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. 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. 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. 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. 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. 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. Banding in inkjet printers
Courtesy of Jos Notermans
Stork Digital Imaging
10. Banding in inkjet printers
• Positioning errors also cause color shifts
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. 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. 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. 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. 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
17. Stork Digital Imaging
colorproofing inkjet printer
Simulation Print Head Capstan Drive System
i
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. 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. Stork Digital Imaging
colorproofing inkjet printer
Scanning accuracy
+/- 2 μm b
/ boundaries
d i
s
nominal curve s(t)
t
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. 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. 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
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. 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. 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. 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. 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. 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. 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. Etchresist printing
p g
Inkjet versus Lithography
Photoplot Laminate UV-exposure Develop
With courtesy of Hylke Veenstra, Oce
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. 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. Conclusions
Accuracy versus Cost
• Cost driven:
– What must be accurate??
– What can be inaccurate?!
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
40. 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
41. 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
42. 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.
49. 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
50. 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
51. 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
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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
