Finite element analysis (FEA) was conducted to investigate the cutting process of a single-layer PET film during rotary die cutting. In a roll-to-roll system, cutting blades formed on rollers were modeled as rigid bodies, while the PET film was modeled as an elastoplastic material using a two-dimensional approach. Stress-strain behavior of the film was measured through experimental tensile testing and used as input data for FEA. Force-displacement data from vertical cutting experiments of PET film were collected to validate the FE model and compared with simulation results. Stress distribution of the film and cutting force per unit thickness during the rotary cutting process were analyzed. The cutting force and range of effective cutting angles were proportional to tip angle of the blade within a range of 25 to 60 degrees, showing a noticeable change in proportionality slope at a tip angle of 40 degrees. As the film tension increased, the cutting force in thickness direction decreased, while that in longitudinal direction remained almost constant. Errors in film feed velocity significantly affected the cutting force. When the film moved slightly slower than the reference velocity, the cutting force was minimized due to reduced contact between the film and blade surface.
Printed electronics is a manufacturing technology that fabricates electronic devices using printing techniques. Due to its characteristics of low cost and simple process, a roll-to-roll printing technique has been used to achieve the large area and mass production of flexible electronic devices such as a thin film transistor. In the roll-to-roll printing process, a fidelity of the engraved pattern position is one of the most important techniques to fabricate high resolution multi-layer electronic devices. In this study, an engraved register mark position measurement system was developed to numerically evaluate the position accuracy of engraved mark in printing roll. The proposed system is based on a high-precision encoder based position control system and a high-resolution machine vision system. The measurement error of the developed system is within the camera resolution ±2.1 μm, verifying the superiority of the system. Using the developed system, we measured the position errors of the engraved register marks for six industrial scale printing rolls. This study suggests that the position error of the engraved mark should be considered to achieve a high precision register control below ±10 μm and necessity of the developed system.
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Tailoring threshold voltage of R2R printed SWCNT thin film transistors for realizing 4 bit ALU Sajjan Parajuli, Younsu Jung, Sagar Shrestha, Jinhwa Park, Chanyeop Ahn, Kiran Shrestha, Bijendra Bishow Maskey, Tae-Yeon Cho, Ji-Ho Eom, Changwoo Lee, Jeong-Taek Kong, Byung-Sung Kim, Taik-Min Lee, SoYoung Kim, Gyoujin Cho npj Flexible Electronics.2024;[Epub] CrossRef
Industrial Roll-to-Roll Printing Register Control Using a Pulse-Width Subdivision Detection Algorithm Bangchao Liu, Youping Chen, Jingming Xie, Bing Chen Applied Sciences.2023; 13(9): 5307. CrossRef
Recently, there has been increasing demand for flexible electronic applications such as flexible displays, foldable smartphones, and flexible batteries based on flexible substrates. The roll-to-roll additive process has attracted tremendous attention regarding manufacturing such flexible electric devices because of its characteristics of eco-friendliness, large area of compatibility, and high flexibility, in contrast to traditional lithography or vaper evaporation methods. The mass production of roll-to-roll process tension control in precision is the most crucial assignment to be achieved. For the tension control, the load cell and dancer systems are used to regulate tension disturbance. A pendulum dancer system was extensively applied for unwinder or rewinder whose span length varied in the roll-to-roll printing and coating process. However, there have been an inadequate number of studies regarding tension control using the dancer system for mass production. In this paper, we propose a mathematical model of center pivot rotary dancer system revolving dual idle rolls around the pivot. Parametric studies are conducted as a function of inertia, span length, width of substrate, and operation velocity. Additionally, an impulse response was conducted for the time domain analysis. These results can be used for the mass production of roll-to-roll additive process.
The purpose of this review paper is to highlight recent efforts and achievements to realize high productivity of micro/nano structure fabrication processes and feasible applications. Due to development in micro/nano fabrication processes, demands on micro/nano related applications are increasing rapidly in various fields. To meet requirements, fabrication process must have high production yield and be automated. Also, fabricated micro/nano structures are expressed on large area substrate. So, it is timely and appropriate to move forward to a new epoch by researching more robust and high throughput fabrication methods, large area fabrication techniques, and new applications. In this review paper, we present a series of recent achievements to overcome some of the limitations in productivity and product size of current fabrication processes, such as photolithography and imprinting lithography. For potential applications, transparent metal electrode, large size optical film, bus wire for narrow bezel, and water collecting surface, are briefly described to expand the application field from the well-known.
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Design of Transparent Conductive Oxides with Metal Patterning Techniques Hyeji Kim, Junghyun Lee, Younggwang Lee, Minwoo Hong, Dohyun Kim, Inpyo Lee, Chanhyuk Choi, Joondong Kim Journal of the Korean Solar Energy Society.2024; 44(5): 33. CrossRef
Fabrication of Nanopatterned Metal Mold based on Zirconia Nanoparticle and its Application into Thermal Replication of Thermoplastic Materials Selim Park, Kyoung Chan Min, Sowon Jang, Yujin Ha, Wook-Bae Kim Journal of the Korean Society for Precision Engineering.2022; 39(7): 501. CrossRef
Variation of a Triangular Pattern Shape due to Shrinkage in the Repeated UV Imprint Process Jiyun Jeong, Su Hyun Choi, Young Tae Cho Journal of the Korean Society of Manufacturing Process Engineers.2020; 19(7): 67. CrossRef
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Recent manufacturing methods for fabricating flexible devices have attracted a keen interest, with a strong demand by industrial manufactures. For thin film application on flexible devices, slot-die coating was found to be the most suitable method having excellent uniformity. Optimization of the reservoir of slot-die coater should be prioritized, since it is an important parameter affecting the uniformity of the final outcome of the coated layer. However, the numerous designs of reservoir makes prototyping difficult, and also results in high manufacturing cost. This study analyzed the velocity deviation of the slot-die coater outlet using CFD analysis, and shape optimization was performed by contour map. We introduce a facile and low-cost fabrication method for a slot-die coater, using polydimethylsiloxane materials and three-dimensional printing technique. The fabricated polymer slot-die coater was further evaluated by the leakage test of solution.
This study proposes a method for identifying correlations between tension and drop height for sessile droplets in a roll-toroll processing system. The effect of tension and drop height on the contact angle of a sessile droplet is presented. Design of experiment (DOE) methodology and statistical analysis are used to define a correlation between the process parameters. The contact angle is decreased while increasing tension and drop height. The influence of the tension is less significant on the contact angle compared with the effect of the drop height. However, tension should be considered as a major parameter because it is not easy to fix with roll eccentricity and compensating speed of the driven roll. The results of this study show that the effect of tension on the contact angle of a sessile droplet is more important than drop height because the drop height is fixed when the process systems are determined.
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Temperature Uniformity Control of 12-Inch Semiconductor Wafer Chuck Using Double-Wall TPMS in Additive Manufacturing Sohyun Park, Jaewook Lee, Seungyeop Lee, Jihyun Sung, Hyungug Jung, Ho Lee, Kunwoo Kim Materials.2025; 18(1): 211. CrossRef
Periodicity of Droplet Impact Behavior by Liquid Viscosity on PDMS Surface Dong Kwan Kang, Sangmin Lee Journal of the Korean Society for Precision Engineering.2022; 39(11): 857. CrossRef
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