Ryojiro Tominaga | FUJI CORPORATION: Why use expensive and damaging lasers to drill microvias when you can print them natively?
11:31 - 13:20
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Summary of the clip:
Why use expensive and damaging lasers to drill microvias when you can print them natively?
Standard fabrication of embedded components often relies on subtractive steps like laser drilling or mechanical routing to expose sensors or create vertical interconnects. Fuji Corporation bypasses these steps entirely by utilizing an additive printing approach to build selective openings directly during the resin deposition phase. This eliminates the risk of laser-induced thermal or physical damage to sensitive embedded silicon.
This capability is especially critical for rugged IoT sensor modules that require absolute waterproofing but must also maintain open access to the environment. For example, a temperature sensor can be fully encapsulated in a protective 3D printed resin block while keeping a precise, open window exposed to receive external infrared radiation.
Additionally, this native patterning process allows for complex multi-layer component stack-ups where microvias are built additively during the filling stage. By avoiding post-processing steps like etching or drilling, the design-to-production workflow is simplified into a single digital process.
In this short video, you can learn:
* The mechanism of forming precise via holes and selective window openings natively without subtractive laser or etching steps.
* How to achieve complete waterproof encapsulation of IoT modules while keeping sensing elements exposed to the environment.
* The layout advantages of building multi-layer component stack-ups using continuous digital resin printing.
๐ **Clip Abstract** This clip explains how additive manufacturing enables the creation of selective open structures and vias around embedded components without laser drilling. It showcases the practical application of this technology in fabricating protected yet functional waterproof IoT sensor modules.
#AdditiveMicrovias, #ResinEncapsulation, #WaterproofIoT, #LaserFreePatterning, #3DPrintedElectronics, #StructuralElectronics
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More Highlights from the same talk.
02:57 - 05:07
Can you build fully functional hybrid electronics in a single machine without traditional PCB etching or soldering?
How can electronics manufacturers consolidate multi-layer circuit fabrication and surface-mount assembly into a single, seamless additive manufacturing workflow?
Traditional printed circuit board assembly relies on discrete, sequential steps that separate substrate fabrication from component mounting. By integrating high-precision material deposition and component placement within a unified modular platform, manufacturers can eliminate these process silos. This hybrid approach combines inkjet printing, dispensing, and robotic pick-and-place technologies to build functional electronic assemblies from the ground up on a single stage.
The additive build-up process relies on the precise, iterative deposition of both dielectric and conductive phases. Inkjet heads deposit specialized resins to form insulating layers, which are immediately cured via integrated ultraviolet exposure. Subsequently, silver nanoparticle inks are inkjet-printed to define conductive traces, followed by in-situ drying and sintering using infrared heaters. This layer-by-layer iteration enables the rapid fabrication of complex, multi-layer circuit architectures without chemical etching.
To transition from passive circuitry to fully active systems, the platform seamlessly bridges additive printing with component assembly. Air dispenser systems deposit silver conductive paste and structural epoxy glue to prepare the mounting sites. The build stage then transitions to a component mounting module for precise pick-and-place alignment, followed by a localized heat-press step that applies simultaneous thermal energy and high pressure to cure the paste, ensuring robust, stable electrical and mechanical connections.
In this short video, you can learn:
* How modular additive systems combine inkjet printing, UV curing, and infrared sintering to fabricate multi-layer circuits.
* The role of integrated air dispensing systems in depositing conductive pastes and structural adhesives for component integration.
* How localized heat-press curing under high pressure ensures stable electrical connections for surface-mounted components.
๐ **Clip Abstract** The speaker explains the process flow of a hybrid additive manufacturing machine that integrates inkjet printing, UV curing, infrared sintering, and fluid dispensing with component pick-and-place assembly. He details how the system iterates these steps to fabricate multi-layer build-up circuits and secure surface-mounted components using a pressurized heat-press module.
