Inkjet printing technology offers enormous advantages for electronics production and is attracting increasing interest.
Today, inkjet printing represents an alternative to the traditional application of solder masks in PCB production. Its advantages in terms of material consumption, waste and adaptability are well known and established. Conventional methods such as screen printing and photo printing are chemical-intensive processes that involve expensive wastewater treatment. With inkjet technology, the material is only applied where it is needed, resulting in virtually no waste as the production process does not involve harsh chemicals for development and removal. These advantages are particularly beneficial when producing large quantities and small mixtures, reducing the cost of consumables and increasing yields.
The advantages of inkjet
A key advantage is the 3D volume control of inkjet. While current technologies offer good lateral control, thickness control has been limited. This limitation has prevented any functional thickness design to date. Inkjet enables precise thickness control, allowing conformal coating and much-needed features such as locally defined solder mask thicknesses for higher stresses, which is a prerequisite for further electrification, for example. This control enables the patterning of solder masks for easier assembly. The patterning of solder masks can control the positioning of components during the reflow process. Simple dams enable precise re-encapsulation to protect against harsh environmental conditions. Inkjet offers the potential for more compact and reliable PCBs compared to traditional dispensing methods.
Dr. Gautero, Product Manager at SUSS, is an expert in inkjet printing as an additive process for PCB manufacturing
Digital control of inkjet printing offers greater design flexibility and faster manufacturing. Rapid prototyping and on-the-fly design changes are possible without the need for new masks. Traditional solder mask plating can take hours, whereas inkjet printing takes minutes, or even seconds on high throughput machines. For the PCB customer, this means a shorter turnaround time, a key value for prototyping. This flexibility is unique for the production of small batches and high volumes.
Hybrid approaches for PCB production
Several PCB production sites in the USA use a hybrid setup. They combine inkjet with traditional processes. The selective use for certain applications or in conjunction with existing systems enables a smooth introduction. For example, inkjet printing can be used for heavy copper applications or enhanced placement designs while maintaining traditional methods for conventional production.
In summary, inkjet printing offers significant advantages in terms of flexibility and sustainability. Reduced waste, minimized chemical consumption and flexible design make it a key technology for the future of PCB manufacturing. The combination of inkjet printing with conventional processes enables smooth integration and customized PCB manufacturing.
