Edge Printing Research Articles

Enhancement of Scan Strategy for Improving Surface Characteristics of the SLMed Inconel 718 Alloy Component

The technique of selective laser melting has garnered significant interest due to its capacity to fabricate metal parts of any shape using a single printing process. In this study, a scan strategy was proposed for printing the inner structure part based on the varying performance of the Inconel 718 alloy part produced using different scan techniques. The test findings indicated that the surface quality of the printed material along the scan line exhibited significantly superior performance in comparison to that produced in a vertical direction to the scan line. Regarding the scan strategy, it is evident that the zigzag shape scan strategy exhibited superior performance in terms of the microstructure of the printed part. This is attributed to the more consistent cooling rate on each scan track. On the other hand, the square-framed scan strategy demonstrated a relatively optimal condition for the bending deformation of the printed part compared to other scan strategies. This is due to the more appropriate behavior of the molten pool during the outer edge printing process. After considering all of these criteria, a novel scan approach was created that included various scan strategies. The test findings indicated that the component produced using this novel scanning technique exhibited the combined benefits of both the square-shaped and zigzag-shaped scanning strategies.

84‐2: Invited Paper: High‐Resolution Additive Manufacturing in the Fabrication of Micro‐LED Displays

This paper demonstrates the use of Ultra‐Precise Dispensing, a high‐resolution additive manufacturing method, in the fabrication of Micro‐LED displays. We demonstrate advancements in achieving ultra‐small feature sizes, high aspect ratios, and the ability to print on complex substrates. The paper presents a number of use cases, such as interconnections on complex topographies, edge printing, microvias filling, and microbumps dispensing. It summarizes the relevance of this technology for Micro‐LED displays fabrication and discusses the prospective future developments in the field of additive manufacturing for display fabrication.

Hierarchical homogenization and experimental evaluation of functionally graded materials manufactured by the fused filament fabrication process

This research study investigates the numerical and experimental characterization of Functionally Graded Materials (FGMs) fabricated by the fused filament fabrication (FFF) process. To design and fabricate FGMs, the gradient-based digital structures were designed using the voxelization method and manufactured with flat and on edge printing orientations. The direct and gradual transition patterns were fabricated, and tensile test method was used to characterize the interface strength. The results indicated that the gradual change in fiber reinforcement reduced the stress concentrations at the interface zone and increased the strength of neat Acrylonitrile Butadiene Styrene (ABS) properties. The homogenization approach was applied along with the finite element method to predict the effective material properties of FFF-made FGMs. It was found that the homogenized values were close to the experimental test results with around 5 % error for flat-oriented parts. Overall, this research work presents an important step toward enabling the effective design and analysis of composite structures using an experimental characterization and computational methodology.

Perspectives and tradeoffs of absorber materials for high NA EUV lithography

Next-generation extreme ultraviolet (EUV) systems with numerical apertures of 0.55 have the potential to provide sub-8-nm half-pitch resolution. The increased importance of stochastic effects at smaller feature sizes places further demands on scanner and mask to provide high contrast images. We use rigorous mask diffraction and imaging simulation to understand the impact of the EUV mask absorber and to identify the most appropriate optical parameters for high NA EUV imaging. Simulations of various use cases and material options indicate two main types of solutions: high extinction materials, especially for lines spaces, and low refractive index materials that can provide phase shift mask solutions. EUV phase masks behave very different from phase shift masks for DUV. Carefully designed low refractive index materials and masks can open up a new path toward high contrast edge printing.

Effect of edge print parameters on microstructure and high temperature solution nitriding response of additively manufactured austenitic stainless steel

The as-built microstructure of edge printing parameters in the laser powder-bed fusion process is investigated as well as the effect of edge parameters on the response to high temperature solution nitriding. The results show that using edge parameters leads to a zone of elongated austenite grains with shallow melt pools. Subjecting parts printed with edge parameters to high temperature solution nitriding (and high temperatures in general) results in the formation of equi-axed grains with a high density of annealing twins. Conversely, bulk parameters create a pinning effect and preserve the fine misorientation structure inside the elongated structure from the as-built condition. The results show that a high temperature solution nitriding treatment is apt to post-processing of additively manufactured 316L.

Mechanical properties of ULTEM 9085 material processed by fused deposition modeling

With the advancement of fused deposition modeling (FDM) additive manufacturing process for producing end use products, there is a great need for new high-performance materials capable of meeting the requirements of different engineering applications. ULTEM 9085 is a thermoplastic material with superior performance that emerged a few years ago. To use this material in different sectors, it is essential to characterize its mechanical properties and predict its behavior and performance. Moreover, in the FDM process, the properties of materials are highly influenced by the processing parameters. In this study, the characterization of the mechanical (tensile, compression and flexural) properties of a high-performance ULTEM 9085 thermoplastic material was carried out. The study also investigated the influence of the parameters on these properties. Test specimens were prepared by varying two different process parameters of the machine (Fortus 450mc), layer orientation (0°, +45°/- 45°and 90°) and build direction (flat, edge and upright). The test results show that the mechanical properties of the material are extremely dependent on the processing parameters. Maximum tensile stress is observed for the parameter combination of 0° layer orientation and edge build direction, whereas maximum compression stress is registered for the parameter combination of 90° layer orientation and flat build direction. Maximum flexural stress is registered for the parameter combination of 0° layer orientation and flat build direction. Over all, among the considered parameters, edge printing direction and 0° layer orientation, resulted in the highest mechanical properties.

