2012 10-15-sirris µprinting-day-zoellmer
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© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Mikro Printing Day at Sirris, 15th October 2012
Volker Zöllmer(1), Edit Pál(2,3), Marcus Maiwald(1), Cindy Behrens(1), Christian Werner(1), Dirk Godlinski(1), Ingo Wirth(1), Matthias Busse(1,2)
(1) Fraunhofer IFAM, Funktionsstrukturen, Bremen, Germany
(2) University of Bremen, Faculty of Production Engineering, Near Net Shape Technology, Bremen, Germany
Functional materials for printed sensor structures
© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Functional materials for printed sensor structures
1. Introduction Fraunhofer-Society and Fraunhofer IFAM
2. Motivation: Functional printing at Fraunhofer IFAM
3. Processes and materials
4. Examples: thermocouples, strain gauges, gas sensors, bio printing
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
1. IntroductionFraunhofer-Institute for Manufacturing Technology and Advanced Materials - IFAM
Departments Shaping and Functional
Materials Adhesive Bonding Technology
and Surfaces
Locations in Bremen and Dresden
Project groups in Oldenburg and Stade
535 Employees
Overall budget in 2011: 40 Mio. €
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Photovoltaic
Displays
Lighting (LED & OLED)
Electronics (RFIDs, Storage, Battery…)
Integrated Smart Systems (Sensors, Textiles,…)
(© OE-A Roadmap for Organic and Printed Electronics, 4th Ed. 2011)
2. Printed Sensor StructuresTechnology platform at Fraunhofer IFAM
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Motivation:
Functionalization of surfaces, parts and components by use of additive manufacturing
Technologies:
Screen printing
Dispensing / ventile printing
Ink-Jet-Printing (Continuous, Drop-On-Demand)
Aerosol JetⓇ
Benefit:
Direct application of miniaturized structures
„Customized“ structures for electronics, sensors, medical applications etc.
2. Printed Sensor StructuresTechnology platform at Fraunhofer IFAM
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Material screening: metals, alloys, polymers, ceramics, bio-materials, …
Ink / paste formulation
Design & Layout
Printing processes: InkJet, Aerosol Jet, Screen printing, dispensing …
Thermal activation: UV, Laser, Oven, …
Characterization: Mechanical, optical, electrical, …
2. Printed Sensor StructuresTechnology platform at Fraunhofer IFAM
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
■ Maskless, non-contact, digital, additive
■ Min. structures of ca. 25 μm
■ Printheads with 16 to 128 nozzles
3. Printed Sensor Structures InkJet printing
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
1. Functional ink is placed in the atomiser, gas flow creates an aerosol 2. Aerosol droplets ca.1-5μm, larger droplets return to ink (gravity effect)3. The aerosol is carried to the deposition head, excess gas removed4. The aerosol is focussed inside the nozzle by a secondary gas flow (sheath gas)
(© Neotechservices)
1
2
3 4
3. Printed Sensor StructuresAerosol Jet®
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Flexible module for customized functionalization
3. Printed Sensor Structures3-d-printing
Printing on 3-d-components
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Flexible module for customized functionalization
3. Printed Sensor Structures3-d-printing
Printing on 3-d-components
Foot pedal of a bicycle functionalized with aerosol printed strain gauges
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
IFAM development of printable inks:
Ag, Au, Pt, Cu, alloys (e.g. CuNiMn, NiCr, …)
Isolators: Ceramics (TiO2, SiO2, …), Polymers
Dielectric Materials
Biological materials: Enzymes, Proteins, DNA, Bio-ceramics…
3. Printed Sensor Structures3-d-printing
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Interactions between (nano-) particles and ink solvents(© www.sciencedirect.com)
3. Printed Sensor StructuresMaterials development
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Ink optimization:
Investigation of sedimentation stabilities
Surface tensions characterization
Contact angle characterization
Viscosity characterization
Particle surface modification
Particle size distributions
Particle morphology (SEM,TEM,...)
Material/phase analysis (EDX, XRD, ...)
Surface characterization (BET, XPS, ...)
