Enhanced geometric precision of non-contact, conformal 3D printing via “error-transferred” towards jetting-direction

Conformal inkjet printing with multi-axis linkage motion platform that enables the fabrication of a variety of curved electronics has drawn great attention recently. However, the geometric precision of inkjet printing on arbitrary surface is a long-term obstacle for the fabrication of curved electronics. Herein, we propose a precision-enhanced method for non-contact, conformal 3D printing based on the unique characteristics of the relatively large error tolerance along jetting-direction. The in-surface geometric precision is enhanced by sacrificing the precision along the jetting-direction, namely “error-transferred” algorithm, after establishing a kinematics model of conformal printer to digitize the movements and error conditions of the axes. The precision-enhanced method has finally been verified by carrying out a corresponding geometric error comparison via simulations and linear-array printing experiments. And the average reduction in geometric error turns out to 20.85% and 12.28% in simulation and experiment results, respectively. We envision that this precision-enhanced method could also be applicable and can be extended to other non-contact process methods such as laser processing, plasma etching, and so on. • A novel precision-enhanced method is proposed for non-contact conformal printing on complex surfaces. • The geometric errors are significantly reduced through “error-transferred” algorithm based on the “precision tolerance” characteristic of jetting direction. • A “circulation substitute” calculation method has been proposed to simplify the removal of absolute value in calculation process. • The algorithm brings about 20.85% and 12.28% precision enhancement in comparison simulation and printing experiment of 5-axis linkage. • The algorithm is also applicable to other non-contact manufacturing methods such as laser processing and plasma etching.