Design and development of high precision elastomeric-stamp wrapping system for roll-to-roll multi-layer microcontact printing

Abstract

Microcontact printing is an emerging printing technique that could potentially find application in the electronics industry. High-speed roll-to-roll equipment was built at Nano Terra, Inc in 2008, for microcontact printing. However, the equipment was a proof-of-concept, capable of single-layer printing, while the industry requires a multi-layer printing capability. In addition, the quality of printing it delivered was not industry competitive. The existing equipment has thus been upgraded with a view to achieve high-precision multi-layer microcontact printing; including a new method to manufacture a flat stamp, design of a high-precision wrapping system, design of a five-axis positioning system, and modification of the impression roller. This thesis describes in detail the design of an innovative high-precision system to wrap the elastomeric stamp on the print roller. This is followed by results of multilayer printing experiments, using the improved equipment. The potential for microcontact printing as a forthcoming technology for the electronics industry was confirmed. Further improvements are also suggested that would help deliver this promise.