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Inkjet in advanced manufacturing
Xaar is a leading manufacturer of industrial inkjet printheads. Inkjet technology is increasingly being used in advanced manufacturing for applications such as decor, direct-to-shape printing, electronics, energy, construction, and 3D printing. Xaar's piezoelectric inkjet printheads offer advantages for manufacturing including non-contact printing, compatibility with a wide range of fluids, scalability, and high productivity. Case studies presented show how inkjet printing is being used for applications such as display manufacturing, solar cell production, and nanoimprint lithography.
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Inkjet in advanced manufacturing
- 1. 1 Inkjet in AdvanceManufacturing Ramon Borrell, CTO 15th Anniversary HVM 2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK www.cir-strategy.com/events
- 2. 2 Contents ● Xaar ● IndustrialInkjet ● Case studies in Advanced Manufacturing
- 3. 3 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Xaar Company Overview ● A world leader in the development of inkjet technology and the leading independent manufacturer of industrial inkjet printheads ● Founded in 1990 as spin-off from Cambridge Consultants Ltd ● 1997 London Listing (XAR) ● Turnover: £96.2m in 2016 ● Employees: 550 ● Over 250 patents granted/pending ● Core business: design, manufacture and sale of printheads. Legacy business from licensing ● Licensees include Seiko Instruments, Konica Minolta and Toshiba Tec ● Direct customers are OEM’s of digital printing equipment ● Acquired EPS (USA) and Blueprinter (Denmark), entering integration business in product printing and 3D printing ● Based on Science Park, Cambridge, UK. Manufacturing Huntingdon, UK.
- 4. 4 Our four strategicpillars Mission: Leading the Digital Inkjet Revolution. Vision: annual sales of £220m by 2020 Maintain Grow New Expand
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- 6. 6 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Industrial Inkjet Today ● Key drivers “More for Less” Manufacturing flexibility Mass customisation ● Analogue to digital shift ● Inkjet expansion to industrial print Commercial – books, brochures, bills Packaging – coding, direct-to-shape Décor – ceramics, laminates, glass Textile – clothing and decor ● Functional applications emerging Electronics – devices and displays Energy – cells, batteries Construction – structural coatings Bio-medical Xaar Industrial, excluding Ceramics, grew 80% YOY in 2017
- 7. 7 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Décor ● …and coatings and conductive inks ● Decorative and functional applications ● Internal and external applications ● Ceramic tiles, Laminates, Glass ● On-demand and short-run printing ● Printing of UV inks, glazes and glass frits… ● Enables new products
- 8. 8 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Direct to Shape ● Direct Printing Packaging – Bottles, Cans Non-uniform shapes ● Broad range of applications Beverage Automotive, aviation General industry ● Replacement of labels and analogue coatings ● On-demand and short-run print ● Skyscraper and multi-axis print modes
- 9. 9 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK • Non contact • Wide range of fluids (any chemistry, only limited by viscosity) • Low cost (£0.4 to £3 per nozzle) • Modular, easy to integrate • Scalable (20mm to 5m) • High productivity (up to 25 l/h per printhead) • Versatile • Many printhead models with broad range of properties • Flexible operation Why is piezo IJ suitable for manufacturing?
- 10. 10 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK • Drops from 0.3pl up to 600pl in current range • From CMOS to glazes • Viscosities from 2 mPa s up to 60 mPa s • From biological samples to polymers for 3D printing • From 128 up to 5680 nozzles per printhead • From microscope slides to 10.5G display glass • Up to 60% solid content by mass • High load of silver nanoparticles • Resolution from 90dpi up to 1200dpi • Braille text to microtext and security features • From 0.2mm to 15mm distance to substrate • Silicon wafers to boxes in motion Xaar Industrial InkJet properties
- 11. 12 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK • Precise structures and features of sub-micron precision • High resolution and high nozzle density • Small drops, multidrop jetting • 64 levels of individual adjustment for each sub drop • To adjust volume or velocity for precise landing • Microsecond level timing adjustment • Up to 16 separate drive signals per printhead • Precise fluid temperature control • Maintain physical properties constant Thin Film Si-MEMS offers unprecedented control
- 12. 13 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Actuator design • Elongate channels, open at both ends, symmetrical design • for true high flow recirculation; provides thermal stability, thermal range, jetting reliability, tolerance to particles and air, tolerance to ink sedimentation even with the most difficult inks, extended viscosity range • Nozzle located in pressure chamber for maximum benefit of recirculation design • Roof mode, bending mode (d31) • 4 rows of channels 300 npi each, interlaced for 1200 dpi printing
- 13. 14 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK • Circular nozzles with high accuracy in location and dimensions, plus excellent uniformity and finish quality • Optimised nozzle shape delivers excellent directionality and low voltage requirements, while benefiting from recirculation Si MEMS nozzle plate + dry etching Straight Tapered Straight
- 14. 15 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Dot placement error launch target of 3S = 5um Long term target 3S = 3um Total landing error could be less than 2um on substrate Excellent dot landing 1mm 1200 dpi pixel grid 10um visibility limit 5um target 3S = 6.06um
- 15. 16 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Excellent text quality Arial 6 pts – 1.5 mm Arial 1 pt – 250 µm Arial 6 pts – 1.5 mm Arial 1 pts – 250 µm
- 16. 17 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Jetting performance
- 17. 18 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK • Highly optimised structure made of 23 distinct layers from 37 deposition steps • Stack geometry dimensions in 3 directions optimised for maximum mechanical efficiency Actuator stack design
- 18. 19 Use cases inAdvanced Manufacturing Xaar Advance Manufacturing is growing 200% CAGR
- 19. 20 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Multiple process using IJ • Obscuration • Conductive tracks • Insulation layer • OLED materials • Encapsulation • Antenna • Decoration Displays and portable devices
- 20. 21 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Cover lens Printing 1. Black Matrix (inkjet) Cover Glass Key Drivers • Cost savings • 80% screen printing yield vs 98% inkjet yield • Less material handling • Less setup/NRE • Screen grid loosens up while inkjet always prints the same exact drop • Faster production: 2+ passes vs single pass • Easier prototyping • On demand - less inventory • Ink height of 2um vs 5-6um for screen printing • Straight lines are shaper with inkjet • 4 color capable for logos, still in single pass.
