Jonathan Stringer

Formation and Stability of Lines Produced by Inkjet Printing

To produce stable lines with parallel sides through inkjet printing, individual drops are deposited on a surface so that they coalesce; this initial liquid line (or bead) must remain stable until it forms a solid. The stable line width is shown to be bounded by two limits, with the lower bound (minimum line width) determined by the maximum drop spacing for stable coalescence and the upper bound determined by the minimum drop spacing below which a bulging instability occurs. The maximum stable track width is also a function of the velocity at which an inkjet printhead traverses the substrate. These bounds are presented in dimensionless form and are shown to agree well with experiment. To enable easier determination of the stability of an arbitrary ink/substrate combination, both the upper and lower bounds are presented in graphical forms to define a region of bead stability in an appropriate parameter space.

Inkjet printing Schwann cells and neuronal analogue NG108-15 cells

Porcine Schwann cells and neuronal analogue NG108-15 cells were printed using a piezoelectric-inkjet-printer with a nozzle diameter of 60 μm, within the range of 70-230 V, with analysis of viability and quality after printing. Neuronal and glial cell viabilities of >86% and >90% were detected immediately after printing and no correlation between voltage applied and cell viability could be seen. Printed neuronal cells were shown to produce neurites earlier compared to controls, and over several days, produced longer neurites which become most evident by day 7. The number of neurites becomes similar by day 7 also, and cells proliferate with a similar viability to that of non-printed cells (controls). This method of inkjet printing cells provides a technical platform for investigating neuron-glial cell interactions with no significant difference to cell viability than standard cell seeding. Such techniques can be utilized for lab-on-a-chip technologies and to create printed neural networks for neuroscience applications.

Utilising inkjet printed paraffin wax for cell patterning applications

We describe a method to prepare patterned environments for eukaryotic cells by inkjet printing paraffin wax onto glass. This technique bypasses the requirement to create a master mould, typically required with the use of polydimethylsiloxane techniques and the printed structure could be immediately used to guide cell proliferation. In a space of 2-3 hours, the desired pattern could be created with computer assisted design, printed and have cells seeded onto the scaffold, which could reduce the cycle time of prototyping micropattern designs. Human dermal fibroblasts and RN22 Schwann cells were seen to proliferate within the fabricated patterns and survive for more than 7 days. Additionally, the wax constructs could be readily removed from the substrate at any stage after cell seeding with the cells continuing to proliferate. Thus, we report on a simple but novel approach for the controlled physical positioning of live cells by wax inkjet printing.

Fabrication of patterned thermoplastic microphases between composite plies by inkjet printing

We report on the pioneering application of inkjet printing in depositing patterned thermoplastic microphases between composite plies and the beneficial effect of the printed thermoplastic on the interlaminar fracture toughness of carbon fibre-reinforced polymer laminates. Double-cantilever beam test and short-beam shear test were employed to investigate the mechanical performances of the engineered composites. The results from this work revealed that by printing thermoplastic poly(ethylene glycol) and poly(methyl methacrylate) between the carbon fibre-reinforced polymer plies, mode I interlaminar fracture toughness (GIc) is noticeably enhanced, whilst the shear strength has also been preserved. Scanning electron microscopy was used to investigate the fracture surfaces generated during the double-cantilever beam test. The microscopic addition of the thermoplastic polymers (approximately 0.015 wt%) did not increase the weight of the composites significantly, which compares favourably to other conventional toughening methods.

Hybrid additive manufacturing of 3D electronic systems

A novel hybrid additive manufacturing (AM) technology combining digital light projection (DLP) stereolithography (SL) with 3D micro-dispensing alongside conventional surface mount packaging is presented in this work. This technology overcomes the inherent limitations of individual AM processes and integrates seamlessly with conventional packaging processes to enable the deposition of multiple materials. This facilitates the creation of bespoke end-use products with complex 3D geometry and multi-layer embedded electronic systems. Through a combination of four-point probe measurement and non-contact focus variation microscopy, it was identified that there was no obvious adverse effect of DLP SL embedding process on the electrical conductivity of printed conductors. The resistivity maintained to be less than 4  ×  10−4 Ω centerdot cm before and after DLP SL embedding when cured at 100 °C for 1 h. The mechanical strength of SL specimens with thick polymerized layers was also identified through tensile testing. It was found that the polymerization thickness should be minimised (less than 2 mm) to maximise the bonding strength. As a demonstrator a polymer pyramid with embedded triple-layer 555 LED blinking circuitry was successfully fabricated to prove the technical viability.

