Reduction of droplet volume by controlling actuating waveforms in inkjet printing for micro-pattern formation

Inkjet printing has proven to be a promising and flexible process methodology for low cost and drop-on-demand pattern formation in small-scale production of micro-electro-mechanical systems. To optimize the micro-patterns formed by inkjet printing, an accurate control of droplet volume is essential and critical. In this study, an inkjet system with a nozzle driven by a circular piezoelectric element was used to explore the impact of different waveforms on droplet volume. The investigation into this study included the impact of unipolar, bipolar, M-shaped and W-shaped waveforms as well as the effects of their amplitudes and pulse durations. The inkjetting behavior of Newtonian and non-Newtonian fluids under different actuating waveforms was studied in order to obtain a maximum reduction in ejected droplet sizes. An effective reduction of droplet volume in the range of 50–80% was demonstrated. The results of inkjetting PEDOT ink on a polished silicon surface showed that a 50% reduction in line width was achieved.