Ethan Secor | Iowa State University: How does real-time monitoring of aerosol density translate to improved process control in aerosol jet printing?
00:03:16 - 00:03:51
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Summary of the clip:
How does real-time monitoring of aerosol density translate to improved process control in aerosol jet printing?
The speaker introduces a technology developed over the past six years: an in-line sensor integrated directly into the aerosol printing process, positioned upstream of the print head. This sensor operates by shining light through the aerosol stream and measuring the amount of light scattered by the micron-sized droplets. The principle is that even transparent droplets scatter light effectively, providing a quantitative measurement of aerosol density.
This real-time measurement of aerosol density is intended for three primary applications. The first and most emphasized is closed-loop control, where changes in the aerosol process are detected in real-time, and process parameters are adjusted to compensate, leading to a more reliable printing process. The other two applications are continuous data stream coordination with the physical part being printed for defect analysis and process science for understanding the aerosol gathering process.
The sensor provides a quick and quantitative measurement of aerosol concentration in real-time during printing. This allows for immediate adjustments to process parameters, enhancing process reliability. The technology leverages the light-scattering properties of micron-sized droplets to accurately gauge aerosol density.
In this short video, you can learn:
* How an in-line sensor measures aerosol density in real-time.
* The three key applications of this sensor technology.
* The principle behind light scattering by aerosol droplets.
📋 **Clip Abstract** This segment introduces an in-line sensor for real-time monitoring of aerosol density in aerosol jet printing. It highlights the sensor's functionality and its potential applications in process control, defect analysis, and process science.
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#AerosolJetPrinting, #InLineSensing, #AerosolDensity, #ClosedLoopControl, #PrintedElectronics, #AdvancedPackaging
This is a highlight of the presentation:
Advancing manufacturing readiness of aerosol jet printing for conformal electronics
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00:06:50 - 00:07:37
How does maintaining a calibration curve during aerosol jet printing ensure consistent deposition rates over extended periods?
How does maintaining a calibration curve during aerosol jet printing ensure consistent deposition rates over extended periods?
The speaker discusses the results of a nine-hour print test conducted to assess the stability and reliability of the real-time sensor. The test involved changing process parameters, specifically the atomizer gas flow rate, and monitoring the sensor readings. The data showed a strong correlation between the real-time sensor readings and the actual cross-sectional area (deposition rate) of the printed material.
A key finding was that even with changes in process parameters, the system maintained a consistent "calibration curve" throughout the nine-hour test. This means that the real-time measurement accurately reflected the actual deposition rate, indicating the sensor's reliability over extended printing periods. The linear deposition rate, derived from the real-time measurement, provided an accurate indication of the actual deposition rate throughout the entire test.
Maintaining this calibration curve is crucial for ensuring consistent printing performance. It demonstrates that the sensor can provide reliable data for process control, even as process parameters drift or are intentionally adjusted. This is essential for achieving consistent material deposition and line width in aerosol jet printing.
In this short video, you can learn:
* The correlation between real-time sensor readings and actual deposition rates.
* The concept of a "calibration curve" in aerosol jet printing.
* The importance of maintaining a stable calibration curve for consistent printing.
📋 **Clip Abstract** This segment presents the results of a nine-hour print test, demonstrating the reliability of the real-time sensor and the importance of maintaining a calibration curve for consistent deposition rates. It highlights the sensor's ability to accurately reflect the actual deposition rate even with changing process parameters.
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#AerosolJetPrinting, #CalibrationCurve, #DepositionRateControl, #RealTimeSensing, #PrintedElectronics, #AdvancedPackaging
00:07:37 - 00:08:24
What are the advantages of using closed-loop control in aerosol jet printing to mitigate long-term process drift?
What are the advantages of using closed-loop control in aerosol jet printing to mitigate long-term process drift?
The speaker transitions to discussing the implementation of closed-loop control using the real-time sensor data. The goal is to automate the adjustment of process parameters to maintain consistent printing performance without manual intervention. The sensor data is connected to the printer control software, enabling it to adjust process parameters, such as the atomizer gas flow rate, on the fly.
A 12-hour print test was conducted using this closed-loop control system. The software automatically adjusted the atomizer gas flow rate to maintain a steady real-time sensor measurement. The results showed a significant improvement in consistency compared to open-loop printing, with a good reduction in long-term drift. While some drift remained (a couple percent per hour), the closed-loop system demonstrated its ability to mitigate the effects of process variations.
By using closed-loop control, the system can automatically compensate for process drift, leading to more consistent printing results over extended periods. This reduces the need for manual adjustments and improves the overall reliability of the aerosol jet printing process. The closed-loop system effectively maintains the desired deposition rate by dynamically adjusting process parameters based on real-time sensor feedback.
In this short video, you can learn:
* How real-time sensor data is used for closed-loop control in aerosol jet printing.
* The benefits of closed-loop control in mitigating long-term process drift.
* The results of a 12-hour print test using a closed-loop control system.
📋 **Clip Abstract** This segment explains the implementation of closed-loop control in aerosol jet printing, using real-time sensor data to automatically adjust process parameters. It demonstrates the effectiveness of this approach in reducing long-term process drift and improving printing consistency.
🔗 Link in comments 👇
#AerosolJetPrinting, #ClosedLoopControl, #ProcessDriftMitigation, #RealTimeProcessControl, #SemiconductorManufacturing, #AdvancedPackaging