Investigation on synchronization of the offset printing process for fine patterning and precision overlay

Offset printing processes are promising candidates for producing printed electronics due to their capacity for fine patterning and suitability for mass production. To print high-resolution patterns with good overlay using offset printing, the velocities of two contact surfaces, which ink is transferred between, should be synchronized perfectly. However, an exact velocity of the contact surfaces is unknown due to several imperfections, including tolerances, blanket swelling, and velocity ripple, which prevents the system from being operated in the synchronized condition. In this paper, a novel method of measurement based on the sticking model of friction force was proposed to determine the best synchronized condition, i.e., the condition in which the rate of synchronization error is minimized. It was verified by experiment that the friction force can accurately represent the rate of synchronization error. Based on the measurement results of the synchronization error, the allowable margin of synchronization error when printing high-resolution patterns was investigated experimentally using reverse offset printing. There is a region where the patterning performance is unchanged even though the synchronization error is varied, and this may be viewed as indirect evidence that printability performance is secured when there is no slip at the contact interface. To understand what happens at the contact surfaces during ink transfer, the deformation model of the blanket's surface was developed. The model estimates how much deformation on the blanket's surface can be borne by the synchronization error when there is no slip at the contact interface. In addition, the model shows that the synchronization error results in scale variation in the machine direction (MD), which means that the printing registration in the MD can be adjusted actively by controlling the synchronization if there is a sufficient margin of synchronization error to guarantee printability. The effect of synchronization on the printing registration was verified experimentally using gravure offset printing. The variations in synchronization result in the differences in the MD scale, and the measured MD scale matches exactly with the modeled MD scale.