On the quantitative assessment of the effect of multiple process parameters on the printed layer height in 3D inkjet printing

Abstract

ABSTRACT 3D inkjet (3D-IJ) printing is recognised for its potential in high-value applications, including printed electronics, tissue engineering and bio-inspired structures, given its precision and ability to deposit multiple materials. The quality of 3D-IJ printed parts is contingent upon meticulous control of the process governing parameters. This study experimentally investigates the influence of various parameters within the 3D-IJ process, i.e., printing resolution, coverage percentage, droplet volume, printing speed and UV-Power and their interaction effects on the printed layer height. The results were analysed statistically using ANOVA and a quadratic regression model was developed to quantitatively identify the relationship between the process response and parameters. Except UV-Power, all parameters, and their interactions with each other had noticeable effects on the printed layer height, with a distinct trend observed for each, affecting the height that ranged from 4.73 µm to 98.58 µm. Increasing printing resolution, coverage percentage and droplet volume resulted in an increase in layer height as all three parameters contribute to a larger volume of dispensed material per layer. Printing resolution was found to be the most influential parameter, evidenced by a significant p-value. Finally, the optimal printing parameters for two scenarios, highest printed layer and cost-effective printing were individually identified.