Aerosol jet printing (AJP) is a complex process for additive electronics that is often unstable. To overcome this instability, observation while printing and control of the printing process using image-based monitoring is demonstrated. This monitoring is validated against images taken after the print and shown highly correlated and useful for the determination of printed linewidth. These images and the observed linewidth are used as input for closed-loop control of the printing process, with print speed changed in response to changes in the observed linewidth. Regression is used to relate these quantities and forms the basis of proportional and proportional integral control. Electrical test structures were printed with controlled and uncontrolled printing, and it was found that the control influenced their linewidth and electrical properties, giving improved uniformity in both size and electrical performance.
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July 2019
Research-Article
Image-Based Closed-Loop Control of Aerosol Jet Printing Using Classical Control Methods
Jack P. Lombardi, III,
Jack P. Lombardi, III
Department of Systems Science and Industrial Engineering,
Binghamton, NY 13902
e-mail: jlombar4@binghamton.edu
Binghamton University
,Binghamton, NY 13902
e-mail: jlombar4@binghamton.edu
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Roozbeh (Ross) Salary,
Roozbeh (Ross) Salary
Division of Mechanical Engineering,
Huntington, WV 25755
e-mail: salary@marshall.edu
Marshall University
,Huntington, WV 25755
e-mail: salary@marshall.edu
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Darshana L. Weerawarne,
Darshana L. Weerawarne
Center for Advanced Microelectronics Manufacturing,
Binghamton, NY 13902
e-mail: dweerawa@binghamton.edu
Binghamton University
,Binghamton, NY 13902
e-mail: dweerawa@binghamton.edu
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Prahalada K. Rao,
Prahalada K. Rao
Department of Mechanical and Materials Engineering,
Lincoln, NE 68588
e-mail: rao@unl.edu
University of Nebraska-Lincoln
,Lincoln, NE 68588
e-mail: rao@unl.edu
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Mark D. Poliks
Mark D. Poliks
1
Department of Systems Science and Industrial Engineering,
Binghamton, NY 13902
e-mail: mpoliks@binghamton.edu
Binghamton University
,Binghamton, NY 13902
e-mail: mpoliks@binghamton.edu
1Corresponding author.
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Jack P. Lombardi, III
Department of Systems Science and Industrial Engineering,
Binghamton, NY 13902
e-mail: jlombar4@binghamton.edu
Binghamton University
,Binghamton, NY 13902
e-mail: jlombar4@binghamton.edu
Roozbeh (Ross) Salary
Division of Mechanical Engineering,
Huntington, WV 25755
e-mail: salary@marshall.edu
Marshall University
,Huntington, WV 25755
e-mail: salary@marshall.edu
Darshana L. Weerawarne
Center for Advanced Microelectronics Manufacturing,
Binghamton, NY 13902
e-mail: dweerawa@binghamton.edu
Binghamton University
,Binghamton, NY 13902
e-mail: dweerawa@binghamton.edu
Prahalada K. Rao
Department of Mechanical and Materials Engineering,
Lincoln, NE 68588
e-mail: rao@unl.edu
University of Nebraska-Lincoln
,Lincoln, NE 68588
e-mail: rao@unl.edu
Mark D. Poliks
Department of Systems Science and Industrial Engineering,
Binghamton, NY 13902
e-mail: mpoliks@binghamton.edu
Binghamton University
,Binghamton, NY 13902
e-mail: mpoliks@binghamton.edu
1Corresponding author.
Manuscript received July 23, 2018; final manuscript received April 10, 2019; published online May 28, 2019. Assoc. Editor: Laine Mears.
J. Manuf. Sci. Eng. Jul 2019, 141(7): 071011 (9 pages)
Published Online: May 28, 2019
Article history
Received:
July 23, 2018
Revision Received:
April 10, 2019
Accepted:
April 11, 2019
Citation
Lombardi, J. P., III, Salary, R. (., Weerawarne, D. L., Rao, P. K., and Poliks, M. D. (May 28, 2019). "Image-Based Closed-Loop Control of Aerosol Jet Printing Using Classical Control Methods." ASME. J. Manuf. Sci. Eng. July 2019; 141(7): 071011. https://doi.org/10.1115/1.4043659
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