Emerging Technologies Academy

High Speed Ink Jet System Design & Process Development Course

Friday, September 9, 2016

Course Focus

IMI’s High Speed Ink Jet System Design & Process Development Course provides an introduction to the real world challenges of high speed printer design. The course focuses on five key areas:

Printer Development Process: Commonly made mistakes from ink supply design, encoder assembly, substrate transport system & other integration issues plus specific design suggestions to minimize issues. Overview of using drop placement error budgets to guide design process.

Jetting Process: How does it work and how do the key process variables affect image quality and reliability. Questions answered such as “what limits the speed of printing”, “most common reasons for jetting reliability issues”, etc.

System Integration & Design Process: Commonly made mistakes during integration from ink supply design, encoder assembly, substrate transport system and other common integration issues plus specific design suggestions to minimize such issues. Also an overview of using drop placement error budgets to guide the design process.

Process Development: Process development & testing procedures to tune printing process including ink/substrate tuning, time from print to drying, interstation vs. standard drying, Ink formulation changes, print quality tuning on range of substrates, screening, color laydown order, ink limiting, substrate pre-treatment, etc.

Vendor & Outside Resources Management: Working closely with experienced vendors will greatly improve any printer development. We will discuss potential advice and testing that can be performed by vendors.

High speed production printer development is very challenging. This course will provide a proven framework for printer development plus practical recommendations on key design areas, testing & solutions to common development mistakes which will:

1. Assist those undertaking design or implementation of ink jet systems by providing critical insights to the design and implementation process

2. Provide the knowledge and understanding to ask the right questions of vendors and consultants for those in the ink jet system selection and installation process.

High Speed Ink Jet System Design & Process Development Course

8:00 am Course Registration

8.30 am Session 1

Course Leader: Rob Rogers, Founder & President, Print3 Technologies, Shawnee, Kansas

High Speed Printer Development: Challenges & Markets

  • Why Digital Printing?
  • Ink Jet vs. Conventional Printing: The Secret is the Cost Curve
  • Current & Emerging Single Pass Markets

Printer Development Process: Key Areas of Focus

  • Overview of Product Development: Key Points
  • System Architectures
  • Process Development Basics: Marriage of Printhead, System, Ink Formulation & Substrates to Meet Market Requirements
  • Market Requirements & Engineering Specifications

Jetting Process & Effect of Ink Properties

  • Slow Motion Video of Jetting
  • Printhead Inputs & Outputs Diagram
  • Rectified Diffusion: What is it & Why does it Result in Reliability Issues?
  • Common Single Pass Printheads
  • Flow Through vs. Non Flow Through Printheads
  • Jetting Effects of Critical Variables
  • Inks: How Ink Properties Effect System Integration & Jetting
  • Summary of Key Process Variables & their Basic Effects on the Jetting process

Overview of Drop Placement Error Budgets

  • Common Sources of Errors
  • Error Budgets Concept
  • Banderly Curve: Determining Drop Placement Errors
  • Printhead Mounting Errors
  • Substrate Transport Errors
  • Statistical Method to Calculate System Errors

12:00 noon Lunch

1:00 pm Session 2

Sub-System Design

  • Encoder Design
  • Printhead Mounting
  • Ink Supply Design
  • Print Electronics Integration
  • Drying/Curing
  • Technical Areas: Key Points

Design of Transport Systems

  • Belt Based Systems
  • Web Based Systems
  • Sheetfed Systems
  • Printing on 3D Parts

Process Development: The Marriage of Printhead, System, Ink Formulation and Substrates

  • Common Process Variables that are Tuned for an Application
  • Process Testing & Equipment
  • Ink/Substrate Interaction
  • Process Development: Key Points

Vendor & Outside Resource Management

  • Key Vendors
  • Advice & Services vendors provide – under utilized resource
  • Overall Design & Development Management Plan

Discussion of Attendee’s Projects

  • Discuss Attendee’s Projects & Issues they are experiencing
  • Alternatively, after adjournment, Rob Rogers will be available for private discussion on specific projects

4:00 pm Adjournment

COURSE LEADER

Rob-Rogers.png

Rob Rogers, Founder & President, Print3 Technologies, Shawnee, Kansas

Rob Rogers is the Founder and President of Print3 Technologies, a one stop shop for contract engineering and technical consulting, assisting clients to rapidly bring world class ink jet products to market.

Rob has been involved in the ink jet industry for over 15 years, where he has been responsible for a wide range of ink jet production printing systems including: high speed on-press variable data printers, ink jet label printing press, 100 part per minute container printer, flooring printer, solar cell deposition system and many others.

Rob formerly worked at Dimatix where he assisted international customers with new product development. Rob was a Co-Founder and Principle Engineer of Jetrion, an EFI company. While at Jetrion he was responsible for multiple custom ink jet production machines and the first commercially successful label press. 

He has consulted for Heidelberg, Mark Andy, and many confidential clients. His team has recently designed and built a print engine for a confidential Fortune 500 company that was demonstrated at the DRUPA trade show.

Rob graduated from Kansas State University with a degree in Mechanical Engineering.