Additively Printed Multilayer Substrate Using Aerosol-Jet Technique

2020 ◽  
Vol 142 (4) ◽  
Author(s):  
Pradeep Lall ◽  
Kartik Goyal ◽  
Nakul Kothari ◽  
Benjamin Leever ◽  
Scott Miller
Keyword(s):  
Process Parameters ◽  
Computer Aided Design ◽  
Process Capability ◽  
Dimensional Accuracy ◽  
High Viscosity ◽  
Process Efficiency ◽  
Low Viscosity ◽  
Aided Design ◽  
Print Process ◽  
Pneumatic Atomizer

Abstract Printing technologies, such as aerosol-jet, open possibilities of miniaturizing interconnects and designing circuits on nonplanar surfaces. Aerosol-jet is a direct-printing technique that provides an alternative manufacturing option to traditional subtractive methods that entail lithography or etching. Additionally, the aerosol-jet technique allows the circuits fabrication using noncontact method. Wide impact areas range from healthcare to wearables to future automotive applications. The aerosol-jet printer from Optomec utilized in this study consists of two types of atomizers, depending on ink viscosity. The ultrasonic atomizer, supports ink with a viscosity range of 1–5 cP, and the pneumatic atomizer that has a larger range of 1–1000 cP. This paper focuses on utilizing the aerosol-jet technique, using both atomizers to develop process parameters, in order to successfully print bimaterial, multilayer circuitry. The insulating material between two conductive lines used in the paper is of very high viscosity of 350 cP, which is suitable for the pneumatic atomizer and silver nanoparticle ink with comparatively low viscosity of 30 cP for the ultrasonic atomizer as a conductive ink. This paper also presents a statistical modeling approach that predicts line attributes, including microvia-diameter, before starting the print process, enabling us to pre-adjust the dimensions in computer-aided design for the desired output. Process parameters can obtain a fine print with satisfactory electrical properties, which develops improved dimensional accuracy. The importance of precleaning the substrate in addition to the printing process efficiency gaged as a function of process capability index and process capability ratio is also presented.

Effect of Process Parameters on Aerosol Jet Printing of Multi-Layer Circuitry

2019 ◽  
Author(s):  
Pradeep Lall ◽  
Kartik Goyal ◽  
Nakul Kothari ◽  
Ben Leever ◽  
Scott Miller
Keyword(s):  
Process Parameters ◽  
Printed Circuit Board ◽  
Process Capability ◽  
Dimensional Accuracy ◽  
High Viscosity ◽  
Circuit Board ◽  
Process Efficiency ◽  
Jet Printing ◽  
Aerosol Jet Printing ◽  
Pneumatic Atomizer

Abstract Printing technologies such as Aerosol Jet provides the freedom of miniaturizing interconnects and producing fine pitch components. Aerosol Jet, a direct printing technique replaces the traditional steps of manufacturing a printed circuit board such as lithography or etching, which are quite expensive, and further allowing the circuits to be fabricated onto all kinds of substrates. Wide impact areas range from healthcare to wearables to future automotive applications. The aerosol jet printer from Optomec utilized in this study, consists of two types of atomizers depending on ink viscosity. One is Ultrasonic Atomizer which supports ink with viscosity range of 1–5cP, and another is Pneumatic Atomizer with large range of suitable viscosity 1–1000cP. This paper focuses on utilizing the aerosol jet printing using both the atomizers to develop process parameters to be able to successfully print bi-material, multi-layer circuitry. The insulating material between two conductive lines used in the paper is of very high viscosity of 350cP, suitable for Pneumatic atomizer and Silver Nano-particle ink with the viscosity suitable for Ultrasonic atomizer as a conductive ink. A statistical modeling approach is presented to predict the attributes such as micro-via diameter before starting the print process, enabling us to pre-adjust the dimensions in CAD for the desired output. Process parameters to obtain a fine print with good electrical properties and better dimensional accuracy are developed. Importance of pre-cleaning the substrate is discussed, in addition to the printing process efficiency gauged as a function of process capability index and process capability ratio.

Process Capability of Aerosol-Jet Additive Processes for Long-Runs Up to 10-Hours

2020 ◽  
Vol 142 (4) ◽  
Author(s):  
Pradeep Lall ◽  
Amrit Abrol ◽  
Nakul Kothari ◽  
Benjamin Leever ◽  
Scott Miller
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Process Capability ◽  
High Volume ◽  
Process Efficiency ◽  
Shear Load ◽  
Additive Processes ◽  
Sintering Time ◽  
Load To Failure ◽  
Aerosol Jet Printing

