Evolution Theory of Ink Jet Technologies - Progress by Component or Architectural Knowledge Masahiko FUJII Marking Technology Laboratory Fuji Xerox Co., Ltd. Printing for Fabrication 2017
Evolution Theory of Ink Jet Technologies- Progress by Component or Architectural Knowledge
Masahiko FUJIIMarking Technology LaboratoryFuji Xerox Co., Ltd.
Printing for Fabrication 2017
3D Printing
High Quality 3D Printer
Involvement in Ink Jet
Continuous Ink Jet
Single Drop DetectorM. Fujii, Optical Drop Sensor of Continuous Ink Jet Printer, 19th Imaging Technology Conference, 1988
Thermal Ink Jet
800dpi MEMS PrintheadM. Fujii, New Thermal Ink Jet Printheadwith Improved Energy Efficiency Using Silicon Reactive Ion Etching, The Journal of Imaging Science and Technology, Vol. 43, No. 4, 1999
Applications of Ink Jet
Micro-Lens ArrayM. Fujii, Issues and Approaches Imposed on Ink Jet for The Progress of Printed Electronics, Transactions on The Japan Institute of Electronics Packaging Vol. 3, No. 1, 2010
Voxel-Based 3D Data Format ‘FAV’
3D Data Handling
T. Takahashi & M. Fujii, Unrestricted 3D Structure Modeling and Seamless Data Flow to 3D Printers Using Voxel-based Data Format FAV (Fab-able Voxel), IS&T’s NIP32, 2016
1985 2008 20171990
1
20042004 / 2005
FUJI XEROX
Macro-Trend of Ink Jet Printer
Small Size
High Image Quality&
High Speed
Siphon Recorder (Kelvin)
Mingograph (Siemens)
1952
1876
1968
Videojet (A.B.Dick)
1996
2003
2011
PM-700C (EPSON)
JetPress 720 (Fuji Film)
True Press Jet 520 (Screen)
ThinkJet (HP)1984
2005
• Diluted Ink• Photo Paper• Small Drop
• Pagewide Printhead• R2R• Fast Drying Ink• Dryer
• Defect Detection & Correction• Impression Cylinder • Under-Coating• Latex Ink• Dryer
High Image Quality
High Speed
2017
2
1938
Next Year (2018) :The 50th Anniversary of The First Ink Jet Printer AppearanceAnd The 80th Anniversary of C. F. Carlson’s Experiment for EP
Next Year (2018) :The 50th Anniversary of The First Ink Jet Printer AppearanceAnd The 80th Anniversary of C. F. Carlson’s Experiment for EP
Definition of Ink Jet
(My) Definition of Ink Jet :
Defining technology is important to identify the invention, and to consider extensions or applications of the technology.
Ink Jet is not a technology only to realize printers.
3
Dropletize liquid including colorants or functional materials,
and
Eject drops to recording target (media) on demand from image (pattern) signal,
then
Bring colorants or functional materials to (on) recording target (media).
Dropletize liquid including colorants or functional materials,
and
Eject drops to recording target (media) on demand from image (pattern) signal,
then
Bring colorants or functional materials to (on) recording target (media).
M. Fujii, S. Sakai, A. Tomotake,H. Eguchi etc. (2008)
Marking Process of EP & Ink Jet
Charge Exposure Development Transfer Fixing CleaningPaper
Photoreceptor
Charge
+ +++++
++++
++ + + + +
+++++
++
Light Source
Latent Image+++
++++
++ + + + +
+++++
+
Toner & Developer++++
++
++
++
+
++
Electrophotography
++
Serial Printer
Ink Drops
Swath
PrintheadInk Jet
Line Printer
Swath
Pagewide Printhead
Ink DropsPaper
Simple Marking Process
4
Small SizeLow Cost
Small Power ConsumptionHigh Stability
High Scalability
Large SizeHigh Cost
Large Power ConsumptionLow Stability
Low Scalability
Possibility & Limitation of Ink Jet
Ink Jet Marking Process is Simple.
Ink Jet Process
SimplicityInk Jet Process
Simplicity Limitation
Marking Process is Achieved Only by Interactions between Ink And Media.
Challenge
Possibility
High Applicability to Various Applications
Simplicity of process has both aspect of a possibility and a limitation.
These two aspects led me my ink jet evolution theory.
