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Emerging Trends of Industrial Inkjet Printing


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Presents current industrial inkjet technologies and details emerging trends for these technologies.

Published in: Technology, Business
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Emerging Trends of Industrial Inkjet Printing

  1. 1. “ Emerging Trends of Industrial Inkjet Printing” Dean A. Hornsby Digital Printing Specialist Pittsburgh, PA Contact : [email_address]
  2. 2. Presentation Overview <ul><ul><li>Inkjet Development Timeline </li></ul></ul><ul><ul><li>Inkjet Technologies </li></ul></ul><ul><ul><li>Inkjet Inks </li></ul></ul><ul><ul><li>Principles of Operation </li></ul></ul><ul><ul><li>Fluid Properties for Inkjet Technologies </li></ul></ul><ul><ul><li>Future Developments </li></ul></ul><ul><ul><li>Traditional & Emerging Applications </li></ul></ul><ul><ul><li>Emerging Markets Example Photo Gallery </li></ul></ul>
  3. 3. Inkjet Development Timeline Developed from a model by Fred Noll, VIP Color Revised December 2006 by Dean Hornsby
  4. 4. Inkjet Technologies <ul><li>DOD Drop On Demand </li></ul><ul><ul><li>Micro-Solenoid Plunger Operated DOD </li></ul></ul><ul><ul><li>Impulse Piezo Ceramic DOD </li></ul></ul><ul><li>CIJ Continuous Inkjet </li></ul><ul><li>Hot Melt Wax Based Impulse DOD/CIJ </li></ul><ul><li>TIJ Thermal Inkjet </li></ul>
  5. 5. Inkjet Technologies <ul><li>Micro Solenoid – Plunger Operated DOD </li></ul><ul><ul><li>Every Drop Ejected Hits Substrate </li></ul></ul><ul><ul><li>Adjustable 2 µl to 1 ml Drop Volume </li></ul></ul><ul><ul><li>Prints Aqueous & Solvent Base Fluids </li></ul></ul><ul><ul><li>Low Frequency Drive (up to 5 KHz) </li></ul></ul><ul><ul><li>Prints @ 32 dpi (Porous & Non Porous Substrates) </li></ul></ul><ul><ul><li>Head Life Up To 2 Billion Cycles </li></ul></ul><ul><ul><li>Generally Inert Materials in Print Head Construction </li></ul></ul><ul><ul><li>Pressure Delivery of Fluid (15 psi) </li></ul></ul>
  6. 6. Inkjet Technologies <ul><li>Impulse – Piezo Ceramic DOD </li></ul><ul><ul><li>Every Drop Ejected Hits Substrate </li></ul></ul><ul><ul><li>Adjustable 2 pl to 100 pl Drop Volume </li></ul></ul><ul><ul><li>Prints Aqueous, Solvent, Oil & Wax Base Fluids </li></ul></ul><ul><ul><li>High Frequency Drive (up to 40 KHz) </li></ul></ul><ul><ul><li>Prints @ 256 dpi (Porous & Non Porous Substrates) </li></ul></ul><ul><ul><li>Head Life Up To 10 Billion Cycles </li></ul></ul><ul><ul><li>Capillary Fluid Feed – Gravity Feed Ink System </li></ul></ul>
  7. 7. Inkjet Technologies <ul><li>Continuous Inkjet </li></ul><ul><ul><li>Continuous Stream of Fluid Drops </li></ul></ul><ul><ul><li>Electrostatic Charge on Drops to Deflect </li></ul></ul><ul><ul><li>Adjustable 6 nl to 100 nl Drop Volume </li></ul></ul><ul><ul><li>Un-charged Drops Return to Fluid System </li></ul></ul><ul><ul><li>Prints Aqueous, Solvent, Wax and Oil Base Fluids </li></ul></ul><ul><ul><li>60,000 to 100,000 Drops Generated Per Second </li></ul></ul><ul><ul><li>Prints up to 100 dpi (Porous & Non Porous Substrates) </li></ul></ul><ul><ul><li>Head Life 5+ years </li></ul></ul><ul><ul><li>Pressure Delivery of Fluids (45 psi) </li></ul></ul>
  8. 8. Inkjet Technologies <ul><li>Drop On Demand – Thermal Inkjet </li></ul><ul><ul><li>Every Drop Ejected Hits Substrate </li></ul></ul><ul><ul><li>Heat Used to Vaporize Fluid to Form Bubble/Eject Drop </li></ul></ul><ul><ul><li>Prints Aqueous Base and UV Curable Fluids </li></ul></ul><ul><ul><li>Home, Office and Wide Format Printers </li></ul></ul><ul><ul><li>Prints @ 4800 x 1200 dpi (Porous Substrate) </li></ul></ul><ul><ul><li>Raster Print Head to Stitch Print Image </li></ul></ul><ul><ul><li>Head Life Approximately 3 Liters </li></ul></ul>