Sub-50 nm patterning of functional oxides by soft lithographic edge printing

We report a fast, versatile and reproducible method to make arbitrary nanoscale patterns of functional metal oxides by edge transfer printing of aqueous metal-loaded water-soluble polyacrylic acid (PAA) solutions on silicon. Patterns of ZnO, CuO, NiO and Fe2O3 with lateral dimensions below 50 nm were realized. The process uses elastomeric PDMS stamps with microscale feature sizes to fabricate nanoscale patterns, so that stamp deformation problems are minimized despite the high resolution.

Fabrication of ultra-fine nanostructures using edge transfer printing

The exploration of new methods and techniques for application in diverse fields, such as photonics, microfluidics, biotechnology and flexible electronics is of increasing scientific and technical interest for multiple uses over distance of 10-100 nm. This article discusses edge transfer printing--a series of unconventional methods derived from soft lithography for nanofabrication. It possesses the advantages of easy fabrication, low-cost and great serviceability. In this paper, we show how to produce exposed edges and use various materials for edge transfer printing, while nanoskiving, nanotransfer edge printing and tunable cracking for nanogaps are introduced. Besides this, different functional materials, such as metals, inorganic semiconductors and polymers, as well as localised heating and charge patterning, are described here as unconventional "inks" for printing. Edge transfer printing, which can effectively produce sub-100 nm scale ultra-fine structures, has broad applications, including metallic nanowires as nanoelectrodes, semiconductor nanowires for chemical sensors, heterostructures of organic semiconductors, plasmonic devices and so forth.

Magnetization Distribution of Tb/in$^{2}$ Class Hard Disks Recorded With Bit Printing and Edge Printing

In this paper, printing characteristics for the bit printing and the edge printing were compared by micromagnetic simulation. As a result, servo signal can be clearly recorded using both printing methods, and printing field dependence of printing performance for each method is considerably different. The transition of bit-printed magnetization is almost straight for any pattern, while that of edge-printed magnetization has several ridges. On the other hand, the edge printing is robust for the change in the printing field, compared with the bit printing.

Magnetic printing characteristics using master disk with perpendicular magnetic anisotropy

With the increase in recording density and capacity of hard-disk drives (HDD), high speed, high precision and low cost servo writing method has become an issue in HDD industry. The magnetic printing was proposed as the ultimate solution for this issue [1-3]. There are two types of magnetic printing methods, which are ‘Bit Printing (BP)’ and ‘Edge Printing (EP)’. BP method is conducted by applying external field whose direction is vertical to the plane of both master disk (Master) and perpendicular magnetic recording (PMR) media (Slave). On the other hand, EP method is conducted by applying external field toward down track direction of both master and slave. In BP for bit length shorter than 100nm, the SNR of perpendicular anisotropic master was higher than isotropic master. And the SNR of EP for the bit length shorter than 50nm was demonstrated.

Fabrication of Gold‐Directed Conducting Polymer Nanoarrays for High‐Performance Gas Sensor

Gold-directed polypyrrole (PPy) nanoarrays are fabricated by hydrogel-assisted nanotransfer edge printing (HnTEP) and electrochemical polymerization. Gold nanoarrays are fabricated through the HnTEP method, which involves metal deposition, hydrogel etching, and nanotransfer edge printing. By utilizing the well-positioned gold nanostructures, PPy nanoarrays with smooth morphology and controllable dimensions are fabricated through in situ electrochemical polymerization, the results of which are characterized by scanning electron microscopy and atomic force microscopy. A gas sensor based on PPy nanoarrays results in excellent sensing capabilities towards NH₃ detection, especially the sensitivity and fast response. This method appears to be general and may aid in the future design and implementation of other active materials which can also be manipulated by the same procedure and serve as functional components for chemical sensing, optoelectronics, biodetection, and other applications.

Influence of a Master Pattern Shape on Magnetic Printing Characteristics

A master pattern with the a line-and-space (L/S) part and a checker part in the servo signals was made by using an FeCo film, and the edge printing characteristics of both parts were compared. The MFM output in the checker part was equal to the L/S part for a bit length of 200 nm, while for a bit length of 100 nm, the MFM output in the checker part decreased by about 30% compared with that in the L/S part, because of the MFM’s low resolution. However, for a bit length of 100 nm, simulation results showed that the edge-printed magnetization of the checker part was equal to that of the L/S part. When the TMR head reproduced both parts, the output in the checker part was equal to that in the L/S part. The optimum printing field for the checker part was the same as that for the L/S part. Moreover, the rate of decrease in the MFM output did not depend on the printing field.