Abstract Traditionally, printed circuit assemblies have been fabricated through a combination of imaging and plating-based subtractive processes involving the use of photo-exposure followed by baths for plating and etching in order to form the necessary circuitry on rigid and flexible laminates. The emergence of a number of additive technologies presents an opportunity for the development of processes for manufacturing of flexible substrates by utilizing mainstream additive processes. Aerosol-jet printing is capable of printing lines and spaces below 10 μm in width. The aerosol-jet system also supports a wide variety of materials, including nanoparticle inks, screen-printing pastes, conductive polymers, insulators, adhesives, and biological matter. The adoption of additive manufacturing for high-volume commercial fabrication requires an understanding of the print consistency and electrical mechanical properties. Little literature that addresses the effect of varying sintering time and temperature on the shear strength and resistivity of the printed lines exists. In this study, the effect of process parameters on the resultant line consistency and mechanical and electrical properties has been studied. Print process parameters studied include sheath rate, mass flow rate, nozzle size, substrate temperature, and chiller temperature. Properties include resistance and shear load to failure of the printed electrical line as a function of varying sintering time and temperature. The aerosol-jet machine has been used to print interconnects. Printed samples have been exposed to different sintering times and temperatures. The resistance and shear load to failure of the printed lines have been measured. The underlying physics of the resultant trend was then investigated using elemental analysis and scanning electron microscopy. The effect of line consistency drift over prolonged runtimes has been measured for up to 10 h of runtime. The printing process efficiency has been gaged as a function of the process capability index (Cpk) and process capability ratio (Cp). Printed samples were studied offline utilizing optical profilometry in order to analyze the consistency within the line width, height, and resistance, and shear load to study the variance in electrical and mechanical properties over time.

Computer Aided Design of Manufacturing of Anchors and Formulation of the Optimization Task for in Use Properties

2013 ◽  
Vol 554-557 ◽  
pp. 372-382
Author(s):  
Mariusz Skóra ◽  
Stanislaw Weglarczyk ◽  
Jan Kusiak ◽  
Maciej Pietrzyk
Keyword(s):  
Computer Aided Design ◽  
Dimensional Accuracy ◽  
Influence Of Process Parameters ◽  
Rheological Models ◽  
Optimization Task ◽  
Multi Stage ◽  
Bainitic Steels ◽  
Computer Aided ◽  
Aided Design ◽  
Selection Of

Computer aided design of the manufacturing technology for anchors is presented in the paper. Evaluation of applicability of various materials for anchors, as well as analysis of the influence of process parameters on the in use properties of product, were the objectives of the research. In the material part, bainitic steels were considered as an alternative for the commonly used C-Mn steels. Possibility of elimination of the heat treatment was evaluated. Rheological models for the investigated steels were developed and implemented into the finite element code for simulations of drawing and multi stage forging. Criteria for the selection of the best manufacturing chain composed dimensional accuracy, tool life and product properties. Industrial trials were performed for the selected cycle and the efficiency of this cycle was evaluated. Finally, simulations of the in use behaviour of the anchor-concrete joint were performed. On the basis of the simulations the optimization task using strength of the joint as the objective function was formulated

scholarly journals Implant Impression Making: Take-Off Guide for Beginners

2021 ◽  
Author(s):  
Aaina Dhanda ◽  
Tarun Kalra ◽  
Manjit Kumar ◽  
Ajay Bansal ◽  
Ruchi Sharma
Keyword(s):  
Computer Aided Design ◽  
Dimensional Accuracy ◽  
Computer Assisted ◽  
Impression Materials ◽  
Starting Point ◽  
Irreversible Hydrocolloid ◽  
Passive Fit ◽  
Edentulous Patients ◽  
Aided Design ◽  
Relationship Of

AbstractDental implants are fixtures that constitute for the replacements of the root of a missing natural tooth. Dental implant therapy has been widely used for the restoration of partially and fully edentulous patients. The implant literature emphasizes the importance of a passively fitting prosthesis to prevent prosthodontic complications or even loss of fixture integration. Failure to achieve a passively fitting prosthesis and force tightening of superstructure may result in complications such as abutment, framework, and gold screw loosening or fracture. Various materials that can be used for making an implant impression are polyether, polyvinylsiloxane, condensation silicone, polysulfide, irreversible hydrocolloid material, and various others. There are various studies in relation to the accuracy of these impression materials out of which various scientists concluded different results with most studies stating polyether with the maximum amount of dimensional accuracy in comparison to other materials. An accurate implant impression plays a significant role and serves as a starting point in the process of producing good working casts. Thus, the accuracy of impression techniques becomes a significant issue in consideration of passive fit. Reproduction of intraoral relationship of implants through impression procedures is the first step in achieving accurate fit prosthesis. This transference is still complicated by the number, angulation, depth, and position of implants. The advent of computer-aided design/computer-assisted manufacturing technology improved the framework fabrication procedures and has increased the precision of fit of implant prosthesis.