  9. 9. <ul><li>What Constitutes an Inkjet Ink </li></ul><ul><ul><li>Resin </li></ul></ul><ul><ul><ul><li>Forms Finished Ink Film and Responsible for Carrying Colorant </li></ul></ul></ul><ul><ul><ul><li>Provides Properties Like Adhesion, Abrasion Resistance, Ultra- Violet Resistance </li></ul></ul></ul><ul><ul><li>Colorant </li></ul></ul><ul><ul><ul><li>Dye – Transparent, Bad UV Stability, Bad Heat Stability, Stays in Solution </li></ul></ul></ul><ul><ul><ul><li>Pigment – Opaque, Good UV Stability, Good Weather Resistance, Flocculates </li></ul></ul></ul>Inkjet Inks
  10. 10. Inkjet Inks <ul><li>What Constitutes an Inkjet Ink </li></ul><ul><ul><li>Solvent </li></ul></ul><ul><ul><ul><li>Enables Resin-Pigment Mixture to be Transferred to the Substrate During Printing. The Choice of Solvent Will Determine Dry Time of Ink </li></ul></ul></ul><ul><ul><li>Additives </li></ul></ul><ul><ul><ul><li>Substances Added in Small Amounts for Flexibility, Improved Flow, Dot Formation, Pigment Stability, etc </li></ul></ul></ul>
  11. 11. Principles of Operation <ul><li>DOD – Micro Solenoid </li></ul><ul><ul><li>Solenoid Coil Actuates Magnetic Plunger Rod </li></ul></ul><ul><ul><li>Manifold Contains Fluid Under Pressure </li></ul></ul><ul><ul><li>Drops Formed By Opening/Closing Plunger </li></ul></ul><ul><ul><li>Stainless Steel/Rubber Materials </li></ul></ul><ul><ul><li>Calibrated to Obtain Uniform Drop Size </li></ul></ul><ul><ul><li>Serviceable Print Head </li></ul></ul><ul><ul><li>Viscosity 1 to 10 cP </li></ul></ul>
  12. 12. Principles of Operation <ul><li>CIJ – Continuous Inkjet </li></ul><ul><ul><li>PZT Ceramic Electrically Excited to Modulate Fluid </li></ul></ul><ul><ul><li>60 kHz to 100 kHz Drop Modulation </li></ul></ul><ul><ul><li>Drops Charged to Deflect Onto Substrate </li></ul></ul><ul><ul><li>Single or Multiple Nozzles Used </li></ul></ul><ul><ul><li>High Velocity Due to High Pressure </li></ul></ul><ul><ul><li>Control Loop for Fluid Management </li></ul></ul><ul><ul><li>Viscosity 1 to 10 cP </li></ul></ul>
  13. 13. Principles of Operation <ul><li>DOD – Piezo Ceramic Impulse </li></ul><ul><ul><li>PZT Material Squeezes to Form Drop Out </li></ul></ul><ul><ul><li>Gravity Feed Fluid Delivery </li></ul></ul><ul><ul><li>Fragile & Propensity to De-prime </li></ul></ul><ul><ul><li>Heated Chamber to Regulate Fluid Viscosity </li></ul></ul><ul><ul><li>Non-Serviceable Print Head </li></ul></ul><ul><ul><li>Viscosity 5 to 20 cP </li></ul></ul>
  14. 14. Principles of Operation <ul><li>TIJ – Thermal Inkjet </li></ul><ul><ul><li>Nozzle Heater Element Vaporizes Fluid to Form Drop </li></ul></ul><ul><ul><li>Typically Self Contained Print Head/Manifold </li></ul></ul><ul><ul><li>Most Can Be Refilled – OEM’s May Prohibit This Act </li></ul></ul><ul><ul><li>Heads Last Longer When Always Wet </li></ul></ul><ul><ul><li>Traditionally Throw-away Print Head Design </li></ul></ul><ul><ul><li>Viscosity 1 to 5 cP </li></ul></ul>                                                                   