Transfer Printing of Metal Nanoparticles with Controllable Dimensions, Placement, and Reproducible Surface-Enhanced Raman Scattering Effects

This paper describes the fabrication of single, multiple strand, and three-dimensional patterning of metal nanoparticles by nanotransfer edge printing (nTEP), a method comprising nanoparticle self-assembly, nanotransfer printing (nTP), and edge lithography. In the process proposed here, 20 nm Au nanoparticles (AuNPs) are deterministically arranged in precise placement by manipulating a topographically patterned poly(dimethylsiloxane) (PDMS) stamp, and Ag nanoparticles are conjugated with AuNP patterns to construct surface-enhanced Raman scattering (SERS)-active substrate to detect trace amounts (10(-13) mol/L) of biological molecules such as thrombin with enhancement up to 10(10). The simple, convenient, and inexpensive procedure has extended nTP and nTEP from using evaporated thin metal film to using self-assembled nanoparticles, and may stretch to other organic and inorganic species to find broad applications in many areas.

Influence of the Master Pattern Angle on Perpendicular Magnetic Contact Printing Characteristics

The influence of the inclination angle of the master pattern on the edge printing characteristics for writing phase servo patterns on perpendicular magnetic recording media was investigated. Even if the master pattern angle is 40 degrees, the printing characteristics are only 10 percent lower than when the angle is 0 degrees. The influence of the inclination angle of the master pattern on the printing characteristics is also small when the bit length is changed. The contribution of the in-plane component of the recording field to magnetization reversal is large in edge printing. Although the perpendicular component of the recording field decreases markedly as the inclination angle of the master pattern increases, edge printing can be used for writing phase servo patterns on slave media.

Analysis of waveform from perpendicular magnetic printed media

Edge printing is one of the perpendicular magnetic printing methods for writing servo signals with high speed, high accuracy and low cost. Sub-peaks of waveform from edge printed media are concerned as the sub-peaks can cause errors during the read-back process. In this study, in order to reduce sub-peaks, the influence of printing field, bit length and patterned magnetic layer thickness of master medium on sub-peaks is investigated by using a metal-evaporated (ME) tape as a slave medium. The results show that sub-peak to main peak ratio decreases with stronger printing field, smaller bit length and thicker patterned magnetic layer of master media.

Well‐Positioned Metallic Nanostructures Fabricated by Nanotransfer Edge Printing

Well‐Positioned Metallic Nanostructures Fabricated by Nanotransfer Edge Printing

Fabrication of ultrafine protein arrays on easy-fabricated metallic nanostructures

In this paper we describe a method to fabricate ultrafine protein arrays on metal nanostructures. The method consists of the simple fabrication of Au nanowire arrays and the immobilization of protein on these wires. After fabricating the metallic nanowire arrays through nanotransfer edge printing, we pattern proteins on the metal arrays through the interactions of protein–mercaptoundecanoic acid and gold. The metallic nanostructures promote the surface-enhanced Raman scattering of the attached protein ultrafine arrays.

垂直磁気転写特性のマスターパターン傾斜角依存性の拡大モデルによる解析

The influence of the inclination angle of the master pattern on the duplication characteristics during the formation of a phase servo pattern on perpendicular magnetic recording media by edge printing was investigated by using an enlarged model. The perpendicular components of both the recording field and the magnetization of the duplicated slave medium decreases as the inclination angle of the master pattern increases. The influence of the inclination angle of the master pattern on the magnetization is small in comparison with the influence on the recording field, and even for an angle of 40 degrees, edge printing on slave media is possible.

Influence of Spacing between Master and Slave Media on Magnetic Duplication Characteristics for Perpendicular Recording Media

There are two methods of writing servo signals with high speed in a perpendicular magnetic recording medium by magnetic duplication: bit printing (BP) and edge printing (EP). In this study, the influence of spacing between master and slave media on duplication characteristics in both BP and EP has been investigated by the three-dimensional finite-element method. The results show that the duplication characteristic in each method is deteriorated with a large spacing. Also, the influence of a small spacing is stronger in BP than in EP.

垂直磁気転写された磁化状態のマイクロマグネティックシミュレーション

We demonstrated the micromagnetic simulation of magnetic duplication for perpendicular magnetic recording (PMR) media. The magnetization distributions of the PMR media duplicated by edge printing (EP) and bit printing (BP) were investigated. The dependence of duplication characteristics on the duplication field was also estimated. An AC erase state in the off-track region appeared for a strong duplication field in EP. The dependence of the duplication characteristics on the duplication field we found in this study is in agreement with that calculated by macroscopic-magnetization analysis in a previous report. Although the intergrain exchange constant has almost not influence on the duplication characteristics in EP, the duplication characteristics in BP are improved as the intergrain exchange constant increases.