5
Drop VolumeDrop Volume Firing FrequencyFiring Frequency
Nozzle ResolutionNozzle Resolution
DirectionalityDirectionality
Ink LatitudeInk Latitude
Nozzle NumberNozzle Number
PenetrabilityPenetrabilityPenetrabilityPenetrability
Multi-ColorMulti-Color
Color ReproductionColor Reproduction
RobustnessRobustness
AbsorbabilityAbsorbability
CircularityCircularity
Gloss ControlGloss Control
Absorption SpeedAbsorption Speed
Concentrating Functions Progress (CFP)
Key Components
Paper(Media)
Printhead
Ink(Functional Liquid)
Image ProcessingDot Placement
System
Maintenance
Ink Supply
CircumjacentTechnologies
Simple Process
6
Progress of system performance has been brought by progress of each key components performance
Concentrating Functions Progress (CFP)Concentrating Functions Progress (CFP)
Keeping merits come from process simplicity of Ink Jet
Image Quality Print Speed
Printer’s Prime Performances
Drop Volume & Image Quality
7
Year
94
Minimum Ink Drop Volume (pl)
10-3
10-2
10-1
100
101
102
1990 1995 2000 2005 2010
27
13
6
3
1
201510-4 0.3
DropDiameter (µm)90
( )
( )
Electrostatic Pull Ink Jet (AIST)
Commercialized Home Printer
(Image Quality Quantified from Visual Aspect)
Sensory Evaluation Score for Image Quality
Ink Jet(Ink Jet Paper)
1995 2000 2005 20101990 2015
Year
Ink Jet(Plain Paper)
Dry EP(Plain Paper)
Drop Volume & Image Quality
7
Year
90 94
Minimum Ink Drop Volume (pl)
10-3
10-2
10-1
100
101
102
1990 1995 2000 2005 2010
27
13
6
3
1
201510-4 0.3
DropDiameter (µm)
( )
( )
Electrostatic Pull Ink Jet (AIST)
Commercialized Home Printer
19961997
20002002
2003 20042005
2006
4
8
12
16Number of Ink Color
Year
4
6
78
9
12
0
Ink Jet(Ink Jet Paper)
1995 2000 2005 20101990 2015
Year
Ink Jet(Plain Paper)
Dry EP(Plain Paper)
(Image Quality Quantified from Visual Aspect)
Sensory Evaluation Score for Image Quality
Speed Factor =Frequency * Nozzle Number
Multi-Path * Resolution * Print Direction- Maintenance - Others
Speed Factor (Print Speed)
Frequency
8
Firing Frequency (kHz)
80
0
20
60
40
1995 2000 2005 20101990 2015
Year
Piezo
Thermal
( )
1995 2000 2005 20101990 2015
Year
Nozzle Number Swath (inch)
212
28
22
20
24
26
210
Nozzle Number
Swath
2-4
2-2
20
22
Nozzle NumberSwath
Speed Factor (Print Speed)
8
Speed Factor =Multi-Path * Resolution * Print Direction
- Maintenance - Others
1995 2000 2005 20101990 2015
Year
215
220
225
230
Firing Drop Number ( /sec)
Tilt : 20.5 = Moore’s Low
Until 2005
≈ Print Speed
≈ Printing Speed
Frequency * Nozzle Number
End of CFP in Consumer Products
Increase of key components performance has almost saturated,and progress of printer performances (image quality, print speed) have ticked over since 2005.
9
I don’t mean that all ink jet technology developments should be stopped.
Volume of Ink Jet printer Shipment in Japan
0
100
200
300
400
500
600
700
800
98 99 00 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16
SFPMFP
20051998 2010 2016Year
Shipment (M)
2000
876543210 If additional technology developments
focusing on consumer market stop, no consumer will feel inconvenient.
New Progress Type
Technologies progress of ink jet stop? NO!
Concentrating Functions Progress (CFP) is still required in other market with different performance axis (required performance) [DF] NOT consumer’s.
10
New type of technology progress has been necessary for new printer market with new hard issues.
One of new markets is commercial printing, and new progress type is Sharing Functions Progress (SFP).
100Resolution (µm)
10 1
10
1
0.1
Layer Thickness (µm)
Ink Jet
Screen
Gravure Offset
Reverse Offset
Flexography
Slot Die Coater
PrintedElectronics
High Viscosity
Small Drop Size
CFP is only approaches in ink jet ?
