电流体动力喷射3D打印工艺参数对泰勒锥和打印图形的影响和规律
|
摘要
电流体动力喷射3D打印是一种新型微纳增材制造技术,它具有成本低、结构简单、精度高、打印材料广泛等突出特点和优势.但是,由于电流体动力喷射3D打印的打印速度快、喷嘴和基底打印距离小,特别是对于微尺度特征图形的打印,其实际图形及打印质量难以直接观测,而且影响打印图形精度和质量的工艺参数较多,各个工艺参数相互耦合和相应作用.因而直接有效的控制打印图形的精度(线宽)和质量(线边缘粗糙度)是其面临的一个挑战性难题.本文提出一种通过调整打印工艺参数间接控制泰勒锥形状和尺寸,进而实现对于打印图形精度和质量有效控制的新方法.建立了线宽与工艺参数、材料性能和基底关系的理论模型;通过实验,系统研究并揭示了电流体动力喷射3D打印工艺参数对泰勒锥和打印图形的影响及其规律;优化出针对同一喷嘴较为理想的喷印工艺窗口;并通过典型实验工程案例研究,采用内径60μm喷嘴实现了最小线宽3μm打印,验证了实验研究结果的正确性和有效性.本文提出的方法和实验研究结果为电流体动力喷射3D打印的打印精度、图形质量和打印稳定性改进及提高奠定了基础,并为简化和易于操作提供了一种切实可行的方法.
Electrohydrodynamic jet 3D printing is an emerging and promising technology of micro-and nano-scale additive manufacturing with a low cost and high resolution,as well as a wide range of printed materials. However,due to the high printing speed and small standoff height between the nozzle and the substrate,it is especially difficult to directly observe and measure the printed patterns.Furthermore,there are many process parameters that affect the printing accuracy and quality,among which each parameter is coupling and interacting. This paper proposed a method of controlling the accuracy and quality of printed patterns based on the regulation of the shape and size of the Taylor cone by varying the process parameters. A theoretical model was then derived and established that describes the relationship between the line width printed with process parameters,printed material,and used substrate. Through the systematic experimental study,the influences and rules of the printing process parameters on the Taylor cone and printed patterns were revealed; Furthermore,the ideal jet printing window for the same nozzle was optimized. Finally,the feasibility and validity of the experimental results were demonstrated by the typical engineering cases,and a pattern of minimum line width of 3 μm was achieved with the nozzle diameter of 60 μm. The proposed method and experimental results provide a basis for further improving the accuracy,quality,and stability for electrohydrodynamic jet 3D printing,and the method offers a feasible solution for simplification and easy operation of actual 3D printing.
Electrohydrodynamic jet 3D printing is an emerging and promising technology of micro-and nano-scale additive manufacturing with a low cost and high resolution,as well as a wide range of printed materials. However,due to the high printing speed and small standoff height between the nozzle and the substrate,it is especially difficult to directly observe and measure the printed patterns.Furthermore,there are many process parameters that affect the printing accuracy and quality,among which each parameter is coupling and interacting. This paper proposed a method of controlling the accuracy and quality of printed patterns based on the regulation of the shape and size of the Taylor cone by varying the process parameters. A theoretical model was then derived and established that describes the relationship between the line width printed with process parameters,printed material,and used substrate. Through the systematic experimental study,the influences and rules of the printing process parameters on the Taylor cone and printed patterns were revealed; Furthermore,the ideal jet printing window for the same nozzle was optimized. Finally,the feasibility and validity of the experimental results were demonstrated by the typical engineering cases,and a pattern of minimum line width of 3 μm was achieved with the nozzle diameter of 60 μm. The proposed method and experimental results provide a basis for further improving the accuracy,quality,and stability for electrohydrodynamic jet 3D printing,and the method offers a feasible solution for simplification and easy operation of actual 3D printing.
