MIT1

Primary anasys
• 1.Flat stamp fabrication • 2. Wrapping the stamp with backing plate onto the roller with alignment and repeatability • 3. Ensuring the roundness of assembled print roller within 4 microns tolerance. • 4. Redesigning the impression roller system to improve its repeatability of parallelism, built up error budget model. • 5. Designing a high precision position system to control the print roller position and orientation. • paring results that achieved by last year's group. • 7. Printing multiple layers as a proof of concept.
Multi-Layer Printing
• most literature discusses methods to align surface to surface,including the alignment between mask and wafer in semiconductor industry, or dip and substrate in inkjet printing, while few have mentioned alignment issue between round subject and flat substrate. Thus references for designing machine capable of multi-layer printing will be mainly from color printing industry.
Stamp Casting Machine
• PDMS as the material for stamp has a low Young's modulus • round wafers (150mm, 200mm and 300mm size). • the thickness of the stamp was shown to affects the pattern transfer and a thin stamp seems to result in better printing quality.
The two major goals of this project and the steps of solution
• First goal:when we change the imprinted roller,we can’t lose the alignment • The solution :1.design of an interchangeable stamp. 2. Fabrication and demonstration of interchangeable stamp. 3.Test results providing data on distortion, and alignment. 4.Budget estimate for manufacturing applications. • Second goal:to improve the overall R2R system. • The solution:o1.Redesigning and implementing the impression roller system. 2. Designing process for multi-layer printing .3. Designing a high precision positioning system. 4..Test results providing data on distortion and alignment. 5.Budget estimate for manufacturing applications.
• Gravure is widely used in high quality printing. Because human eyes are not sensitive to features less than 40 micron wide, the feedback system for gravure machines usually set the accuracy at 100 micron or less. Errors in two key directions have been compensated. One is the direction of substrate motion during printing, or the "path"; the other is the direction perpendicular to the path on substrate plate. The latter is easy to adjust by moving roller along its axis; the error in path is sensed and compensated using sleeve displacement between the roller and the sleeve
Design and Manufacturing of High Precision Roll-to-Roll Multilayer Printing Machine Machine Upgrade
摘要
• 2008年，一批麻省理工大学工程硕士学生建立了一个卷 轴机器，该机器是将巯基印刷到柔性金基材上。经过试 验发现该机器在高速打印（400英尺/分钟）中表现出良 好的性能。由于单层印刷在工业应用中受到限制，我们 将该机器重新配置为多层印刷。我们的项目包括开发一 种能够制造高质量模板的设备，这对印刷质量至关重要; 提高了卷对卷机精度，这有助于提高机器的可重复性。 另外，我们设计了一种采用相同技术的多层印刷系统， 并使用升级后的机器进行了演示。与其他机器制精度在 ±32p微米的机器相比较，由新机器压印出的精度可以 达到16微米左右，厚度可以达到1194微米左右。由于机 器的多层印刷，则需要更好地控制辊筒驱动系统和更好 的套准测量来满足必要的规格。可以实现沿打印方向 1017微米和113微米的对准误差
Task Division
Soft Lithography
• The limitation of Photolithography : 1.a feature size of about 100 nm 2. high cost and technology development.3. it cannot be used on non-planar surfaces. • The types of soft lithography:replica molding (REM), microtransfer molding (mTM), micromolding in capillaries (MIMIC), and solvent-assisted micromolding (SAMIM) . • Specially, Self-assembly • Self-assembly refers to the spontaneous formation of molecules into organized structures by non-covalent forces. The resulting structure is highly uniform, defect-free owing to thermal equilibrium, and in the lowest energy form.
Micro-coipment
the physical appearance of the R2R machine
a summary of relevant results about the equipment
• 1. Neither printing pressure nor speed was found to have a significant effect on spatial distortions and pattern dimensions in the range of settings we used. • 2. It is possible to print a robust etch-resisting SAM at very high speeds (400 ft/min, unit area contact time 5ms). • 3. At very high speeds (400ft/min), some systematic air trapping was observed • 4. The alignment of the stamp on the backing may have a significant effect on distortion patterns.
casting machine Nano-Terra limitation
PDMS Peeling Process
• In general, at the peel front, boundary conditions are different on the two sides of the PDMS stamp; in fact, on one side, the surface of the film has zero shear stress (or very small shear stress, in our case) because it is not attached any surface (or to a different surface), while on the other side, the film adheres to the silicon master and shear stress is imposed on it by the substrate. This configuration creates a singularity around the peel front. This very small and thin zone is characterized by a highly variable stress values. This stress singularity in the normal direction causes the separation of the film at the peel-fron