – Automated substrate transport through machine – Accuracy/machine dynamics – Product cost • Concept; combination of: p; – Force frame/metro frame – Moving shuttle/printheads; accurate – Master/slave; double linear motor/belt drive combination – Moving mass e.g. UV pincuring lamps; belt drive; non-accurate – Clamping mechanism metro frame/temperature conditioned vacuum table – Calibration: • Non-linearity scanning/stepping • Perpendicularity sca e pe d cu a ty scanning/stepping g/stepp g direction
  29. 29. AGFA M-press Tiger • Heat sources – Printheads: • Max. 30W/head; 64 heads/shuttle • T i l UV i k t Typical ink temperature: 45 t 65°C t to – UV-sources • 2 ti times 12kW pin curing ( t continuous power) i i (not ti ) – Linear motors: • F Fast scan direction/scanning di i / i • Slow scan direction/stepping
  30. 30. AGFA M-press Tiger • Shuttle: – Fast scan direction: • Master/slave linear motor/belt drive for scanning motion • “Pre/post ignition” (SW/HW); T known – Slow scan scan direction • Linear motor for stepping motion • Head positioning devices • Temp control ± 0.1°C during 1 print cycle • ± 1° C over longer periods • SW correction not possible
  31. 31. AGFA M-press Tiger • Substrate table: – Jetting distance 1.5 mm • Landing distance/drop speed/drop angle g p p p g Reference side for table, gripper, shuttle – Table flatness adjustable – Height tolerance table 0.15 mm overall – Equal temperature over alu table/table shape Gripper (steel) motion – Expansion length/width during print Gripper • Within print duration: ± 0.1°C overall • Ambient temperature controlled Substrate motion through printing system – table and substrate – Overlay inkjet print/screen print: Table (alu) • Compensation start print position (T known) t.c.o.g. • Reference side/line; • Table thermal center of gravity • Gripper position
  32. 32. Etchresist printing p g Inkjet versus Lithography Photoplot Laminate UV-exposure Develop With courtesy of Hylke Veenstra, Oce
  33. 33. Etchresist printing tc es st p t g Application requirements Requirements • 100 micron tracks ± 7,5% • 100 micron spaces ± 7,5% • etch-compensation with 5 micron steps t h ti ith i t • layer to layer registration 25 micron • 24 24” x 24” printable area 24 • 30 seconds per side • first pass yield 95% p y With courtesy of Hylke Veenstra, Oce
  34. 34. Etchresist printing tc es st p t g Layout considerations functional model • PAINT/redundancy – 3 rows print heads • 1 row active • 1 row checking (PAINT- technology by Océ) • 1 row stand by y • Rotation correction for substrate position on table – H-drive of print head shuttle • Decrease print head firing inaccuracy – Low flying height < 0.3 mm; decrease mispositioning d t d i iti i due to droplet speed and angle variations
  35. 35. Conclusions Accuracy versus Cost • Cost driven: – What must be accurate?? – What can be inaccurate?!
  36. 36. Trends printing/jetting Graphical/Functional IJ printing • Layout trends: y – Graphical/jetting: • Productivity; > m2 /h (’94->’99->2006->2009 resp. 2->20->400->750 m2 /h) • One-off cost (offset/screen print) vs. flexibility) • Flexibility – Vs. e.g. offset/screen print – Formats > – Range of materials > – Degree of automated substrate handling • Accuracy no issue – Spin off graphical/jetting • 3 D structures/Rapid Prototyping/Manufacturing: – Productivity > – Size > – Accuracy > (Shape and size, surface structure) • Manufacture based on inkjet technology – Replacement lithography on behalf of PCB/Flat Panel Display-manufacture » Productivity >; cost/m2 or cost per placement » Flexibility » Accuracy > Moore’s law; also on PCB-level (resolution on behalf of PCB manufacture >> graphical) – Further development of graphical print heads for functional jetting
  37. 37. Appendix General info NTS Group
  38. 38. NTS Group June 2009 January, 2010 J
  39. 39. Snap shot information NTS p • Privately owned, created in 2005 in a merger of Nebato owned (est. 1954) and Te Strake (est. 1947) • Head office in Eindhoven (NL) manufacturing locations in (NL), NL, P.R. of China, Czech Republic and Israel • 700 employees turnover >100 M Euro employees, • Focussed on full life cycle support in manufacturing of opto- mechatronic systems and components for world wide h t i t d t f ld id operating OEM’s
  40. 40. NTS-Group Companies p p 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
  41. 41. NTS Competences p • Engineering & Making Competences: • Specialised platforms for accurate positioning and handling; • O ti and laser t h l Optics d l 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.
  42. 42. International organization g NTS-group
  43. 43. Markets 40% 35% 3 % 35% 30% 25% 25% 20% 18% 15% 10% 9% 10% 5% 3% 0% Analytical Semicon Printing Medical Solar Other Markets served in 2008
  44. 44. Semicon products overview ASSEMBLEON MANIA ASME ASML DEK
  45. 45. Analytical products overview Phenom-World SPECTRO
  46. 46. Medical products overview Elekta Philips Medical Systems Zimmer MVM DORC
  47. 47. Printing products overview Punch Graphix Buhrs Stork Prints Heidelberg GOSS Océ Agfa - Thieme
  48. 48. Technology competence : Integrator gy p g • Mechatronics • Manufacturing g – Positioning & handling – Lowcost concepts & system – Motion building blocks architecture – Machine dynamics – Calibration & test in production p – Precision mechanics – Reproducebility knowledge – Power electronics – Embedded software • Optics & vision • Inkjet specific • Physics – Handling of substrate (roll to roll , sheet to sheet, xy) sheet • Environment – Interaction with ink, inkhead – Cleanroom and substrate – Temperature p – Intelligent synchronisation with – Vacuum jetting-system • Calibration knowledge – Cleaning
  49. 49. Motion Controlled systems : synergy by reuse of proven solutions(technology) m/s Velocity Accuracy V l i -A 100 10 Textile Electronics/ Semiconductor Packaging. 1 Agro CDr/DVDr Printing CD/DVD 0.1 Medical mastering t i Textile Graphical 0.01 0.001 mm 1 0.1 0.01 0.001
  50. 50. 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
  51. 51. PowerPoint heeft het automatisch downloaden v an deze externe afbeelding niet toegestaan om te v oork omen dat uw priv acy in het gev aar k omt. U k unt de afbeelding alsnog downloaden en weergev en door op de berichtenbalk op Opties te k lik k en en v erv olgens Externe inhoud inschak elen te k iezen. Our core competence : complex system integration p p y g Motion controlled Inkjet Equipment area j q p Jetting System area S stem Application area A li ti Ink, Inkhead & substrate Processes & environment

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