Fraunhofer Institute for Manufacturing Engineering and Automation IPA
All Nozzles at a Glance: New Approaches to Inkjet Process Development and Monitoring
In brief
How can inkjet become a reliable production technology? Together with droptical GmbH and Quantica GmbH, the Fraunhofer IPA is developing approaches to process development and in-line monitoring for industrial applications.
In detail
The industrial use of inkjet technologies requires stable processes and reliable quality monitoring. Unlike in graphic printing applications, functional inkjet printing is not just about a printed image, but about the targeted processing of materials such as paints, adhesives, coatings, or electronic materials. If a nozzle fails or droplet formation changes, this can directly impair the function of the printed product.
Development of Dropwatching and Inline Monitoring System
In collaboration with droptical GmbH and Quantica GmbH, the Fraunhofer IPA is working on two complementary lines of development as part of a ZIM project. On the one hand, Dropwatching is being used as a tool for process development. This involves visualizing and analyzing individual droplets to qualify new materials, evaluate print parameters, and better understand the causes of defects such as unstable droplet formation or air entrapment.
On the other hand, a compact system for inline monitoring is being developed directly at the printhead. The goal is to move beyond simply observing individual nozzles in the lab and instead monitor all nozzles during the printing process. This would be an important step toward reliably ensuring the stability of inkjet processes in production as well.
To this end, Quantica GmbH is further developing its printhead platform for high-viscosity materials. This involves a robust printhead architecture, a suitable nozzle layout, and the processing of new material classes. Droptical GmbH is contributing miniaturized camera and optical systems that enable integration within the confined space of the printhead. The Fraunhofer IPA is responsible for process development, fluidic design, the integration of new sensor technology into the fluid system, as well as setup and testing in the laboratory.
Laborsetup
Im Aufbau befindlicher Prototyp für ein Inline-Integration
Process Development and System Integration at Fraunhofer IPA
The Fraunhofer IPA is developing the fundamental process technologies required to reliably process new materials via inkjet. This includes fluidic system design, material qualification, and analysis of droplet formation. A key focus is on sensor technology within the fluid system. It is designed to detect critical conditions such as air pockets, pressure fluctuations, unstable flow rates, or changes in the material at an early stage, before they affect droplet formation and, consequently, print quality.
The sensor data is linked with drop-watching recordings and other process data. This provides a better understanding of how the fluidics, printhead, and material interact. In parallel, Fraunhofer IPA is developing and validating robust process windows for high-viscosity and functional materials.
In the long term, the concepts developed are intended to help detect process errors earlier, reduce scrap, and make new material systems—from coatings to adhesives—usable for industrial inkjet applications.
Insights into the project
»Our technology was originally developed for the optical monitoring of dispensing processes. This joint project enables us to apply this expertise to the requirements of inkjet printing and tap into a new market segment. The close collaboration with Fraunhofer IPA and Quantica GmbH allows us to develop and validate these concepts under real-world process conditions.«
Matthias Leininger, Managing Director and CTO of droptical GmbH
Der Inkjet-Prüfstand am Fraunhofer IPA liefert per Software Parameter für einen langzeitstabilen Tropfenausstoß und erkennt ausgefallene Düsen (links). Im ZIM-Projekt entwickelt Droptical auf dieser Basis ein Multikamerasystem, das alle Düsen des Druckkopfs (Quantica NovaJet) über die gesamte Druckkopfbreite überwachen kann (rechts).