Printing Roll Manufacturing using Laser Scanner

w w w . i j m r e t . o r g I S S N : 2 4 5 6 - 5 6 2 8 Page 1
International Journal of Modern Research in Engineering and Technology (IJMRET)
www.ijmret.org Volume 2 Issue 8 ǁ December 2017
Printing Roll Manufacturing using Laser Scanner
Heeshin Kang1
, Jiwhan Noh2
1, 2
(Department of Laser & Electron Beam Application/ Korea Institute of Machinery & Materials,
Korea)
ABSTRACT :Research for the development of the roll-to-roll printing process in lieu of the existing
semiconductor process is actively underway. The roll-to-roll printing system can enable electronic
devices to be mass-produced at low cost. This study was conducted to develop the manufacturing
technology of the printing roll used in the printing process of electronic devices. The indirect laser
engraving technology was used to create printable roll made of chrome-coated roll after coating the
surface of the steel roll with copper and polymer, ablating the polymer on the surface of the roll, and
etching the roll. The 3-dimensional laser scanner and roll rotating systems were constructed, and the
system control program was developed. We used 100W-grade fiber laser, 3-dimensional laser
scanner, and 3-axis moving stage system with a rotating axis. We derived the optimal conditions by
performing laser patterning experiments, and we were able to secure the minimum line width of 24 ㎛
by using the developed 3-dimensional laser scanner system.
KEYWORDS -3-dimensional, laser, scanner, roll, printing, patterning
I. INTRODUCTION
Most manufacturers currently produce
electronic devices in the wafer-based
semiconductor process, which requires high-priced
equipment and robust process technologies.
Therefore, it is essential to develop an alternative
semiconductor process that can mass-produce
electronic devices at low cost. To this end,
researches are ongoing to study the processes for
the mass production of electronic devices based on
the roll-to-roll printing process, which is a
conventional mass-printing method. The roll-to-roll
printing method has drawn attention because the
process technology can mass-produce secondary
semiconductors such as RFID tag, electronic paper,
solar cell, and smart sensor at low cost.
Commercializing such production method requires
two technologies of printing equipment: conductive
ink and conductive polymer. The process of
printing electronic devices using a printing roll
requires a technology for processing the printing
roll. The printing roll processes include flexo
printing, offset printing, screen printing, and
gravure printing.[1,2] The processes of
manufacturing gravure printing roll include
electronic sculpture, indirect laser engraving, and
direct laser engraving.[3,4] As the leading
technology today, the indirect laser engraving
technology involves coating the printing roll
surface with polymer or black paint, patterning the
electronic device circuit using laser beam, and
etching the circuit on the roll surface through the
etching and coating processes. Since the degree of
integration of printed electronic device has been
increasing, the line width and spacing of the
printing roll pattern have been decreasing.
Therefore, there is growing demand for the printing
roll patterning process to produce 20 ~ 30 ㎛, but
there has yet to be a system that can flawlessly
yield the micro line width.
This study developed the indirect laser
patterning technology and laser processing system
using a 3D laser scanner to process the printing roll
with micro line patterns and conducted a laser
patterning test. The 3D laser scanner patterning test
observed the micro line widths with optical
microscope to deduce the optimal laser condition.
It also studied the technology for improving the
precision of the laser patterning system using a 3D
laser scanner.
II. TEST APPARATUS AND METHOD
Fig. 1(a) presents the 3D laser scanner
patterning system configured for manufacturing the
printing roll as part of this study. It features the
copper plated roll with the surface spray-coated
with black polymer. Fig. 1(b) shows the overall

