Shape evolution of multiple interacting droplets in inkjet deposition

Abstract

Purpose – The aim of this paper is to advance the understanding of the droplet deposition process to better predict and control the manufacturing results for ink-jet deposition. Design/methodology/approach – As material interface has both geometric and physical significance to manufacturing, the approach the authors take is to study the interface evolution during the material joining process in ink-jet deposition using a novel shape metric and a previously developed powerful simulation tool. This tool is an experimentally validated numerical solver based on the combination of the lattice Boltzmann method and the phase-field model that enabled efficient simulation of multiple-droplet interactions in three dimensions. Findings – The underlying physics of two-droplet interaction is carefully examined, which provides deep insights into the effects of the printing conditions on the interface evolution of multiple-droplet interaction. By studying line printing, it is found that increasing impact velocity or decreasing fluid viscosity can reduce manufacturing time. For array printing, the authors have found the issue of air bubble entrapment that can lead to voids in the manufactured parts. Research limitations/implications – The array of droplets impinges simultaneously, in contrast to most ink-jet printers. Sequential impingement of lines of droplet needs to be studied. Also, impingement on non-planar surfaces has not been investigated yet, but is important for additive manufacturing. Finally, it is recognized that the droplet hardening mechanisms need to be incorporated in the simulation tool to predict and control the final shape and size of the arbitrary features and manufacturing time for ink-jet deposition. Practical implications – The research findings in this paper imply opportunities for optimization of printing conditions and print head design. Furthermore, if precise droplet control can be achieved, it may be possible to eliminate the need for leveling roller in the current commercial printers to save machine and manufacturing cost. Originality/value – This work represents one of the first attempts for a systematic study of the interface dynamics of multiple-droplet interaction in ink-jet deposition enabled by the novel shape metric proposed in the paper and a previously developed numerical solver. The findings in this paper advanced the understanding of the droplet deposition process. The physics-based approach of analyzing the simulation results of the interface dynamics provides deep insights into how to predict and control the manufacturing relevant outcomes, and optimization of the deposition parameters is made possible under the same framework.