Innovation in industrial inkjet technology - I4T
Lead Research Organisation:
University of Cambridge
Department Name: Engineering
Abstract
Industrial inkjet technology involves the generation, manipulation and deposition of very small drops of liquid (typically 20-50 um diameter) under digital control. The UK is recognised internationally as a leader in this area. Inkjet technology already dominates the desktop printing market. In commercial printing, it is rapidly becoming established for short-run applications and has, in only a few years, conquered a market previously occupied by conventional screen-printing equipment, where its great flexibility and inherent scalability give significant advantages. If higher printing speeds and greater quality can be achieved, then it will also be able to move into large-volume commercial printing. Apart from these printing applications, novel opportunities for inkjet deposition are also beginning to be exploited commercially in the manufacturing of high-value, high precision products (e.g. flat-panel displays, printed/plastic electronics, photovoltaic cells for power generation). By extending the existing benefits of inkjet methods (e.g. flexible, digital, non-contact, additive) to attain the speed, coverage and material diversity of conventional printing and manufacturing systems, we can transform inkjet from its present status as a niche technology into a group of mainstream processes, with the UK as a major player. But in order for this transformation to happen, we need a much better understanding of the science underlying the formation and behaviour of very small liquid drops at very short timescales, and to widen the range of materials which can be manipulated in this way, especially to allow fluids with high solids content (i.e. colloidal fluids) to be deposited. This cross-disciplinary programme of research is strongly supported by a consortium of nine UK-based companies and will bring together established research groups from three major UK universities to study three themes focused on key aspects of the industrial inkjet process: the formulation, rheology and jetting behaviour of colloidal printing fluids; understanding and controlling dynamic micro-scale drop impact, spreading and fixing; and development and validation of an advanced process model for industrial inkjet. Within these themes we aim to: develop a theoretical and practical understanding of how to make stable high solid-content colloids suitable for inkjet deposition, and how they behave in an inkjet system and on the substrate; explore post-impact processes that determine the structure and functionality of the printed features, including surface morphology, chemistry and surface treatment, fluid dynamics of wetting and the interaction of successively printed materials; and develop a set of models, validated by precise measurements and underlying physical theory, to describe all aspects of the formation and ultimate fate of ink drops. Industrial beneficiaries will include companies in the fields of inkjet printing and digital manufacturing, as well as other companies involved in the precise manipulation of small liquid droplets: examples of sectors include pharmaceuticals, agrochemicals, combustion, coating application, materials processing, and particle technology. Academic beneficiaries, apart from researchers working directly on inkjet technology, will include those in the fields of rheology, fluid mechanics, microfluidics, materials science and surface engineering.
Planned Impact
Immediate beneficiaries from the research will include the nine Project Partners, who represent the majority of UK companies involved in the development of equipment and materials for the industrial application of inkjet and several companies at the forefront of the application of inkjet to printing or manufacturing. The UK is recognised internationally as a leader in this emerging area. The printing industry plays a major role in the UK economy (the printed products market alone is worth ~14 billion annually, not including any manufacturing). In industrial printing, benefits from the work will include: faster printing, in terms of substrate speed and fluid throughput; seamless single-pass printing with sequential deposition of several different kinds of fluid; more accurate feature definition; reduced development timescales for fluids and printing systems, through the use of validated modelling; and the availability of novel tools for monitoring, process design and control, and optimization. Inkjet is also an enabling technology for the potentially disruptive plastics electronics industry, on which the UK is well-placed to capitalise in the near to medium term; it is also employed in the manufacture of photovoltaic power generators. There are also numerous potential applications of inkjet technology within the direct-write area and in other manufacturing sectors; one in particular is the dosing of active agents in pharmaceutical manufacture. The UK has a global presence in the pharmaceutical industry. For manufacturing applications such as these the benefits will include: the ability to deposit a much wider range of materials, including fluids with high solids content; improved ability to predict and control the behaviour of drops on impact; and better fundamental understanding of droplet deposition and spreading. Other industrial sectors which may benefit from the research outputs, either directly or via the enhancement of fundamental understanding, include pharmaceuticals (for drug delivery by inhalation), agrochemicals (e.g. crop spraying and product manufacture), combustion, coating application, materials processing, and particle technology. The use of inkjet printing as a tool for depositing cells and other biological materials for tissue engineering and the fabrication of diagnostic sensors forms a lively research area, and outputs from the programme should be of benefit to future developments, both academic and commercial, in these healthcare-related areas. The generic expertise developed by research staff during the project will be of direct benefit to potential future employers in all the above sectors. The investigators have experience of working with industrial partners and outputs will be transferred through written reports, exchange of 'know-how' through training workshops and/or exchange of staff, through commercial development of instrumentation, and through the supply of software. Benefits to the wider industrial user community, both in the UK and abroad, will result from delivery of the outputs via the usual channels of academic publication and academically-focused seminars and conferences, but also through publication of summary articles in the trade press and through presentations and tutorials at conferences and meetings with a strong industrial attendance. A biennial Symposium on Applied Inkjet Science is also planned and aimed to attract delegates from the industrial research and development sector. In some cases (e.g. improved rheological measurements, diagnostic instrumentation or modelling) outputs may lead to new instruments or software which will be exploited through the universities in accordance with the consortium agreement, for example through licensing agreements or the formation of spin-out companies; the investigators have experience of both routes.