S. Tokito, The 4th Workshop on Flexible Organic Electronics (2017)
Image QualityImage Quality
Photo FinishingPhoto Finishing
Commercial PrintingCommercial Printing
Print SpeedPrint Speed
TransactionalTransactional
HomeHome
Serial Printhead
: Technical Difficulties to Overcome Boundary
Pagewide Printhead
Plane View of Ink Jet Market
Sharing Functions ProgressSharing Functions Progress
Concentrating Functions ProgressConcentrating Functions ProgressDigital FabricationDigital Fabrication
Light ProductionLight ProductionLow / Mid.
High
OfficeOffice
11
Concentrating Functions ProgressConcentrating Functions Progress
Serious Issues in Commercial Printing Market
Line Printer : One Pass Process
No Multi-Pass
Compatibility of High Speed & High Image Quality
Image FormingOn Non-Permeable Media
New Type of Technology ProgressNot Saddle Printhead or Ink
New Type of Technology ProgressNot Saddle Printhead or Ink
Sharing Functions ProgressSharing Functions Progress
12
Challenge
Permeable Media
Dot
Ink Jet Media
Existing Market(Consumer, Office, Photo)
Non-Permeable Media(Coated Paper for Offset)
Dot
Commercial Printing Market
Offset Coated Paper
Image FormingOn Non-Permeable MediaOne Pass Image Quality
for Commercial Printing
High Speed Printing with Cut Paper
Sharing Functions Progress (SFP)
BeforeCompensation
AfterCompensation
• Under-Coating• Drying System• Latex Ink
• Defect Detection• Defect Compensation• Impression Cylinder
No Under-Coating Under-Coating
• Drying System• Anti-Curl Agent• Impression Cylinder• Air Conditioner• Pagewide Printhead
Sharing Functions ProgressSharing Functions Progress
13
Many ink jet Merits (small size, low cost, low energy Consumption) are lost.
Direction of Technology Progress
2005
Concentrating Functions Progress
(CFP)
Concentrating Functions Progress
(CFP)
• Drop Volume• Firing Frequency• Resolution• Multi-Color• Penetrability• Color Reproduction
Imaging Process is Achieved Only by Interactions between Ink And Media.
Sharing Functions Progress
(SFP)
Sharing Functions Progress
(SFP)
Commercial Printing• Transfer• Drying, Cooling• Defect Detecting & Correction• Under-Coating• Pagewide Printhead
14
?
Concentrating Functions Progress
(CFP)
Concentrating Functions Progress
(CFP)
Digital Fabrication• Functional Ink• Printhead Firing High Viscosity• Media (Substrate) Reformulation
Digital Fabrication• Hydrophobic / Hydrophilic Control
IncrementalInnovation
RadicalInnovation
Innovation Portfolio by Henderson & Clark
15
CFPArchitecture
Linkage between Core Concepts and Components
Reinforced Overturned
Changed
Unchanged
Core Component(Core Concept)
ModularInnovation
ArchitecturalInnovation
Architectural Knowledge
Component Knowledge
R. Henderson & K. Clark, Architectural Innovation: The ReconfigurationExisting Product Technologies and the Failure of Established Firm (1990)
≈SFP
Charged DeflectionHertz TypeElectrostatic Pull
PIJ,TIJ,AIP,ERFElectrostatic Pull Ink JetElectrostatic Actuator
1980
ArchitecturalKnowledge
ComponentKnowledge
Try And Error of Combinations
2005~
Improvement of Components
PIJ, TIJ
Captive CIJ
Dominant Design
Continuous Ink Jet
On Demand Ink Jet
Technology Progress of Ink Jet
Stream, Ultra-Stream
16
Concentrating Functions Progress
Architectural Knowledge Again?!
Try New CombinationsChange Architecture
Sharing Functions Progress
Break Off
Drop VolumeFiring FrequencyNozzle Number
Ink Penetrability
Charged Deflection (Binary)
Vista JETJetRix
LILO
Commercial Printing Market
Dominant Design
Approaches & Dominant Design
Various ink jet approaches to commercial printing exist, but the dominant design has NOT been established yet.
17
(Liquid EP)
AqueousUV
(Dry EP)Under-Coating
No Under-Coating
Direct IJTransfer IJ
Contradiction of Progress in Commercial Printing Market
Binary Deflection
Thermal Ink Jet, Piezo Ink Jet
Concentrating FunctionsProgress (CFP)
Architectural Knowledge Component Knowledge
1980 2005 Present
Captive CIJ
On Demand
Continuous
ConsumerConsumerOfficeOffice IndustryIndustry
Digital Fabrication
Digital Fabrication
Architectural Knowledge
Sharing Functions Progress (SFP)
Commercial Printing
18
Big NameBig Name
Venture or start-ups assumes architectural progress essentially.