Fabrication and Design of Customized Maxillofacial Biomodel for Implant Using Computer Aided Design and Rapid Prototyping Technique

2013 ◽  
Vol 391 ◽  
pp. 406-409 ◽  
Author(s):  
Wan Yusoff Way ◽  
M. Aichouni ◽  
M. Zul Amzar Zulkiflee ◽  
Mohd Sallehuddin Ahmad Derifaee
Keyword(s):  
Rapid Prototyping ◽  
Computer Aided Design ◽  
Fused Deposition Modeling ◽  
Dimensional Accuracy ◽  
Design Technology ◽  
Fused Deposition ◽  
Computer Aided ◽  
Analysis Computer ◽  
Operational Error ◽  
Aided Design

The purpose of this research is to fabricate bio-model that based on Rapid Prototyping technology which is by using Fused Deposition Modeling (FDM) and designing an implant by using a Computer Aided Design technology. A case study from Hospital Kuala Lumpur which is the maxillofacial will be fabricated by using FDM technique. The completed 3D prototype or biomodel will be analyzed to makes the result more truthful in terms of the dimensional accuracy, operational error and cost analysis. Computer aided design technology is used to design the customized implant in order to replace the fractured maxilla part.

Process Capability of Aerosol-Jet Additive Processes for Long-Runs up to 10-Hours

2019 ◽  
Author(s):  
Pradeep Lall ◽  
Amrit Abrol ◽  
Nakul Kothari ◽  
Ben Leever ◽  
Scott Miller
Keyword(s):  
Mechanical Properties ◽  
Process Parameters ◽  
Process Capability ◽  
High Volume ◽  
Process Efficiency ◽  
Shear Load ◽  
Additive Processes ◽  
Sintering Time ◽  
Load To Failure ◽  
Aerosol Jet Printing

Abstract Traditionally, the printed circuit assemblies have been fabricated through a combination of imaging and plating based subtractive processes involving use of photo-exposure followed by baths for plating and etching to form the needed circuitry on rigid and flexible laminates. Additive electronics is finding applications for fabrication of IoT sensors. The emergence of a number of additive technologies poses an opportunity for the development of processes for manufacture of flexible substrates using mainstream additive processes, which are now commercially available. Aerosol-Jet printing has shown the capability for printing lines and spaces below 10 μm in width. The Aerosol-Jet system supports a wide variety of materials, including nanoparticle inks and screen-printing pastes, conductive polymers, insulators, adhesives, and even biological matter. The adoption of additive manufacturing for high-volume commercial fabrication requires an understanding of the print consistency, electrical and mechanical properties. Little literature exists that addresses the effect of varying sintering time and temperature on the shear strength and resistivity of the printed lines. In this study, the effect of process parameters on the resultant line-consistency, mechanical and electrical properties has been studied. Print process parameters studied include the sheath rate, mass flow rate, nozzle size, substrate temperature and chiller temperature. Properties include resistance and shear load to failure of the printed electrical line as a function of varying sintering time and varying sintering temperature. Aerosol-Jet machine has been used to print interconnects. Printed samples have been exposed to different sintering times and temperatures. The resistance and shear load to failure of the printed lines has been measured. The underlying physics of the resultant trend was then investigated using elemental analysis and SEM. The effect of line-consistency driftover prolonged runtimes has been measured for up to 10-hours of runtime. Printing process efficiency has been gauged a function of process capability index (Cpk) and process capability ratio (Cp). Printed samples were studied offline using optical Profilometry to analyze the consistency within the line width, line height, line resistance and shear load to study the variance in the electrical and mechanical properties over time.

scholarly journals 3D-Extrusion Manufacturing of a Kaolinite Dough Taken in Its Pristine State

2021 ◽  
Vol 8 ◽  
Author(s):  
Séverine A. E. Boyer ◽  
Lucie Jandet ◽  
Alain Burr
Keyword(s):  
Process Parameters ◽  
Computer Aided Design ◽  
Raw Materials ◽  
Sustainable Manufacturing ◽  
Model Material ◽  
Optimization Of Process Parameters ◽  
Complex Shapes ◽  
Deposition Modeling ◽  
Aided Design

Ceramic is among the complicated materials to use in the design of fine objects. Complex shapes without any major defect are not easy to produce. In most of the cases, the production of ceramic parts is the results of three steps. Firstly, the “sculpture” of the raw piece by adding raw materials to lead to the final object. Secondly, the “drying” and finally the “high temperature oven-dry” of the dried raw object to transform the granular dough into a nice consistent compact material. Exploiting the special characteristics of ceramic is not only a thing of the past. Nowadays new possibilities, i.e., shapes and styles, can be offered in the use of ceramics, and especially where it concerns the application of the Additive Manufacturing (AM) concept. The combination of Computer Aided Design (CAD) to AM opens a completely new means of finding novel ways of processing final objects. By choosing to use kaolin clay without any chemical additions (or improvers) as “a model material,” the ability to produce controlled structures with freedom in design by additive deposition modeling is exposed. Discussions relate to the concomitant control of the process parameters, the kaolin hydration and the complexity of printed structures. The optimization of process parameters (nozzle speed, layer thickness, wall thickness) were defined with the calibration of the material flow. Both windows adjusting water content in dough (%wt) and imposing pressure in the tank of the 3D printer have been defined accordingly. The role of layer impression support was also found to be important. This study credits to use the state-of-the art technique (3D printing) to explore sustainable manufacturing of potteries.

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