Organisations
- University of Cambridge (Lead Research Organisation)
- Cambridge Display Technology (Collaboration)
- XAAR PLC (Collaboration)
- Domino (UK) (Collaboration)
- Sun Chemical Ltd (Collaboration)
- FFEI (Collaboration)
- Linx Printing Technologies Ltd (Collaboration)
- Sericol Group Ltd (Collaboration)
- Inca Digital Printers Ltd (Collaboration)
- Domino (United Kingdom) (Project Partner)
- Sun Chemical (United Kingdom) (Project Partner)
- Sumitomo Chemical (United Kingdom) (Project Partner)
- Fujifilm (United Kingdom) (Project Partner)
- Linx Printing technologies Plc (Project Partner)
- GlaxoSmithKline (United Kingdom) (Project Partner)
- Inca Digital Printers (United Kingdom) (Project Partner)
- Fujifilm (United Kingdom) (Project Partner)
- Xaar (United Kingdom) (Project Partner)
Publications
Johns AS
(2017)
Ink-Jet Printing of High-Molecular-Weight Polymers in Oil-in-Water Emulsions.
in ACS applied materials & interfaces
Talbot EL
(2015)
Printing small dots from large drops.
in ACS applied materials & interfaces
Talbot EL
(2014)
Control of the particle distribution in inkjet printing through an evaporation-driven sol-gel transition.
in ACS applied materials & interfaces
García F
(2014)
The breakup length of harmonically stimulated capillary jets
in Applied Physics Letters
Dhillon P
(2014)
Topographical length scales of hierarchical superhydrophobic surfaces
in Applied Surface Science
Castrejon-Pita J. R.
(2013)
FUTURE, OPPORTUNITIES AND CHALLENGES OF INKJET TECHNOLOGIES
in ATOMIZATION AND SPRAYS
Castrejon-Pita J
(2013)
FUTURE, OPPORTUNITIES AND CHALLENGES OF INKJET TECHNOLOGIES
in Atomization and Sprays
Lorber B
(2014)
Adult rat retinal ganglion cells and glia can be printed by piezoelectric inkjet printing.
in Biofabrication
Castrejón-Pita JR
(2011)
The dynamics of the impact and coalescence of droplets on a solid surface.
in Biomicrofluidics
Brown P
(2015)
Controlling picolitre droplet impact dynamics by tailoring the solid subsurface
in Colloids and Surfaces A: Physicochemical and Engineering Aspects
Description | This research has studied the way in which small drops of liquid are generated and then behave on impact with a surface, in the context of inkjet printing. Inkjet printing is a process which is rapidly replacing more conventional methods for some types of commercial printing, and is also of great interest as a manufacturing process - it can be used to deposit precise patterns of all kinds of materials and so is valuable in the areas of micromanufacturing, electronics, biomanufacturing, medical diagnostics and 3D printing (additive manufacturing). In our work we have extended the understanding of the way in which complex fluids (such as suspensions of particles and solutions of polymers) behave under printing conditions. We have developed powerful computer models for drop and jet formation and experimental methods and equipment which are now being used by industrial partners. We have explored the way in which these very small drops of liquid behave on impact, coalesce with neighbouring drops and merge to form continuous lines. A university spin-out company has been set up to exploit inkjet-printed liquid crystal lasers. |
Exploitation Route | Many of the findings are already being taken forward by existing industrial partners, and we anticipate their application in diverse industrial sectors, as well as in future research by ourselves and other academic groups. |
Sectors | Aerospace Defence and Marine Agriculture Food and Drink Chemicals Creative Economy Education Electronics Energy Healthcare Manufacturing including Industrial Biotechology Culture Heritage Museums and Collections Pharmaceuticals and Medical Biotechnology Retail Security and Diplomacy |
URL | http://www.ifm.eng.cam.ac.uk/research/irc/i4t/about/ |
Description | The following outputs from the project have been exploited by our industrial partners and others: • increased understanding of the behaviour of fluids with high solids content and containing polymers, leading to the ability to print increasingly complex fluids • improved ability to control drop placement accuracy through better methods of understanding factors controlling jet directionality and aerodynamic effects on drops in flight • improved ability to predict and control the behaviour (spreading/curing/drying) of drops on impact and during coalescence on a non-porous substrate • reduced development timescales for fluids and printing systems, through the use of validated modelling, for complex fluids • the use of advanced imaging techniques including micro-PIV and holographic methods to study flow in nozzles and jets, and also droplet fields . the development of a new filament-stretching rheometer . new understanding of free-surface fluid flow . new method for fabrication of liquid crystal lasers dots by inkjet printing |
First Year Of Impact | 2011 |