๐ค Speaker: Ryojiro Tominaga
๐ข Company: FUJI CORPORATION
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Event: Additive, Sustainable or 3D Electronics Innovations Day 2025
๐ Location: TechBlick Online Platform
๐ Learn more at the next TechBlick event: https://www.techblick.com
#AdditiveManufacturingElectronics, #SilverNanoparticleInk, #LowTemperatureSMT, #DirectWriteElectronics, #StructuralElectronics, #HybridElectronics
00:05:18 - 00:06:31
Can Additive Manufacturing of Electronics consistently deliver sub-100-micron trace resolutions with ultra-low resistance variation?
Can Additive Manufacturing of Electronics consistently deliver sub-100-micron trace resolutions with ultra-low resistance variation?
Traditional additive manufacturing of electronics (AME) often struggles with the tight tolerances and dimensional stability needed to compete with standard subtractive PCBs. Fuji Corporationโs FPM-Trinity machine overcomes this bottleneck by utilizing advanced inkjet printheads that currently achieve 100 to 200-micrometer land/space circuit traces. Through ongoing R&D optimization of materials and print mechanics, they are actively pushing these limits down to 80 to 90 micrometers.
A major hurdle in printed electronics is electrical consistency, but this system yields highly uniform traces. Across a test panel of over 100 printed silver traces, the distribution of resistance variation is kept within a tight window of plus or minus 6 percent. This level of uniformity is critical for reliable high-speed signal routing and power distribution without hot spots.
Furthermore, the system is designed for true 3D spatial routing rather than just simple planar printing. It possesses the capability to form blind vias to establish secure layer-to-layer electrical connections. This enables the fabrication of complex build-up substrates of up to five circuit layers, paving the way for fully 3D-integrated electronics.
In this short video, you can learn:
* The trace resolution limits of state-of-the-art AME inkjet printing down to 80-90 micrometers.
* How to achieve tight control over trace resistance variation (within +/-6%) across hundreds of printed features.
* The structural process of printing multi-layer 3D-buildup substrates using blind vias for interlayer connections.
๐ **Clip Abstract** This clip highlights the high-resolution printing capabilities of Fuji's latest additive manufacturing of electronics (AME) machine. It demonstrates how precise print control achieves ultra-low trace resistance variation and enables 3D multi-layer build-ups using blind vias up to five layers.
#AdditiveManufacturingOfElectronics, #InkjetPrintedElectronics, #BlindVias, #Sub100MicronTraces, #3DStructuralElectronics, #AdvancedPackaging
16:32 - 19:22
How does direct-write electronics handle clogged nozzles in production without ruining the circuit?
How does direct-write electronics handle clogged nozzles in production without ruining the circuit?
Achieving sub-100 micrometer line widths and spaces with inkjet printing is highly challenging due to nozzle clogging and droplet deviation. While Fuji's current production standards target 140 micrometer traces and 200 micrometer spaces, their latest internal evaluations demonstrate successful fabrication at sub-100 micrometer resolutions. However, maintaining high yields at these dimensions requires active mitigation of printhead instability.
Instead of relying solely on traditional downstream automated optical inspection (AOI) or electrical testing to catch errors post-fabrication, Fuji's system addresses defects in real-time. The machine features an integrated monitoring system that inspects jetting behavior, droplet accuracy, and nozzle health during the printing process itself.
If a nozzle clog or drop deviation is detected, the printhead's digital control system automatically compensates by adjusting the printing image on-the-fly. This real-time print correction maintains overall circuit integrity and process stability, paving the way for reliable industrial production of highly dense, additive electronics.
In this short video, you can learn:
* The current standard and developmental limits of fine-line trace resolution and pitch down to sub-100 micrometers.
* Why traditional post-process AOI is insufficient for high-yield additive electronics manufacturing.
* How automated real-time drop monitoring and digital print image compensation prevent failures caused by clogged nozzles.
๐ **Clip Abstract** This segment covers the resolution capabilities of Fuji's inkjet system and their unique real-time quality control methodology. It explains how the machine automatically compensates for nozzle failures on-the-fly to ensure process stability and high production yields.
#ActiveNozzleCompensation, #RealTimeDropMonitoring, #DigitalPrintCompensation, #FineLineInkjet, #AdditiveElectronics, #DirectWriteElectronics