Machine learning approach to monitor inkjet jetting status based on the piezo self-sensing.

One of the advantages of inkjet printing in digital manufacturing is the ability to use multiple nozzles simultaneously to improve the productivity of the processes. However, the use of multiple nozzles makes inkjet status monitoring more difficult. The jetting nozzles must be carefully selected to ensure the quality of printed products, which is challenging for most inkjet processes that use multi-nozzles. In this article, we improved inkjet print head monitoring based on self-sensing signals by using machine learning algorithms. Specifically, supervised machine learning models were used to classify nozzle jetting conditions. For this purpose, the self-sensing signals were acquired, and the feature information was extracted for training. A vision algorithm was developed to label the nozzle status for classification. The trained models showed that the classification accuracy is higher than 99.6% when self-sensing signals are used for monitoring. We also proposed a so-called hybrid monitoring method using trained machine learning models, which divides the feature space into three regions based on predicted jetting probability: certain jetting, certain non-jetting, and doubt regions. Then, the nozzles with uncertain status in the doubt region can be verified by jet visualization to improve the accuracy and efficiency of the monitoring process.

Mobilization of Heavy Metals in a Saline Confined Aquifer as a Consequence of Rainwater Injection: A Case Study in Southern Vietnam.

An artificial recharge test was performed in Ho Chi Minh City, Vietnam to see the geochemical response of a saline coastal plain aquifer to the injected rainwater. The results show that the rainwater injection can cause mobilization of heavy metals due to pyrite oxidation and this phenomenon can persist even after the full recovery of the injected water. In this study, a 30-m-deep well was installed in a confined aquifer. Pyrite framboids were observed in the sediment samples collected during the well drilling. A total of 400 L rainwater was injected into the well for 70 min. After waiting 63 h, the well was extracted at a pump speed of 2.7 L/min and the chemistry of the pumped groundwater was monitored for 10 h. The groundwater showed geochemical features close to rainwater at the early stage of pumping and gradually changed to those of the background waters, especially, in electrical conductivity and Cl- concentration, as the pumping proceeded. However, the groundwater pumped in the later stage showed much increased concentrations in SO42-, total iron (FeT), AsT, Ni, Mn and Zn relative to the calculated mixing concentrations due to pyrite oxidation even though NO3-, the pyrite oxidant, already had disappeared. It was revealed from the geochemical modeling that the persistent pyrite oxidation was the result of the reaction with ferrihydrite, which precipitated in pores of the sediment by the injection of aerated water. We believe our study is a good example showing the importance of careful design of the artificial recharge systems to avoid or minimize the geochemical disturbance of aquifer.

Hybrid Device Fabrication Using Roll-to-Roll Printing for Personal Environmental Monitoring.

Roll-to-roll (R2R) printing methods are well known as additive, cost-effective, and ecologically friendly mass-production methods for processing functional materials and fabricating devices. However, implementing R2R printing to fabricate sophisticated devices is challenging because of the efficiency of material processing, the alignment, and the vulnerability of the polymeric substrate during printing. Therefore, this study proposes the fabrication process of a hybrid device to solve the problems. The device was created so that four layers, composed of polymer insulating layers and conductive circuit layers, are entirely screen-printed layer by layer onto a roll of polyethylene terephthalate (PET) film to produce the circuit. Registration control methods were presented to deal with the PET substrate during printing, and then solid-state components and sensors were assembled and soldered to the printed circuits of the completed devices. In this way, the quality of the devices could be ensured, and the devices could be massively used for specific purposes. Specifically, a hybrid device for personal environmental monitoring was fabricated in this study. The importance of environmental challenges to human welfare and sustainable development is growing. As a result, environmental monitoring is essential to protect public health and serve as a basis for policymaking. In addition to the fabrication of the monitoring devices, a whole monitoring system was also developed to collect and process the data. Here, the monitored data from the fabricated device were personally collected via a mobile phone and uploaded to a cloud server for additional processing. The information could then be utilized for local or global monitoring purposes, moving one step toward creating tools for big data analysis and forecasting. The successful deployment of this system could be a foundation for creating and developing systems for other prospective uses.

AI-assisted reliability assessment for gravure offset printing system.

In printed electronics, flawless printing quality is crucial for electronic device fabrication. While printing defects may reduce the performance or even cause a failure in the electronic device, there is a challenge in quality evaluation using conventional computer vision tools for printing defect recognition. This study proposed the computer vision approach based on artificial intelligence (AI) and deep convolutional neural networks. First, the data set with printed line images was collected and labeled. Second, the overall printing quality classification model was trained and evaluated using the Grad-CAM visualization technique. Third and last, the pretrained object detection model YOLOv3 was fine-tuned for local printing defect detection. Before fine-tuning, ground truth bounding boxes were analyzed, and anchor box sizes were chosen using the k-means clustering algorithm. The overall printing quality and local defect detection AI models were integrated with the roll-based gravure offset system. This AI approach is also expected to complement more accurate printing reliability analysis firmly.

