Challenges within Functional Printing Flaws’ Detection

What is functional printing?

Digital Printing Application Landscape

Digital Printing Application Landscape

Functional printing in many fields

Add functionalities but not at any cost

• Add functional properties without additional processing steps

• Keep the scrap as low as possible

o production fast start-up

o minimal processing variations

o production repetitiveness

• Keep the yield as high as possible

o production speed; web width

o fast job change (customization)

o no breach of the processing/production flow

It is essential to control, measure and monitor all process parameters in line at each production steps

Continuous monitoring of manufacturing process

• Type of controls:

o registration control at each processing step

o surface quality/aspect control

o geometrical position control of

printed patterns

o printing control

o screen control

o ………

Retrieve defects which degrade the functionality

CASE STUDY : Printed circuits

• 2D analysis of print quality

o very high resolution for surface, patterning and ink transfer defect detection

o precise measurements for registration and alignment control

o automatic classification to distinguish functional from

cosmetic defects

Cosmetic defects

Functional defects

Software inspection tool

• At each production step the relative position of the new layer to the previous ones must be controlled.

• Software tool colors the views in order to overlap images of different steps

Layer 1 before and after colourmanipulation

Layer 2 before and after colour manipulation

Layer 2 overlapped has a layer. The swipe is set to have only one part of the image overlapped. Transparency allows to keep seeing layer 1.

CASE STUDY : OPV

• Double sides printing and see-through effect

• Metallic ink printing and rolling bar effect

CASE STUDY : Ultra security printings

CASE STUDY : Anti-counterfeiting printing

• Genius product has patterns perfectly aliened on the edges.

• All processes steps must ensure a patterns alignment accuracy to within a tenth of a millimeter.

CASE STUDY : Varnish thin protective layer

• Post-print varnish is a thin invisible protective layer on both sides of the banknote applied as last step in the printing process.

• The varnish protects the printing from tear and wear and it protects the security features.

Technical solution

Camera based inspection

• High-resolution image processing systems, line-scan camera based

• Killer defects detection :

o coating, laminating defects

o structuring/laser scribing defects

o base material defects

o environmental contamination / inclusions and foreign particles

• Features’ geometrical and dimensional control

• Multi spectral control

Multi spectral analysis

Red Green Blue

IR 960 nm UV 255, 360, 395 nm

Benefits

• Minimize number of defects to improve lifetime and efficiency

• High accuracy inspection, measurement and analysis enable

process characterisation and validation

• Quality management in multi-step processes identification of

the origin of the defects

• Full traceability along the entire production

• A French Company, a Global presence

• More than 20 years of expertise in its core specialties

• More than 2000 inspection systems installed worldwide

• Headquarters in Lyon, France

IN-CORE Systèmes

Thank you for your attention!

IN-CORE Systèmes10 rue Ampère69680 CHASSIEU FRANCE

www.incore-systemes.com

Dr Michel PopovicGeneral Managermpo@incore-systemes.com