引文
[1]Lan H B,Li D C,Lu B H.Micro and nano scale 3D printing.Sci Sin Technol,2015,45(9):919(兰红波,李涤尘,卢秉恒.微纳尺度3D打印.中国科学:技术科学,2015,45(9):919)
[2]Yudistira H T,Tenggara A P,Oh S S,et al.High-resolution electrohydrodynamic jet printing for the direct fabrication of 3D multilayer terahertz metamaterial of high refractive index.J Micromech Microeng,2015,25(4):045006-1
[3]Onses M S,Sutanto E,Ferreira P M,et al.Mechanisms,capabilities,and applications of high-resolution electrohydrodynamic jet printing.Small,2015,11(34):4237
[4]Lee A,Jin H,Dang H W,et al.Optimization of experimental parameters to determine the jetting regimes in electrohydrodynamic printing.Langmuir,2013,29(44):13630
[5]Park J U,Hardy M,Kang S J,et al.High-resoluting eletrohydrodynamic jet printing.Nat Mater,2007,6(10):782
[6]Yang J J,Zhang Z Y,Lan H B,et al.Jetting mechanism and rules of micro scale 3D printing based on EHD.T Chin Soc Agric Mach,2016,47(6):401(杨建军,张志远,兰红波,等.基于EHD微尺度3D打印喷射机理与规律研究.农业机械学报,2016,47(6):401)
[7]Choi K J,Rahman K,Muhammad N M,et al.Electrohydrodynamic inkjet-micro pattern fabrication for printed electronics applications//Recent Advances in Nanofabrication Techniques and Applications[2017-05-31]https://www.intechopen.com/books/recent-advances-in-nanofabrication-techniques-and-applications/electrohydrodynamic-inkjet-micro-pattern-fabrication-for-printed-electronics-applications
[8]Wei C,Qin H T,Chiu C P,et al.Drop-on-demand E-jet printing of continuous interconnects with AC-pulse modulation on highly insulating substrates.J Manuf Syst,2015,37(2):505
[9]Rahman K,Ali K,Muhammad N M,et al.Fine resolution dropon-demand electrohydrodynamic patterning of conductive silver tracks on glass substrate.Appl Phys A,2012,111(2):593
[10]Kim Y,Jang S,Oh J H.High-resolution electrohydrodynamic printing of silver nanoparticle ink via commercial hypodermic needles.Appl Phys Lett,2015,106(1):1261
[11]Huang F L,Sun Q,Zhang L B,et al.Overview on the micropatterned printing method by near-field electrohydrodynamic cone jet.Mech Electr Eng Technol,2017,46(2):58(黄风立,孙权,张礼兵,等.近场电流体动力锥射流微图案化打印方法研究综述.机电工程技术,2017,46(2):58)
[12]Park J,Park J W,Nasrabadi A M,et al.Methodology to set up nozzle-to-substrate gap for high resolution electrohydrodynamic jet printing.Appl Phys Lett,2016,109(13):134104
[13]Zhao X,He J K,Xu F Y,et al.Electrohydrodynamic printing:a potential tool for high-resolution hydrogel/cell patterning.Virtual Phys Prototyping,2016,11(1):57
[14]Korvink J G,Smith P J,Shin D Y.Inkjet-Based Micromanufacturing.Hoboken:Wiley-VCH Verlag Gmb H&Co,2012
[15]Park J,Kim B,Kim S,et al.Prediction of drop-on-demand(DOD)pattern size in pulse voltage-applied electrohydrodynamic(EHD)jet printing of Ag colloid ink.Appl Phys A,2014,117:2225
[16]Gao F Q,Sonin A A.Precise doposition of molten microdrops:the physics of digital microfabrication.Proc R Soc A,1994,444(1922):533
[17]Li J L.Electrospray.Shanghai:Shanghai Jiao Tong University Press,2012(李建林.电场喷射.上海:上海交通大学出版社,2012)
[18]Taylor G.Disintegration of water drops in an electric field.Proc R Soc London Ser A,1964,280(1382):383