IoT device fabrication using roll-to-roll printing process.

With the development of technology, wireless and IoT devices are increasingly used from daily life to industry, placing demands on rapid and efficient manufacturing processes. This study demonstrates the fabrication of an IoT device using a roll-to-roll printing process, which could shorten the device fabrication time and reduce the cost of mass production. Here, the fabricated IoT device is designed to acquire data through the sensor, process the data, and communicate with end-user devices via Bluetooth communication. For fabrication, a four-layer circuit platform consisting of two conductive layers, an insulating layer including through holes, and a solder resist layer is directly printed using a roll-to-roll screen printing method. After the printing of the circuit platform, an additional layer of solder paste is printed to assemble the electrical components into the device, inspiring the fully roll-to-roll process for device fabrication. Successful IoT device deployment opens the chance to broaden the roll-to-roll fabrication process to other flexible and multilayer electronic applications.

High-Efficiency Electrospray Deposition Method for Nonconductive Substrates: Applications of Superhydrophobic Coatings.

When highly insulating materials are used as substrates for electronic devices, manufacturing yields become worse, and electronic components are often damaged due to undissipated electrostatic charges on such substrates. In the case of electrospray deposition, the problem of undissipated charges is particularly vexing. If charges accumulated on the substrate are not properly compensated, a repulsive force is generated against the incoming charged droplets, which negatively affects the uniformity and deposition rate of the coating layer. In order to overcome this limitation, we demonstrated a new electrospray method, which can significantly increase the deposition efficiency even in the presence of accumulated charges on nonconductive substrates. A highly reliable superhydrophobic layer was uniformly deposited on highly insulating substrates, including printed circuit board (PCB), polyester (PET), and polyimide (PI) substrates.

Three-dimensional surface printing method for interconnecting electrodes on opposite sides of substrates.

As the application of the direct printing method becomes diversified, printing on substrates with non-flat surfaces is increasingly required. However, printing on three-dimensional surfaces suffers from a number of difficulties, which include ink flow due to gravity, and the connection of print lines over sharp edges. This study presents an effective way to print a fine pattern (~ 30 µm) on three different faces with sharp edge boundaries. The method uses a deflectable and stretchable jet stream of conductive ink, which is produced by near-field electrospinning (NFES) technique. Due to added polymer in the ink, the jet stream from the nozzle is less likely to be disconnected, even when it is deposited over sharp edges of objects. As a practical industrial application, we demonstrate that the method can be effectively used for recent display applications, which require the connection of electrical signal and power on both sides of the glass. When the total length of printed lines along the 'Π' shaped glass surfaces was 1.2 mm, we could achieve the average resistance of 0.84 Ω.

How to manipulate droplet jetting from needle type jet dispensers.

The needle-type inkjet dispenser has been widely used for various research and industrial purposes. The droplet jetting from the dispenser is closely related to the needle motion, which strikes against the nozzle seat. The strike of the needle on the nozzle seat often cause additional impact due to the bounce back, which may produce multiple droplets per jetting trigger. However, the needle motion is difficult to measure, and the actual behaviors have been known little. In this study, we measured the needle motion using an accelerometer and visualized jetting images to understand jetting behavior in relation to the needle motion. Then, we investigated various parameter effects on needle motion and jetting behaviors based on our proposed measurement methods. From the experimental results, we found that needle travel distance should be in the optimal range in order to produce single droplet per jetting trigger. In conclusion, we proposed an effective parameter selection method for the optimal jetting based on understanding of the jetting physics.

High-resolution Patterning Using Two Modes of Electrohydrodynamic Jet: Drop on Demand and Near-field Electrospinning.

Electrohydrodynamic (EHD) jet printing has drawn attention in various fields because it can be used as a high-resolution and low-cost direct patterning tool. EHD printing uses a fluidic supplier to maintain the extruded meniscus by pushing the ink out of the nozzle tip. The electric field is then used to pull the meniscus down to the substrate to produce high-resolution patterns. Two modes of EHD printing have been used for fine patterning: continuous near-field electrospinning (NFES) and dot-based drop-on-demand (DOD) EHD printing. According to the printing modes, the requirements for the printing equipment and ink viscosity will differ. Even though two different modes can be implemented with a single EHD printer, the realization methods significantly differ in terms of ink, fluidic system, and driving voltage. Consequently, without a proper understanding of the jetting requirements and limitations, it is difficult to obtain the desired results. The purpose of this paper is to present a guideline so that inexperienced researchers can reduce the trial and error efforts to use the EHD jet for their specific research and development purposes. To demonstrate the fine-patterning implementation, we use Ag nanoparticle ink for the conductive patterning in the protocol. In addition, we also present the generalized printing guidelines that can be used for other types of ink for various fine-patterning applications.