The use of inkjet printing in electronics manufacturing may be nascent, but as this article explains, each technological advancement makes the process easier to implement.
By Tim Phillips
In recent years, piezoelectric drop-on-demand inkjet technology has garnered significant interest in the field of printed electronics (Figure 1). The basic process of the technology is as follows: Every nozzle in an inkjet printhead contains an ink chamber attached to the ink reservoir. At the back of the chamber is a piezoelectric crystal that vibrates when it receives a charge of electricity. The crystal vibrates inward, extruding an ink droplet from the nozzle and then vibrates outward to replenish the ink in the chamber by pulling more in from the attached reservoir (Figure 2). This mechanism allows the printing of complex, repeatable patterns as defined by a digital image file.
While printing ink onto paper with a desktop digital printer (or onto many other substrates using an industrial system) is common, the same piezoelectric inkjet process can be used to deposit conductive materials instead, hence the term printed electronics. It should be also be noted that while piezoelectric technology is not the only useful approach to printed electronics its preferable drop size and resolution makes it the current industry standard.
Drop-on-demand inkjet deposition of nano-particle conductive inks has already found niches in the fields of photovoltaics, OLEDs, displays, and RFID. Flexibility sets inkjet apart from traditional methods; inkjet technology allows for the additive deposition of thin-line circuits on a range of substrates (Figure 3), including those that are three dimensional. This also cuts costs because materials are only deposited where necessary. This is especially significant because some conductive materials are very expensive.
Inkjet is also non-contact, which means fragile substrates will not be damaged as they are with other methodologies. Printing electronics using inkjet is also significantly less labor intensive and removes the need for expensive tooling or consumables that are a necessary burden in traditional circuit manufacture. The process of tooling is not only time consuming and expensive, but storage and replacements also are an added detriment. Using inkjet, alterations for deposition patterns can be made immediately because there is no wait for a new mask or screen.
Conductive inks
Most circuit boards are printed using expensive vacuum deposition and photolithographic patterning, both of which produce high amounts of environmentally damaging toxic waste. This issue does not apply with inkjet technology. Inkjet also enables the use of biodegradable organic materials that cause less harm to the environment.
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