Session: 16-01-01: Government Agency Student Poster Competition

Paper Number: 149578

149578 - Optimization of R2r Gravure Printing Process With Pressure Control and Cad Simulation 

Roll-to-roll (R2R) gravure printing is a type of low-cost printing process that involves the transfer of ink onto a flexible web substrate, continuously passing between two rollers: a gravure and an impression roller. This printing technique is promising for creating flexible electronic devices on a large scale. As it rotates, the gravure roller picks up ink and a doctor blade scrapes the excess ink off the top surface of the gravure roller. This ensures that the ink only remains in the depressions of the gravure roller. While the impression roller pushes the substrate against the gravure roller, the ink from the gravure roller is deposited onto the substrate, printing the desired pattern. For this printing process, the quality of the printing result is determined by the amount of ink transferred from the depressions of the gravure roller onto the substrate, correlating to printed pattern size. A complete depositing of the ink is crucial for high resolution and detail in printing. An important parameter that affects this aspect of print quality is the pressure on the substrate, which is caused by the force exerted on the gravure roller by the impression roller in their radial directions. The state-of-the-art gravure printing modules lack control of this parameter; pressure is not applied evenly throughout the substrate, specifically in the axial direction. This yields a low quality, half-printed substrate as only one-half of the roller is creating sufficient pressure for printing. A solution to this issue is a pressure control method designed to vary the amounts of force applied on the gravure roller by the impression roller in both the axial and radial directions, along with a CAD simulation model that measures the pressure caused by said force. The force applied in the radial direction will control the amount of ink deposited into the substrate (pressure intensity), whereas the force applied in the axial direction will control the ink distribution (pressure spread). The CAD technology will analyze the contact area and the pressures of the rollers by considering the material properties of the real-life model parts. To precisely control the intensity of the pressure, a linear stepper motor that produces a desired force in the radial direction is installed. At the tip of this motor, a counter-rotation part is placed on a rail, allowing it to move in the axial direction to distribute the pressure. The pressures throughout the substrate can be calculated once the printing contact area is defined, testing the printing quality control of the system. The desired result for this project can advance gravure printing processes, as it suggests increased control of accurate depositing of ink from the gravure roller to the substrate.

Presenting Author: Hannah Kwon University of Massachusetts Amherst

Presenting Author Biography: Hannah Kwon is currently pursuing a bachelor's degree in mechanical engineering at the University of Massachusetts Amherst. Despite being in the early stages of her academic career, Hannah shows a strong passion for engineering and a dedication to mastering the fundamental principles of the field. She is particularly interested in CAD modeling, MATLAB programming, and theory. Hannah is actively involved in student organizations such as the American Society for Mechanical Engineers (ASME) and the Korean Students Association (KSA). She is eager to gain hands-on experience through research, where she hopes to apply her theoretical knowledge to real-life problems. Her research interests include precision manufacturing and quality control. With a commitment to innovation and education, Hannah Kwon aspires to make significant contributions to the field of mechanical engineering as she helps to advance sustainable and efficient technologies in the future.

Authors:

Hannah Kwon University of Massachusetts Amherst
Sam Bui University of Massachusetts Amherst
Connor Mackey University of Massachusetts Amherst
Jingyang Yan University of Massachusetts Amherst
Xiaoning Jin Northeastern University
Xian Du University of Massachusetts Amherst