Repeatability Evaluation of Direct-Write Printing on Flexible and Three-Dimensional Geometries

There are unknowns in available conductive inks as well as direct-write printing setup and printing processes, which make repeatable results difficult. The repeatability plans developed in this effort will identify processes we can use so that we always achieve our expected results. These plans identify: 1) the applications of focus; 2) requirements for the applications; 3) a process to select inks and other items based on those requirements and on what is already known about the inks or process to develop new inks; and 4) verification that requirements are met by printing. Plans were followed to print interconnects, which include an insulating ramp and conductive lines over the insulating ramp. Practice runs were performed and tested successfully. When the print was performed on the actual chip, the conductive lines were broken. Lessons learned were gathered from this print and incorporated into the printing plan. Such lessons lincluded additional alignment checks and added passes of conductive lines to make them more robust. A separate plan was followed to print a detector pattern. Several detector patterns were printed on a variety of substrates, and survived functional testing in the detector chamber.