David Savastano, Editor12.16.09
It is increasingly clear that numerous printed electronics (PE) concepts are heading from the initial R&D phase to pilot and full-scale production.
With an eye toward enabling commercial production of printed electronics, Austin, TX-based NovaCentrix® showcased its newest hardware innovation, the PulseForge® 3300 processing tool, at Printed Electronics USA 09 in San Jose, CA.
The PulseForge 3300 tool is the latest in NovaCentrix’ series of processing tools. The PulseForge 1100 tool was conceived as a general purpose R&D tool capable of processing a wide variety of materials, but it was not designed for production use.
The PulseForge 3100 tool, introduced to the market last year, was designed specifically for production-scale processing at power levels optimal for metal-based inks and films.
The new PulseForge 3300 tool is designed to process materials demanding higher energy levels, such as silicon, zinc oxide and ceramics, used for printed logic, display, and photovoltaic applications on low-temperature substrates. The 3300 product is designed for roll-to-roll and conveyor-based materials processing.
The PulseForge 3300 tool generates the very high processing temperatures required for recrystallization and annealing, but without damaging low-temperature underlying materials like polymeric substrates or adjacent organic materials. This is accomplished by using proprietary high-intensity lamps at very short pulse durations.
In addition to its processing tools, NovaCentrix is noted for its Metalon® conductive silver and copper-based inks. The company’s expertise in conductive ink technology played a key role in developing the PulseForge 3100 toolset. Stan Farnsworth, vice president of marketing for NovaCentrix, noted that the experience gained with the 3100 tool was then important in the creation of the 3300 tool.
“NovaCentrix’ initial target market was on metal-based ink developers and users, and this remains our target market for the PulseForge 3100 tools,” said Farnsworth. ”The 3100 tool was a logical first production-capable product for us, combining our expertise in metal inks with our experience developing and using the general purpose PulseForge 1100 R&D processing tool. Based on the materials many of our customers were bringing to us, we knew there was also a need for an additional toolset for processing the higher-temperature materials like silicon. We knew that the engineering and hardware requirements to meet that need would be tremendously difficult to achieve. The 3100 tool was an important stepping stone for our team.”
“The level of hardware engineering needed to achieve the types of energy exposures required for solar and silicon-based ink production, regulating the exposures through imbedded control systems, and reducing that overall system complexity into a simple-to-use operator interface, were important challenges,” Farnsworth said. “The NovaCentrix team has done an exceptional job.”
PulseForge 3300 tool production rates are user controlled to suit the unique exposure profiles different materials. Some material systems may be processed at speeds up to 100-300 meters/minute. “This is much faster than most of our customers require, but we feel it is important for the PulseForge production tool not to be the limiting factor for production. The tools we had operating at the Printed Electronics USA 09 event in San Jose were capable of a combined production rate approaching one million linear feet of low energy material processing in 24 hours,” said Farnsworth. “Additionally, the flexibility of our PulseForge tools helps customers significantly reduce their scale-up risk,” Farnsworth added. “PulseForge tools are suited for small-scale and pilot production, as well as for full-speed production when needed. The same PulseForge tool and process conditions can be used for development as well as full-scale commercial production.”
Customer demand has been strong. Farnsworth noted that the first PulseForge 3300 tool was bought before NovaCentrix even officially launched the tool.
“We already have 3300s in the field,” Farnsworth said. “We shipped our first tool before the official launch, and the customer response has been great. In fact, our customers are important partners for us. We work together to develop the right process conditions to achieve their performance and cost goals.”
NovaCentrix brought a functional PulseForge 3300 system to Printed Electronics USA 09, and having an operational tool allowed customers to see some of its capabilities first hand. “The reaction to the PulseForge tools at Printed Electronics USA 09 was really gratifying,” said Farnsworth. “Operating our equipment in real time at these shows helps NovaCentrix educate the industry and increase customers’ understanding of how our tools can help their company. In fact, a large portion of the time at the event was devoted to running specific samples brought by interested groups.”
Farnsworth sees a bright future for the PE industry and NovaCentrix as the PE space continues to evolve toward broader commercialization.
“It is exciting to play a part in taking new technologies to commercialization,” said Farnsworth. “What we are experiencing, including at the event in San Jose, is a shift in market emphasis from concept to product. Though NovaCentrix regularly meets with companies new to printed electronics, we are increasingly engaged by companies well beyond the concept phase. I can say that a lot of activity is quietly happening behind the scenes inside our customers’ organizations.
“The PE market is moving forward as more companies head toward commercialization,” Farnsworth added. “Eventually, product designers will become more and more confident that PE can add value to their products. Having these kinds of tools available and accessible is important as it allows customers to see a pathway to production.”