Laser-Assisted Deposition for High-Speed Multi-Material Printing
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Solution Overview
Problem
Conventional printing techniques for viscous materials, such as screen printing and dispensing systems, face limitations in speed, versatility, and the ability to handle multiple materials simultaneously, particularly in low-volume production and complex droplet size requirements.
Innovation Solution
A system that integrates digital laser-assisted deposition with post-processing capabilities, allowing for high-speed, high-resolution printing and simultaneous application of multiple materials, using a donor module with adjustable angles and a transport unit for precise material placement and inspection, along with optional UV curing and drying units.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If screen printing is used to print viscous materials, then large surfaces can be printed and the basic equipment is inexpensive, but it cannot produce thick enough layers to provide requisite conductance and cannot handle multiple materials simultaneously
Solution Approach 1:
The patent replaces the mechanical screen printing system with a laser-based deposition system. The laser beam selectively heats and evaporates solvent from viscous material droplets, enabling precise control over material deposition without mechanical screens. This allows multiple materials to be printed simultaneously at high speed while maintaining layer thickness control for conductive applications.
Solution Approach 2:
The patent changes the fundamental parameter of material state from liquid/paste (requiring mechanical forcing through screens) to controlled evaporation of solvent from viscous material. By controlling laser parameters (power, duration, scanning speed) and material properties (viscosity, solvent evaporation rate), the system achieves precise deposition of multiple materials simultaneously without the limitations of mechanical screen systems.
2Productivity
If screen printing is used for high-volume production, then throughput is high, but setup time is complex and involved making it not cost effective for low quantities
Solution Approach 1:
The patent eliminates the mechanical screen assembly and disassembly process entirely by using a laser-based system with digital control. Materials are deposited directly through controlled laser evaporation of solvent from viscous material, allowing rapid reconfiguration of printing patterns by changing digital parameters rather than physically reassembling screens. This reduces setup time significantly while maintaining high throughput capability.
3Adaptability or versatility
If screen printing is used, then only one material can be printed at a time, but the process is simple and straightforward
Solution Approach 1:
The patent replaces the single-material screen printing process with a multi-material laser evaporation system. Multiple viscous materials can be deposited simultaneously or sequentially by controlling laser parameters and material delivery mechanisms, enabling complex multi-layer structures and patterns without the physical complexity of managing multiple screens and stencils.
4Manufacturing precision
If screen printing is used to print materials with identical droplet sizes, then the uniform aperture size ensures consistency, but it cannot print materials with different droplet sizes in the same layer
Solution Approach 1:
The patent uses laser parameter control (power, duration, scanning speed) and material properties (viscosity, surface tension) to precisely control droplet formation and evaporation rates. This allows the system to produce different droplet sizes in the same layer by adjusting processing parameters rather than relying on fixed aperture sizes, achieving both precision and versatility.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables high-speed, high-resolution printing with improved repeatability and versatility, allowing for continuous production without cleaning, and the ability to handle multiple materials and post-processing operations efficiently.
Implementation Method 1
A laser beam is scanned over a sample to evaporate a solvent from a viscous material
Implementation Method 2
A laser beam is scanned over a sample to evaporate a solvent from a viscous material
Data Source
AI summary
In systems for printing a viscous material, the printing and post processing of the viscous material are performed sequentially one after another. In an initial step, a viscous material is printed on a sample mounted on a receiver substrate using a donor module and a laser scanner, and then the donor module is replaced with a post processing system for performing a post processing operation (and vice versa). Multiple post processing operations can be performed, and multiple different materials can be printed on the same layer. The systems can increase the speed, resolution and diversity of materials printed on the same sample, and opens the possibilities for new designs.