Development Organization Development Organization or Resource Allocation
Based on Dominant Design
Do
min
an
t D
esig
n
Stream, Ultra-Stream
Contradiction of Progress in Commercial Printing Market
Architectural Innovation should be brought by venture companies or start-ups essentially.
On the other hand, Big companies have stored ink jet technologies and know-how required for commercial printing market.
Here, we have contradiction of progress.
No one can stop digitalization of commercial printing, what this contradiction brings?
19
Contrivances to Activate Ink Jet Technologies Progress
Ink Jet Incubation+
For both SFP (Architectural Innovation) and CFP (Incremental Innovation),
Full-Blown ink jet technologies owned by ink jet companies should be transfer or licensed to new challengers. (Don’t enclose for the already stop-glowing market.)
Ink Jet Technical Networking (Community) in Japan
Engineers and Researchers network (Community) will help to share common information and create new applications and make innovations.
20
Architectural progress in Additive Manufacturing
Material Jetting
1989
J. Sakai
Binder Jetting
1989
E. M. Sachs
Vat Photo-polymerization
1980
H. Kodama
Powder BedFusion
1986
C. R. DeckardMaterial
Extrusion
1989
S. S. Crump
Sheet Lamination
1987
M. Feygin
Directed Energy Deposition
1995
G. K. Lewis
Additive Manufacturing Is Categorized into 7 Methods.
These 7 Methods were Invented in 1980’s or 1990’s.
About 30 years pasts, then...
Additive Manufacturing Is Categorized into 7 Methods.
These 7 Methods were Invented in 1980’s or 1990’s.
About 30 years pasts, then...
21
Vat Photo-polymerization
1980
Powder BedFusion
1986
Sheet Lamination
1987
Material Extrusion
1989
Binder Jetting
1989 Material Jetting
1989
Directed Energy Deposition
1995
J. Sakai
E. M. Sachs
H. Kodama C. R. DeckardS. S. Crump
M. Feygin
G. K. Lewis
21
Shift
• Material Latitude• Productivity• Cost
Rapid Prototyping
Indirect Manufacturing
3D Production
Custom Manufacturing
Complex Manufacturing
- Target Shift of Additive Manufacturing
Architectural progress in Additive Manufacturing
Vat Photo-polymerization
1980
Powder BedFusion
1986
Sheet Lamination
1987
Material Extrusion
1989
Binder Jetting
1989 Material Jetting
1989
Directed Energy Deposition
1995
J. Sakai
E. M. Sachs
H. Kodama C. R. DeckardS. S. Crump
M. Feygin
G. K. Lewis
Architectural progress in Additive Manufacturing
HPMulti Jet Fusion
Xaar & Loughborough UniversityHigh Speed Sintering
2017
21
Vat Photo-polymerization
1980
Powder BedFusion
1986
Sheet Lamination
1987
Material Extrusion
1989
Binder Jetting
1989 Material Jetting
1989
Directed Energy Deposition
1995
J. Sakai
E. M. Sachs
H. Kodama C. R. DeckardS. S. Crump
M. Feygin
G. K. Lewis
Architectural progress in Additive Manufacturing
XYZ Printingda Vinci Color 3D printer
2017
21
Vat Photo-polymerization
1980
Powder BedFusion
1986
Sheet Lamination
1987
Material Extrusion
1989
Binder Jetting
1989 Material Jetting
1989
Directed Energy Deposition
1995
J. Sakai
E. M. Sachs
H. Kodama C. R. DeckardS. S. Crump
M. Feygin
G. K. Lewis
Architectural progress in Additive Manufacturing
21
CarbonCLIP2016
Listen this afternoon’s Keynote please.
Many New processes (new architectures) not categorized in 7 existing methods have been researched and proposed.
Many New processes (new architectures) not categorized in 7 existing methods have been researched and proposed.
In R&D PhaseIn R&D Phase
Conclusion & Suggestion
2005 was one of important turning years for ink jet technology progress.
22
Full-blown ink jet technologies owned by ink jet companies should be transferred or licensed to new challengers to activate both CFP and SFP.
Two type of ink jet technology progress exist. Concentrating Functions Progress (CFP) Sharing Functions Progress (SFP)
CFP is still required for digital fabrication, SFP is necessary for commercial printing.
In commercial printing market, a contradiction of progress has occurred, and dominant design has NOT been established yet.
CFP generates Incremental Innovation, SFP brings Architectural Innovation.