Sector | Creative Economy,Electronics,Manufacturing, including Industrial Biotechology,Pharmaceuticals and Medical Biotechnology,Other |
Impact Types | Economic |
Description | EPSRC High-End Computing Consortia |
Amount | £397,424 (GBP) |
Funding ID | EP/L00030X/1 |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 05/2013 |
End | 05/2018 |
Description | EPSRC Industrial CASE Award |
Amount | £92,000 (GBP) |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 09/2015 |
End | 03/2019 |
Description | EPSRC call: Future Formulation of Complex Products |
Amount | £2,270,560 (GBP) |
Funding ID | EP/N025245/1 |
Organisation | Engineering and Physical Sciences Research Council (EPSRC) |
Sector | Public |
Country | United Kingdom |
Start | 06/2016 |
End | 06/2020 |
Title | Trimaster 4 |
Description | Filament-stretching rheometer with very high speed capability |
Type Of Material | Improvements to research infrastructure |
Provided To Others? | No |
Impact | Enables study of Newtonian and non-Newtonian fluids by filament-stretching rheometry under conditions close to those experienced in inkjet printing |
Description | Cambridge Display Technology Ltd |
Organisation | Cambridge Display Technology |
Country | United Kingdom |
Sector | Private |
Start Year | 2005 |
Description | Domino U K Ltd |
Organisation | Domino (UK) |
Country | United Kingdom |
Sector | Private |
Start Year | 2005 |
Description | FFEI Limited |
Organisation | FFEI |
Country | United Kingdom |
Sector | Private |
Start Year | 2005 |
Description | Inca Digital Printers Ltd |
Organisation | Inca Digital Printers Ltd |
Country | United Kingdom |
Sector | Private |
Start Year | 2005 |
Description | Linx Printing technologies Plc |
Organisation | Linx Printing Technologies Ltd |
Country | United Kingdom |
Sector | Private |
Start Year | 2005 |
Description | Sericol Group Ltd |
Organisation | Sericol Group Ltd |
Country | United Kingdom |
Sector | Private |
Start Year | 2005 |
Description | Sun Chemical Ltd |
Organisation | Sun Chemical Ltd |
Country | Canada |
Sector | Private |
Start Year | 2005 |
Description | Xaar Plc |
Organisation | Xaar plc |
Country | United Kingdom |
Sector | Private |
Start Year | 2005 |
Title | A novel method for on demand droplet generation |
Description | A novel method for on demand droplet generation |
IP Reference | GB1214798.9 |
Protection | Patent application published |
Year Protection Granted | |
Licensed | No |
Impact | - |
Title | PRINTING OF LIQUID CRYSTAL DROPLET LASER RESONATORS ON A WET POLYMER SOLUTION AND PRODUCT MADE THEREWITH |
Description | A photonic device is manufactured by: (i) providing (e.g. by inkjet printing) an aliquot of a liquid crystal material (504); and (ii) depositing the aliquot onto the surface of a flowable material layer (502) to form a liquid crystal deposit, the flowable material and the LC material being substantially immiscible. The liquid crystal deposit adopts a deformed shape relative to the shape of the aliquot due to interaction with the flowable material layer. This promotes alignment of the LC material. Incorporation of a laser dye allows the photonic device to function as a laser, which can be operated above or below threshold depending on the circumstances. The photonic device can also be used as a passive device based on the photonic bandgap of the aligned LC material. |
IP Reference | WO2013175225 |
Protection | Patent application published |
Year Protection Granted | 2013 |
Licensed | Commercial In Confidence |
Impact | Confidential |
Company Name | Ilumink |
Description | Ilumink has developed a method of printing lasers, which can be used for authentication documents, security purposes and anti-counterfeiting. |
Year Established | 2013 |
Impact | Based upon world-leading breakthroughs in printable laser technology at the University of Cambridge, ilumink is developing new approaches for physical authentication. |
Website | http://www.tracerco.com |
Description | Annual public demonstrations during open day event |
Form Of Engagement Activity | Participation in an open day or visit at my research institution |
Part Of Official Scheme? | Yes |
Geographic Reach | Regional |
Primary Audience | Public/other audiences |
Results and Impact | Various different demonstrations given over the years stimulating interest in fluid dynamics and inkjet technology. Lots of audience participation and positive feedback. Audience mainly school age children with parents so adding to a positive view about engineering to this group. |
Year(s) Of Engagement Activity | 2010,2011,2012,2013,2014,2015 |
URL | http://www.sciencefestival.cam.ac.uk/ |
Description | Invited presentation at The Inkjet Conference, Dusseldorf, October 2015 |
Form Of Engagement Activity | A talk or presentation |
Part Of Official Scheme? | No |
Geographic Reach | International |
Primary Audience | Professional Practitioners |
Results and Impact | - |
Year(s) Of Engagement Activity | 2015 |