High yield growth of patterned vertically aligned carbon nanotubes using inkjet-printed catalyst.

This study reports on the fabrication of vertically aligned carbon nanotubes localized at specific sites on a growth substrate by deposition of a nanoparticle suspension using inkjet printing. Carbon nanotubes were grown with high yield as vertically aligned forests to a length of approximately 400 μm. The use of inkjet printing for catalyst fabrication considerably improves the production rate of vertically aligned patterned nanotube forests compared with conventional patterning techniques, for example, electron beam lithography or photolithography.

Biocompatible silk fibroin scaffold prepared by reactive inkjet printing

It has recently been shown that regenerated silk fibroin (RSF) aqueous solution can be printed using an inkjet printer. In this communication, we demonstrate an alternative reactive inkjet printing method that provides control over RSF crystallinity through β-sheet concentration. A biocompatible film has successfully been produced through the alternate printing of RSF aqueous solution and methanol using reactive inkjet printing. Control over the formation of the β-sheet structure was achieved by printing different ratios of RSF to methanol and was confirmed using Fourier Transform Infra Red spectroscopy. The biocompatibility of the printed silk scaffold was demonstrated by the growth of fibroblast cells upon its surface.

Dynamically controlled deposition of colloidal nanoparticle suspension in evaporating drops using laser radiation

Dynamic control of the distribution of polystyrene suspended nanoparticles in evaporating droplets is investigated using a 2.9 μm high power laser. Under laser radiation a droplet is locally heated and fluid flows are induced that overcome the capillary flow, and thus a reversal of the coffee-stain effect is observed. Suspension particles are accumulated in a localised area, one order of magnitude smaller than the original droplet size. By scanning the laser beam over the droplet, particles can be deposited in an arbitrary pattern. This finding raises the possibility for direct laser writing of suspended particles through a liquid layer. Furthermore, a highly uniform coating is possible by manipulating the laser beam diameter and exposure time. The effect is expected to be universally applicable to aqueous solutions independent of solutes (either particles or molecules) and deposited substrates.

Investigation of printable threshold overhang angle in extrusion-based additive manufacturing for reducing support waste

ABSTRACT Notwithstanding the widespread use and large number of advantages over traditional subtractive manufacturing techniques, the application of additive manufacturing technologies is currently limited by undesirable support material waste. Support structures are unavoidable when manufacturing objects with overhangs in extrusion-based Additive manufacturing, leading to extra build time and material waste. In a manufacturing process, different parameters such as cooling fan speed, print speed and print temperature can make a great contribution to printable overhang angle size. In this study, effects of these parameters on printable overhang angle size are studied theoretically and experimentally. First, theoretical analysis of printable overhang is conducted. Then experiments of overhangs with 20°, 30°, 40° and 50° are carried out with regard to different parameters on an FDM printer. According to the results, the printable threshold overhang angle varies substantially with printing conditions. The findings of this paper can then be applied for setting a lower threshold overhang angle for reducing support waste in the future. The findings can also provide some reference for future research in high-precision printing by adjusting relevant print parameters.

Micro electronic systems via multifunctional additive manufacturing

Purpose This paper aims to demonstrate the improved functionality of additive manufacturing technology provided by combining multiple processes for the fabrication of packaged electronics. Design/methodology/approach This research is focused on the improvement in resolution of conductor deposition methods through experimentation with build parameters. Material dispensing with two different low temperature curing isotropic conductive adhesive materials was characterised for their application in printing each of three different conductor designs, traces, z-axis connections and fine pitch flip chip interconnects. Once optimised, demonstrator size can be minimised within the limitations of the chosen processes and materials. Findings The proposed method of printing z-axis through layer connections was successful with pillars 2 mm in height and 550 µm in width produced. Dispensing characterisation also resulted in tracks 134 µm in width and 38 µm in height allowing surface mount assembly of 0603 components and thin-shrink small outline packaged integrated circuits. Small 149-µm flip chip interconnects deposited at a 457-µm pitch have also been used for packaging silicon bare die. Originality/value This paper presents an improved multifunctional additive manufacturing method to produce fully packaged multilayer electronic systems. It discusses the development of new 3D printed, through layer z-axis connections and the use of a single electrically conductive adhesive material to produce all conductors. This facilitates the surface mount assembly of components directly onto these conductors before stereolithography is used to fully package multiple layers of circuitry in a photopolymer.