  15. 15. Fluid Properties for Inkjet Technologies <ul><li>Critical Application Considerations </li></ul><ul><ul><li>Select Print Head Technology for </li></ul></ul><ul><ul><ul><li>Chemical Compatibility </li></ul></ul></ul><ul><ul><ul><li>Viscosity Range </li></ul></ul></ul><ul><ul><ul><li>Drop Volume Delivery </li></ul></ul></ul><ul><ul><ul><li>Number of Nozzles Required </li></ul></ul></ul><ul><ul><ul><li>Life of Print Head </li></ul></ul></ul><ul><ul><li>Match Fluid Delivery System with Fluids </li></ul></ul><ul><ul><ul><li>Re-circulate, Air Over Fluid or Gravity Feed </li></ul></ul></ul><ul><ul><li>Be Careful of Fluid Tubing Lengths </li></ul></ul>                                                                   
  16. 16. Future Developments <ul><li>Keep an Eye Out! </li></ul><ul><ul><ul><li>Many Variables Influence Print Performance </li></ul></ul></ul><ul><ul><ul><li>Inkjet is a Blend of Black Art and Science </li></ul></ul></ul><ul><ul><ul><li>Over 3,500 Patents Exist in the Inkjet World Today </li></ul></ul></ul><ul><ul><ul><li>Europe Has a Strong Focus on Environmentally Friendly Fluids </li></ul></ul></ul><ul><ul><ul><li>The Term Eco-Fluids is Used = Economy not Environment </li></ul></ul></ul><ul><ul><ul><li>MEMS is Helping Lower Print Head Cost </li></ul></ul></ul><ul><ul><ul><li>It’s a Razor/Razor Blade Business </li></ul></ul></ul><ul><ul><ul><li>Emerging Markets Will Shadow Traditional Within 10 Years </li></ul></ul></ul>                                                                   
  17. 17. Traditional & Emerging Applications <ul><li>Traditional </li></ul><ul><ul><li>Mark & Code Onto Food & Drug Packaging </li></ul></ul><ul><ul><li>Apply Text, Date, Time and Bar Codes (Non Contact) </li></ul></ul><ul><ul><li>On Demand “Born on Date” Code (Budweiser) </li></ul></ul><ul><ul><li>Fast Print Code Changeover </li></ul></ul><ul><ul><li>Low Cost (10 Character Inkjet Code = 1/100 th of 1¢ or less </li></ul></ul><ul><ul><li>$15 Billion Dollar Industry </li></ul></ul>
  18. 18. Traditional & Emerging Applications <ul><li>Emerging </li></ul><ul><ul><li>Gray-scale Print Quality for Industrial Markers </li></ul></ul><ul><ul><li>6 Axis Robot Integration </li></ul></ul><ul><ul><li>Micro Fabrication of Parts From Solid Model CAD </li></ul></ul><ul><ul><li>Print Electronic Paper, Flexible Circuits or Antennas </li></ul></ul><ul><ul><li>Bio Printing Applications </li></ul></ul><ul><ul><ul><li>Protein Analysis, DNA Sampling, Blood Testing, Tissue Engineering, Quantum Dots, Organ Scaffold, Chemical Analyzers </li></ul></ul></ul><ul><ul><li>Semiconductors </li></ul></ul><ul><ul><ul><li>OLED & PLED Displays, Transistors, MEMS Transducers and Sensors </li></ul></ul></ul>
  19. 19. Traditional & Emerging Applications <ul><li>Emerging </li></ul><ul><ul><li>Print Polymer Based Fiber Networks (Network Routers/Hubs) </li></ul></ul><ul><ul><li>Custom Decal and Decoration for Textiles, Furniture or Durable Goods </li></ul></ul><ul><ul><li>Synthesize Flavors and Aromas on Demand </li></ul></ul><ul><ul><li>Texturing of Material Surfaces </li></ul></ul><ul><ul><li>Estimate $20+ Billion Dollar Industry by 2015 </li></ul></ul>
  20. 20. Emerging Inkjet Markets Examples <ul><li>Industrial Gray-scale Printing (Micro-solenoid DOD) </li></ul><ul><ul><li>Ability to Use Conventional Print Heads </li></ul></ul><ul><ul><li>Real Change is Software & Electronic Drivers (Print Engine) </li></ul></ul><ul><ul><li>Example of Taking the Conventional & Revitalizing It </li></ul></ul>Print engine developed by Matthews Australasia P/L contact:
  21. 21. Emerging Inkjet Markets Examples <ul><li>Industrial Gray-scale Printing (Micro-solenoid DOD) </li></ul>Traditional Line Printing – No Depth
  22. 22. Emerging Inkjet Markets Examples <ul><li>Industrial Gray-scale Printing (Micro-solenoid DOD) </li></ul>Emerging Technology – Shading to Add Depth