- 21. 22 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Display PI Layer PI Machine • Using 1002 GS6 Alpha 5 heads • Extra robustness to jet aggressive Polyimide fluid • 16 heads per machine • 8 X 8” tablets per sheet • 333,600 tablets per month Key Drivers • Non contact printing • Reduced breakage • Much cleaner than flexo • Can control thickness in isolation layer much better
- 22. 23 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Inkjet Antenna – reduces total height ink Screen print paste Display Screen Print Process Inkjet Process Inkjet silver nano ink Display Inkjet Screen-print 27µm Main reason for using inkjet is height – 2um for silver ink and passivation layers vs 6um with screen printing. Customer wants to reduce total thickness of mobile device and tablets.
- 23. 24 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Touchscreen 1. Black Matrix (inkjet) 3. OC1 Insulator (inkjet) 4. Metal Trace (gravure) 2. ITO Grid (gravure) 5. OC2 Overcoat (inkjet) X X X Y Y Cover Glass ● Displays for mobile devices ● Multilayer touchscreen – 2.5D printing ● Multiple print technologies Flexography Off-set gravure Inkjet
- 24. 25 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Smart Glass Merk Window Tech • Use Liquid Crystal in windows to darken interior of commercial buildings • Also have touch capability to create venetian blind type appearance • Have 4 business partners who will license • Big potential as the volume of glass needed per building • Using Xaar 1002 to print PI isolation layer
- 25. 26 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Solar Cell ● Schmid (Germany) ● Selective Emitter Technology - Nanojet ● 1,650 wafers / hour (single lane) ● 1270 x 1080 dpi (adjustable) ● 32um track width (±2-3um) ● Uptime 95% ● Low breakage: Contact-free process Very smooth wafer handling ● Reduced silver cost ● 0.3% cell efficiency gain
- 26. 27 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Solar Cell Inkjet Process (Seed+Plate) high conductive plated silver conductive seed ink Burn-In Cell emitter 47.5µm 11 µm Nano-Jet + Ag LIP
- 27. 28 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Nano Imprint Lithography Information supplied courtesy of ● Canon Nanotechnologies (USA) ● Acquired in 2014 ● Feature sizes down to 23nm ● 2013 – First 450mm patterned disk with Jet and Flash ™ ● Uses Xaar 1003 AMpX variant ● Drop sizes under 1.0pL at high frequency
- 28. 29 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK 16nm 11nm 22nm 10nm Pillars 2.4nm Features J. Rogers 22nm Information supplied courtesy of Nano Imprint Lithography
- 29. 30 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Jet and Flash™ Imprint Lithography
- 30. 33 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK 25n m 3D printing ● 7 processing technologies ● Range of materials Metals; Polymers; Ceramics; Paper ● Applications Modelling Prototyping Bespoke manufacturing Small batch manufacturing ● 3 inkjet based technologies Direct material jetting - polymers Binder jetting – to powder bed Powder bed fusion - HSS
- 31. 34 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK High Speed Sintering
- 32. 35 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK High Speed Sintering
- 33. 36 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Part cost projections Euros
- 34. 37 15th Anniversary HVM2107 & Graphene New Materials Conference 2-3 November 2017 Cambridge, UK Ramon Borrell, CTO Xaar plc Cambridge, UK ramon.borrell@xaar.com Thank you! Wafer of actuators for 5601 Xaar new 5601 GS3 Thin Film Si-MEMS printhead