3. Printed Sensor Structures3-d-printing
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
CuNiMn is an appropriate material for printed strain gauges
Cu0.55Ni0.44Mn0.01 (constantan)
low temperature coefficienct of resistance (TCR)
mechanical properties
Ag CuNiMn
TCR: 3.8 x 10-3 K-1 TCR: 0.01 x 10-3 K-1
Commercially available fromdifferent suppliers
not commercially available
3. Printed Sensor StructuresMaterials development
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Different physical and chemical approaches:
VERL (Vacuum Evaporation on Running Liquids)
Peparation of Cu55Ni45Mn1 – alloy inks
3. Printed Sensor StructuresMaterials development
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Sintering
Remove organic content
Enhance electrical conductivity
Optimize mechanical properties
Oven sintering under H2, N2, Argon, … (up to 1700 °C) Substrate limitations, relatively long processing time)
Laser Sintering
Microwave Sintering
UV Curing
Sintering under pressure
Electrical sintering
100 nm
3. Printed Sensor StructuresSintering technology
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Electrical conductivity of CuNi structures:
Dr. Edit Pál, et al. ISIS Scientific Centre, University of Bremen
TEM: CuNiChemical process
TEM: CuNiPhysical process
3. Printed Sensor StructuresDevelopment of printable alloy inks
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Strain gauge printed on steel substrate
Wheatstone full bridge
Resistance Rx = additional resistance for bridge balancing
Measuring setup parameters:
Room temperature continuous strain (1000 N tensile
stress, 500 N compressive stress testing frequency 25 Hz 105 cycles
5 mm5 mm
4. Printed Sensor StructuresPrinted strain gauges for SHM - applications
AlR
llk
RR
R
F
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
CuNiMn - strain gauges printed on ceramic substrates
4. Printed Sensor StructuresPrinted strain gauges for SHM - applications
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Dynamic test (tensile stress: 1000 N, compressive stress: 500 N, 25 Hz, 7675 cycles)
Reproducible signals of Ag-strain gauges
No significant influence of porous structure
4. Printed Sensor StructuresPrinted strain gauges for SHM - applications
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Thermocouple: Seebeck Effect
TNU materialmaterial )( 21
4. Printed Sensor StructuresPrinted thermocouples for SHM - applications
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Printed thermocouple and heating structure
Heating structure
TNU materialmaterial )( 21
U
DT
4. Printed Sensor StructuresPrinted thermocouples for SHM - applications
Thermocouple
linear increase of thermocouple voltage in dependance of temperature difference between hot and cold junctions
Seebeck coefficient of printed thermocouple comparable with Seebeck coefficient of bulk material
printed thermocouple allows direct temperature measurements on surfaces and components
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Thermocouple
linear increase of thermocouple voltage in dependance of temperature difference between hot and cold junctions
Seebeck coefficient of printed thermocouple comparable with Seebeck coefficient of bulk material
printed thermocouple allows direct temperature measurements on surfaces and components
4. Printed Sensor StructuresPrinted thermocouples for SHM - applications
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
4. Printed Sensor StructuresSensor structures for gas detection
Deposition of functionalized interdigital structures
Digital structures of noble metals
Customized functionalization to enhance sensitivity and selectivity
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
4. Printed Sensor StructuresSensor structures for gas detection
Deposition of functionalized interdigital structures
Use of e.g. metal oxides as gas sensitive functionalization
High specific surface
SnO2, ZnO, WO3
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
BSA - FITC
BSA - Rhodamin
BSA - Alexa Fluor 350
Printing of fluorescence marked BSA-Proteine materials
4. Printed Sensor StructuresSensor structures for gas detection
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Functionalization of interdigital structures
High specific surface, high sensitivity
E.g.: Functionalization with enzymes
4. Printed Sensor StructuresSensor structures for gas detection
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Printing of bio ceramics for cell growth management
Day 7
Day 1
4. Printed Bio CeramicsCell growth management
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Printing of bio ceramics for cell growth management
4. Printed Bio CeramicsCell growth management
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Functional materials for printed sensor structures- Summary
Functional printing as a flexible technology platform for sensor deposition and integration.
Printing processes, functional inks and thermal post treatment have to be considered
Printing technologies are feasible for e.g.
Strain sensor structures and thermocouples
Gas sensor structures and deposition of gas sensitive materials
Integration of sensor structures in composites
Printing of bio materials possible
© Fraunhofer© Fraunhofer IFAMContact: Dr. Volker Zöllmer, Tel.: +49 421-2246-114volker.zoellmer@ifam.fraunhofer.de
Volker Zöllmer(1), Edit Pál(2,3), Marcus Maiwald(1), Cindy Behrens(1), Christian Werner(1), Dirk Godlinski(1), Ingo Wirth(1), Matthias Busse(1,2)
(1) Fraunhofer IFAM, Funktionsstrukturen, Bremen, Germany
(2) University of Bremen, Faculty of Production Engineering, Near Net Shape Technology, Bremen, Germany
Thank you for your attention!
Functional materials for printed sensor structures- Acknowledgments
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