www.ijmret.org Volume 2 Issue 8 ǁDecember 2017.
laser patterning system used in the test to check
various patterns.
(a)
(b)
(c)
Fig. 1. Indirect laser patterning for manufacturing
the printing roll; (a) polymer-coated roll (b) laser
patterning system (c) manufacturing process
Manufacturing a printing roll patterned
with the intended shape requires creating the
pattern with a CAD program first and removing the
black polymer on the roll surface by emitting laser
using the 3D laser scanner in the same shape as that
created by the CAD program. Fig. 1(c) illustrates
the process of final manufacturing of a printing roll
through the etching and plating process after laser
patterning on the roll coated with polymer. Plating
the steel base roll with copper at the beginning of
the printing roll manufacturing process improves
the coating performance and corrosion resistance of
polymer after laser patterning. The post-processing
adds final chrome plating after the corrosion
process to increase the strength of the roll surface
during printing before finalizing the printing roll.
Table 1 lists the main specifications of the laser
patterning system, process variables, and main
components of black polymer coating the roll
coated with copper.
Table 1. Specifications of the laser patterning
system
Laser Power 100 W
Laser Wavelength 1070 nm
Focal Length of F-theta Lens 80 mm
Diameter of Beam Spot 20 ㎛
Moving Stage XY table
Rotating Speed 20 rpm
Diameter of Printing Roll 125 mm
Thickness of Copper Coating 250 ㎛
Thickness of Black Polymer 3~4 ㎛
Thickness of Chrome Coating 6~7 ㎛
Chemical Name & Common
Name
Contents (%)
Acryl Groups Resin 9.0-11.0
Inorganic Pigments 4.5-5.5
Propyleneglycol Mono Ethyl
Ether
21.0-23.0
Isopropyl Alcohol 3.0-5.0
Toluene 8.0-10.0
Methyl Ethyl Ketone 12.0-14.0
Ethyl Acetate 34.0-36.0

Among the main system components, the laser
oscillator uses 100W-grade fiber laser system,
whereas the moving unit consists of the X-Y table,
roll rotating axis, 3D laser scanner, and optical
module. It uses the 3D laser scanner system instead
of the laser head moving unit to create an arbitrary
pattern in the 10 x 10 mm section since it enables
high-speed patterning. The scanner type has many
advantages over the head moving type because of
the continuity and repeatability of the pattern. We
developed the 3D laser scanner-based system for
printing roll laser patterning using 3D laser
scanner, scanner oscillation unit, and interface with
the moving axis. Fig. 2 shows the block diagram of
the 3D laser scanner system. The varioscan that
enables transport along the z-axis according to the
variation of roll curvature can emit laser beam with
constant focal distance even when the scanning
distance changes.
Fig. 2. Diagram of the 3-dimensional laser scanner
system
Fig. 3 presents a picture of the 3D laser
scanner system. The z-axis moving distance that
compensates the focal distance for varying roll
curvature is ± 4 mm, and the maximum moving
speed is 1m/sec. The image area of the F-theta lens
is 47 x 47 mm, whereas the focal distance is 80
mm. The aperture is set to 14 mm. Fig. 4 shows a
page of the control software of the processing
system of the laser scanner-based printing roll. The
software has functions such as laser control,
scanner system control, processing system
movement control, coordinate data extraction from
CAD files, and configuration parameter setting.
Fig. 3. 3-dimensional laser scanner system with z
axis
Fig. 4. Window of system control software
We designed and fabricated a base roll for
the printing roll and conducted basic performance
test and evaluation of the laser scanner patterning
system. The study of the printing roll laser process
included the experiment by varying the laser
output, patterning speed, and focal distance as
shown in Fig. 5. The purpose was to find the
optimal process variables through the observation
of the correlation between the process variables and
line widths. We also conducted a laser patterning
test according to the rotation speed and roll
position to determine the precision of the laser
patterning system for processing the printing roll.
Table 2 shows the experimental conditions
according to laser output and patterning speed. We
created 16 identical patterns, positioned them at 5
mm interval along the roll axis direction, and
conducted the patterning test in the circumferential
direction under 12 laser outputs and 12 speeds. Fig.
6 shows the pattern forms at different output and
speed conditions.

Fig. 5. Experimental conditions for 3-dimensional
laser scanner engraving by power, speed, and
position
Table 2. Experimental conditions
(a)
(b)
Fig. 6. Patterns for manufacturing the printing roll;
(a) for power condition (b) for speed condition
III. TEST RESULT
The basic test varied the laser output,
patterning speed, and focal length and repeated the
condition of laser output of 0.3 W, patterning speed
of 1m/sec, and focal length 79.050 mm to produce
the minimum line width. Instead of the
conventional polymer photo-curable method using
UV laser, we used the black polymer coating
method since it has no development process. The
process involved spraying black polymer on the
surface of the steel roll with copper coating and
emitting laser in the specified pattern to remove the
black polymer. After the laser patterning process,
the final printing roll was manufactured through the
etching and chrome coating processes.
Fig. 7 shows the measurement of the line
widths of the 10 x 10 mm pattern using 2D
microscope after passing the black polymer-coated
roll through laser patterning, etching, and chrome
coating processes. Fig. 8 presents the measurement
of line widths and depth using 3D microscope. The
minimum line widths were 24.6 ㎛ and 23.7 ㎛ for
the horizontal line and vertical line, respectively,
and the depth was 9.55 ㎛.

