Effect of Process Parameters on the Performance of Drop-On-Demand 3D Inkjet Printing: Geometrical-Based Modeling and Experimental Validation

As additive manufacturing has evolved, 3D inkjet printing (IJP) has become a promising alternative manufacturing method able to manufacture functional multi-material parts in a single process. However, issues with part quality in terms of dimensional errors and lack of precision still restrict its industrial and commercial applications. This study aims at improving the dimensional accuracy of 3D IJP parts by developing an optimization-oriented simulation tool of droplet behavior during the drop-on-demand 3D IJP process. The simulation approach takes into consideration the effect of droplet volume, droplet center-to-center distance, coverage percentage of jetted droplets, the contact angle of the ink on the solid substrate and coalescence performance of overlapping droplets, in addition to the number of printed layers. Following the development of the simulation tool using MATLAB, its feasibility was experimentally validated and the results showed a good agreement with a maximum deviation of 2.25% for horizontal features. In addition, the simulated horizontal features are compared with the results of “Inkraster” software, which also illustrates droplet behavior, however, only in 2D. For vertical features, a dial gauge indicator is used to measure the sample height, and the validation results show that the simulation tool can predicate the height of the sample with an average error of 10.89% for a large droplet diameter and 8.09% for a small diameter. The simulation results were found to be in a good agreement with the dimensions of the printed parts. The developed tool was then used to elucidate the effect of resolution of processed TIFF image and droplet diameter on the dimensional accuracy of 3D IJP parts

A prototype for 3D electrohydrodynamic printing

Electrohydrodynamic direct writing is a flexible cost effective alternative technique that is capable of producing a very fine jet of liquid in the presence of an external electric field. This jet can then be used to pattern surfaces in an ordered and controlled fashion and offers a robust route to low cost large area micro and nano-manufacturing. Unlike other types of direct writing techniques, the liquid in electrohydrodynamic printing is subjected to both pushing and pulling forces. The pushing force is brought about by the constant flow rate that is maintained via high precision mechanical pumps while a pulling force is applied through a potential difference that is applied between the nozzle and the ground electrode and as a result a fine jet can be generated to pattern surfaces. The impracticality of use and the cost of building micrometre and sub-micrometre sized nozzles to print narrow line widths warrant an investigation into alternative means of dispensing printing inks using nozzles that are cheap to produce, easy to handle and consistent in delivery. The enormous capillary pressures that would have to be overcome in order to print highly viscous materials with micrometre and sub-micrometre sized nozzles may also limit the types of feed that could be used in printing narrow line widths. Thus, the initial work described is focused on improving print head design in an attempt to electrohydrodynamic print pattern narrow line widths using silk fibroin. This is followed by work where we attempt to design and construct of a new electrohydrodynamic printing machine with the sole purpose of expediting research in electrohydrodynamic printing in a flexible, feasible and user friendly manner. To achieve this, replicating rapid prototype technology is merged with conventional electrohydrodynamic printing phenomena to produce a EHD printing machine capable of print depositing narrow line widths. In order to validate the device the work also describes an attempt to print a fully formed human ear out of polycaprolactone. Finally, we investigate an approach to the electohydrodynamic printing of nasal septal scaffolds using the microfabrication system that was developed and optimized in our laboratory. In these initial stages we were successful in showing the degree of control and flexibility we possess when manufacturing constructs out of a biodegradable polymer ( polycaprolactone) from the micro to macro scale through manipulation of just one process parameter (concentration). This work also features characterization of scaffold mechanical properties using a recently invented Atomic force microscopy technique called PeakForce QNM (Quantitative Nanomechanical Property Mapping)

Inkjet Printing of Functional Inks for Smart Products

Inkjet printing is a recent promising technology for direct patterning of solution-based materials over different substrates. It is particularly interesting for applications in the flexible electronics field and smart products manufacturing, as it allows for rapid prototyping, design freedom, and is compatible with conductive, semiconductive, and dielectric inks that can be cured at low temperatures over several types of substrates. Moreover, the inkjet process allows for ink economization, since great electrical conductivity can be achieved despite the deposition of small volumes of ink. This chapter describes the overall process, the main inks and their features, the critical process variables, and its limitations. Applications related to inkjet printing of functional materials and smart products are highlighted. New technology advancements and trends are finally addressed