  23. 23. Emerging Inkjet Markets Examples <ul><li>Industrial Printing Using 6 Axis Robot </li></ul><ul><ul><li>Replace Conventional Stenciling Method </li></ul></ul><ul><ul><li>Clean, Fast & Automated Printing for Industrial Application </li></ul></ul><ul><ul><li>Every Drop of Ink is Deposited on the Substrate </li></ul></ul><ul><ul><li>No Overspray, Satisfies OCHA Safety Regulations </li></ul></ul><ul><ul><li>Possible Applications: </li></ul></ul><ul><ul><ul><li>Stencil Printer for Stacked Material </li></ul></ul></ul><ul><ul><ul><li>Model Construction by Scaffolding Layers of Resin/Bio Material </li></ul></ul></ul><ul><ul><ul><li>Printing Billboards onto the Most Unusual Substrates </li></ul></ul></ul>
  24. 24. Emerging Inkjet Markets Examples
  25. 25. Emerging Inkjet Markets Examples <ul><li>Electronics </li></ul><ul><ul><li>RFID Tags </li></ul></ul><ul><ul><li>OLED & PLED </li></ul></ul><ul><ul><li>Flat Screen Manufacturing </li></ul></ul><ul><ul><li>Electronic Circuits </li></ul></ul><ul><ul><li>Transistors </li></ul></ul><ul><ul><li>MEMS Devices </li></ul></ul><ul><ul><li>Electronic Paper </li></ul></ul>
  26. 26. Emerging Inkjet Markets Examples <ul><li>Biomedical </li></ul><ul><ul><li>Protein Analysis </li></ul></ul><ul><ul><li>DNA Sampling </li></ul></ul><ul><ul><li>Blood Testing </li></ul></ul><ul><ul><li>Tissue Engineering </li></ul></ul><ul><ul><li>Quantum Dots </li></ul></ul><ul><ul><li>Organ Scaffold </li></ul></ul><ul><ul><li>Chemical Analyzers </li></ul></ul>
  27. 27. Emerging Inkjet Markets Examples <ul><li>3D Model & Prototyping </li></ul><ul><ul><li>Rapid Engineering Development </li></ul></ul><ul><ul><li>Reduce Errors, Time & Cost </li></ul></ul><ul><ul><li>Test Market Without High Cost </li></ul></ul><ul><ul><li>“ See to Believe” Concepts </li></ul></ul><ul><ul><li>CAM – Screen to Machine </li></ul></ul>
  28. 28. Emerging Inkjet Markets Examples <ul><li>Non Contact Decoration & Texture </li></ul><ul><ul><li>Ability to Enhance Low Quality Materials </li></ul></ul><ul><ul><li>Allows Purchase of Low Cost Materials </li></ul></ul><ul><ul><li>Use of More Recycled Materials </li></ul></ul><ul><ul><li>Creative Ways to Increase Profit Margins </li></ul></ul>
  29. 29. Emerging Inkjet Markets Examples <ul><li>High Definition Decoration & Art </li></ul><ul><ul><li>Revitalize Traditional Markets </li></ul></ul><ul><ul><li>Think “Outside the Box” </li></ul></ul>Casket images released with approval of F&F Metal Products Inc Contact Gail Morgan 903-454-9637
  30. 30. Emerging Inkjet Markets Examples <ul><li>Aroma Jetting for Value Perception </li></ul><ul><ul><li>Smell is the New Dimension in Marketing Products </li></ul></ul><ul><ul><li>Scents Used to Enhance Product Perceived Value </li></ul></ul><ul><ul><li>Scent Can be Mixed With Ink = One Product </li></ul></ul><ul><ul><li>Range from New Car Smell, Band-Aids to All Varieties of Fruit </li></ul></ul><ul><ul><li>Scent Invoices Using Aromatherapy to Calm Down Customers </li></ul></ul><ul><ul><li>Enhance Video Game Experience </li></ul></ul>
  31. 31. Emerging Inkjet Markets Examples <ul><li>Many More Applications Waiting to be Discovered </li></ul><ul><li>Think Creatively on How to Use Technology </li></ul><ul><li>Partner With Other Companies </li></ul><ul><ul><li>Offer Turnkey Solutions </li></ul></ul><ul><ul><li>Take Advantage of Others Expertise </li></ul></ul><ul><ul><li>Creative Brainstorming & Cross Marketing Opportunities </li></ul></ul><ul><li>Global Markets Demand Innovation </li></ul><ul><li>Success Breeds Success </li></ul>
  32. 32. End of Presentation. Dean A. Hornsby Digital Printing Specialist Pittsburgh, PA Contact : [email_address]