Fig. 7. Measurements of line width after laser
patterning, etching, and chrome coating
Fig. 8. Measurements of line width and depth after
chrome coating (horizontal line: 24.6 ㎛, vertical
line: 23.7 ㎛, depth: 9.55 ㎛)
Fig. 9 presents the observation result of
line width change according to laser output. The
test condition included patterning speed of 1 m/sec
and focal distance of 79.050 mm under laser
outputs of 0.3, 0.6, 1.0, and 1.4 W. Both horizontal
and vertical lines were found to have changed
inversely as the output increased.
(a)
(b)
Fig. 9. Measurements of line width by laser power;
(a) microscope image (b) graph by power
Fig. 10 shows the observation result of
line width change according to laser output. The
test condition included laser output of 0.3 W and
focal distance of 79.050 mm under patterning
speeds of l30, 200, 600, and 1,000 mm/sec. Both
horizontal and vertical lines were found to have
changed proportionally as the speed increased.
(a)

(b)
Fig. 10. Measurements of line width by patterning
speed; (a) microscope image (b) graph by speed
Fig. 11 shows a magnified picture of the
10 x 10 mm pattern shape produced from the roll
with black polymer coating using the 3D laser
scanner.
Fig. 11. 10 x 10 mm pattern on the manufactured
printing roll using the 3-dimensional scanner
system (laser power: 0.3 W, speed: 1m/sec, focal
length: 79.050 mm)
IV. CONCLUSION
This study investigated the process of
manufacturing the printing roll using a 100W-grade
fiber laser with wavelength band of 1070 nm. The
test adopted the indirect laser patterning that used
black polymer coating.
The test result according to laser output
and patterning speed showed that the line width of
the pattern changed proportionally when only the
laser output increased and changed inversely when
only the patterning speed increased, with all other
conditions remaining the same. The precision
electronic printing rolls currently require line
widths of 20 ~ 30 ㎛ and depth of about 10 ㎛. The
test result of this study showed minimum line
width of 23.7 ㎛ and pattern depth of 9.55 ㎛(Fig.
8). The optimal condition for the laser patterning of
the printing roll was laser output of 0.3 W and
patterning speed of 1 m/sec. A laser patterning test
using a laser scanner with 10 x 10 mm working
area was conducted, with precise square patterns
and circular patterns fabricated.
We intend to improve system performance
and increase precision by analyzing the result of
the investigation of process and system obtained
through this study. Furthermore, we will continue
the development of the control software with focus
on increasing productivity.
REFERENCES
[1] B.O. Choi, D.S. Kim, T.M. Lee, C.H. Kim, M.H. Lee
and G.J. Lim, Study on the roll printing process for fine
line-width printing, The Korea Society of Mechanical
Engineering, Fall Conference Lecture and Journal,
2005, 2377-2381.
[2] JeongSeo, Laser plate marking of R2R printing roll for
printed electronic device, Optical Society of Korea,
Optics and Technology, 13(4), 2009, 25-31.
[3] H.G. Sohn and JeongSeo, Direct/indirect laser
patterning of printing roll for printed electronics, Korea
Society for Precision Engineering, Journal of 2008
Spring Conference, 2008, 399-400.
[4] S.R. Goh, Gravure printing roll processing technology,
The Korea Society of Mechanical Engineering, Journal
of KSME, 49(8), 2009, 37-40.
[5] S. J. Seok, Laser micro-patterning software
development for manufacturing of pattern roll for
printed electronics,2013 IEEE 22nd International
Symposium on Industrial Electronics, ISIE 2013, Article
number 6563740, 2013.
[6] J. Loffler, Laser scribing and printing processes for
thin-film PV devices, 37th IEEE Photovoltaic
Specialists Conference, PVSC 2011, Article number
6186689, 2011, 003451-003454.

Printing Roll Manufacturing using Laser Scanner

More Related Content

What's hot (19)

Similar to Printing Roll Manufacturing using Laser Scanner (20)

More from International Journal of Modern Research in Engineering and Technology (20)

Recently uploaded (20)

Printing Roll Manufacturing using Laser Scanner