[19]Hayati I,Baikey A I,Tadros T F.Mechanism of stable jet formation in electrohydrodynamic atomization.Nature,1986,319(6048):41
[2]Yudistira H T,Tenggara A P,Oh S S,et al.High-resolution electrohydrodynamic jet printing for the direct fabrication of 3D multilayer terahertz metamaterial of high refractive index.J Micromech Microeng,2015,25(4):045006-1
[3]Onses M S,Sutanto E,Ferreira P M,et al.Mechanisms,capabilities,and applications of high-resolution electrohydrodynamic jet printing.Small,2015,11(34):4237
[4]Lee A,Jin H,Dang H W,et al.Optimization of experimental parameters to determine the jetting regimes in electrohydrodynamic printing.Langmuir,2013,29(44):13630
[5]Park J U,Hardy M,Kang S J,et al.High-resoluting eletrohydrodynamic jet printing.Nat Mater,2007,6(10):782
[6]Yang J J,Zhang Z Y,Lan H B,et al.Jetting mechanism and rules of micro scale 3D printing based on EHD.T Chin Soc Agric Mach,2016,47(6):401(杨建军,张志远,兰红波,等.基于EHD微尺度3D打印喷射机理与规律研究.农业机械学报,2016,47(6):401)
[7]Choi K J,Rahman K,Muhammad N M,et al.Electrohydrodynamic inkjet-micro pattern fabrication for printed electronics applications//Recent Advances in Nanofabrication Techniques and Applications[2017-05-31]https://www.intechopen.com/books/recent-advances-in-nanofabrication-techniques-and-applications/electrohydrodynamic-inkjet-micro-pattern-fabrication-for-printed-electronics-applications
[8]Wei C,Qin H T,Chiu C P,et al.Drop-on-demand E-jet printing of continuous interconnects with AC-pulse modulation on highly insulating substrates.J Manuf Syst,2015,37(2):505
[9]Rahman K,Ali K,Muhammad N M,et al.Fine resolution dropon-demand electrohydrodynamic patterning of conductive silver tracks on glass substrate.Appl Phys A,2012,111(2):593
[10]Kim Y,Jang S,Oh J H.High-resolution electrohydrodynamic printing of silver nanoparticle ink via commercial hypodermic needles.Appl Phys Lett,2015,106(1):1261
[11]Huang F L,Sun Q,Zhang L B,et al.Overview on the micropatterned printing method by near-field electrohydrodynamic cone jet.Mech Electr Eng Technol,2017,46(2):58(黄风立,孙权,张礼兵,等.近场电流体动力锥射流微图案化打印方法研究综述.机电工程技术,2017,46(2):58)
[12]Park J,Park J W,Nasrabadi A M,et al.Methodology to set up nozzle-to-substrate gap for high resolution electrohydrodynamic jet printing.Appl Phys Lett,2016,109(13):134104
[13]Zhao X,He J K,Xu F Y,et al.Electrohydrodynamic printing:a potential tool for high-resolution hydrogel/cell patterning.Virtual Phys Prototyping,2016,11(1):57
[14]Korvink J G,Smith P J,Shin D Y.Inkjet-Based Micromanufacturing.Hoboken:Wiley-VCH Verlag Gmb H&Co,2012
[15]Park J,Kim B,Kim S,et al.Prediction of drop-on-demand(DOD)pattern size in pulse voltage-applied electrohydrodynamic(EHD)jet printing of Ag colloid ink.Appl Phys A,2014,117:2225
[16]Gao F Q,Sonin A A.Precise doposition of molten microdrops:the physics of digital microfabrication.Proc R Soc A,1994,444(1922):533
[17]Li J L.Electrospray.Shanghai:Shanghai Jiao Tong University Press,2012(李建林.电场喷射.上海:上海交通大学出版社,2012)
[18]Taylor G.Disintegration of water drops in an electric field.Proc R Soc London Ser A,1964,280(1382):383
[19]Hayati I,Baikey A I,Tadros T F.Mechanism of stable jet formation in electrohydrodynamic atomization.Nature,1986,319(6048):41