Multi-response optimization of R2R gravure printing using orthogonal array and principal component analysis as a weighting factor

Abstract

Control over the quality of roll-to-roll gravure-printed silver-nanoparticle electrodes such as continuity, line width, and thickness is of importance to create high-resolution patterns of low resistance. In this regard, the multi-response optimization of gravure printing is required for industrial practice. To address this problem, the Taguchi method coupled with principal component analysis has been applied for multi-objective optimization of roll-to-roll gravure printing of silver-nanoparticle electrode to attain optimal condition within design space. The three-quality characteristics including continuity, pattern line width, and pattern thickness were simultaneously considered for optimization. The process parameters with three levels considered are ink viscosity, air nip pressure, and printing speed. First, Taguchi method was utilized to determine single-objective optimization. Then, the signal-to-noise ratios obtained from Taguchi method were used in principal component analysis to define a weighting factor of three-quality characteristics for multi-objective optimization. Finally, experiments were conducted to evaluate the proposed method, and the results demonstrate an improvement to the well-defined line width, thickness, and continuity of silver-nanoparticle electrodes under optimal parameter settings.