Inkjet Metrology II: Resolved Effects of Ejection Frequency, Fluidic Pressure, and Droplet Number on Reproducible Drop-on-Demand Dispensing
Abstract

We report highly reproducible gravimetric and optical measurements of microdroplets that lend insights into the fundamentals of drop-on-demand (DOD) printing. Baseline fluidic pressure within the DOD dispenser was controlled to within 0.02 hPa, enabling long-term stability in dispensed droplet mass with observed variations near 1% (RSD) for isobutanol. The gravimetric measurements were sensitive enough to detect and avoid unwanted effects from air bubbles within the dispenser. The gravimetric and optical velocity measurements enabled consistent determination of droplet kinetic energy that governed baseline behavior across the operational variables. Mass and velocity were influenced in a nonlinear manner by the frequency of droplet ejection, the fluidic pressure within the dispensing device, and the number of droplets dispensed in a burst. Resolved effects were attributable to several possible mechanisms including acoustic resonances, energy partitioning from systematic orifice refill dynamics, pressure wavelets created within the dispenser cavity during “first-drop” formation, and residual ring-down after last-drop emergence.
Introduction
Experimental Section
Droplet Dispense and Characterization System
Figure 1

Figure 1. System for drop-on-demand generation of microdrops and gravimetric/optical characterizations. To move precisely between the balance and camera, the PZT device and fluid reservoir were mounted together on an x–y–z stage and rotating armature (not shown). The pressure control system for the reservoir headspace is shown in Supporting Information (I).
Selection of Operational Dispense Conditions
Orifice
Fluid Rheology
Fluid Contamination
Fluidic Pressure

Driving Waveform

Figure 2

Figure 2. Idealized schematic of acoustic wave propagation in a DOD dispensing device.
Measurements
Droplet Velocity
Gravimetry

dispense duration (s) | |||||
---|---|---|---|---|---|
droplets per trigger | triggers | total number of droplets | 500 Hz | 5556 Hz | 20 kHz |
20 000 | 1 | 20 000 | 40.0 | 3.6 | 1.0 |
10 000 | 2 | 20 000 | 40.4 | 4.0 | 1.4 |
5000 | 4 | 20 000 | 41.2 | 4.8 | 2.2 |
1000 | 10 | 10 000 | 23.6 | 5.4 | 4.1 |
500 | 20 | 10 000 | 27.6 | 9.4 | 8.1 |
100 | 50 | 5000 | 29.6 | 20.5 | 19.9 |
50 | 100 | 5000 | 49.6 | 40.5 | 39.9 |
30 | 200 | 6000 | 91.6 | 80.7 | 79.9 |
25 | 200 | 5000 | 89.6 | 80.5 | 79.9 |
20 | 300 | 6000 | 131.6 | 120.7 | 119.9 |
16 | 500 | 8000 | 215.6 | 201.0 | 200.0 |
13 | 500 | 6500 | 212.6 | 200.8 | 199.9 |
10 | 500 | 5000 | 209.6 | 200.5 | 199.9 |
8 | 1000 | 8000 | 415.6 | 401.0 | 400.0 |
6 | 1000 | 6000 | 411.6 | 400.7 | 399.9 |
4 | 1500 | 6000 | 611.6 | 600.7 | 599.9 |
3 | 2000 | 6000 | 811.6 | 800.7 | 799.9 |
2 | 2000 | 4000 | 807.6 | 800.3 | 799.8 |
1 | 2000 | 2000 | 803.6 | 800.0 | 799.7 |
Droplet Mass and Velocity versus Ejection Frequency
Droplet Mass and Velocity versus Fluidic Pressure
Average and Differential Droplet Mass versus Burst Size
Results and Discussion
Dynamics of Droplet Formation
Droplet Characteristics versus Ejection Frequency
Figure 3

Figure 3. Characteristics of IBA microdrops across ejection cycle periods from 42 μs to 400 ms (ejection frequencies from 24 kHz to 2.5 Hz, top scale) using a single driving waveform and constant fluidic pressure. Droplet formation characteristics demarcate three regions: resonant (24 kHz to 3 kHz); transitional (3 kHz to 500 Hz); and quiescent (<500 Hz). Short-term analytical imprecision (standard deviation) is within the size of the markers. Long-term reducibility for each characteristic was measured at selected ejection periods noted by multiple crosses on the mass plot. See text for further description.
The Resonant Region
The Transitional Region
The Quiescent Region
Droplet Characteristics versus Fluidic Pressure
Figure 4

Figure 4. Sensitivity of IBA droplet mass, velocity, and kinetic energy to fluidic pressure at four ejection frequencies. Uncertainties are within the sizes of the data markers.
Droplet Characteristics versus Burst Size
Figure 5

Figure 5. Profiles of average and differential droplet mass ejected at 5556 and 500 Hz as a function of burst size. Fluid was isobutanol ejected from a PZT device using a single waveform and a constant fluid pressure. Error bars are expanded uncertainties about the means of replicated measurements.
Figure 6

Figure 6. Images of IBA droplets ejected at 5556 Hz. Images a–e depict a four-droplet burst sequence, with each image separated in virtual time by 180 μs, the ejection cycle period. Lines were added to identify a particular droplet across the sequence. Because 5556 Hz is an antiresonance frequency, the first droplet traveled at a greater velocity than the following droplets, which eventually reached a minimum steady-state velocity as depicted by the continuous ejection image at right. This steady-state condition required continuous ejection of at least 100 droplets as measured by mass; see Figure 5.
Figure 7

Figure 7. Profiles of average and differential droplet mass ejected at 20 kHz as a function of burst size. Fluid was isobutanol ejected from a PZT device using a single waveform and a constant fluid pressure. Error bars are expanded uncertainties about the means of replicated measurements.
Figure 8

Figure 8. Images of IBA droplets ejected at 20 kHz. Each row of images depicts a 2-droplet, 3-droplet, or 5-droplet burst sequence, with each image separated in time by 50 μs, the ejection period. Lines were added to identify a particular droplet across each sequence. Note that the 2-droplet burst includes a satellite from the last droplet, while the 3-droplet and 5-droplet bursts include a satellite plus superfluous ejecta emerging after the last droplet. Because 20 kHz is a resonance frequency, the first droplet traveled at a slower velocity than did the following droplets, which overtook and coalesced with that droplet. The steady-state condition is depicted by the image at right, which was reached after continuous ejection of about 100 droplets as measured by mass; see Figure 7.
Reproducibility of Droplet Mass and Velocity Measurements
gravimetry | optical analysis | |||||
---|---|---|---|---|---|---|
ejection frequency (Hz) | dispense conditiona | burst size (no. droplets × no. repeats) | average droplet mass (ng) | long-term variation (RSD) | average droplet velocity (m/s) | long-term variation (sd, m/s) |
10 | Q | 5000 × 1 | 49.3 | 1.3% (n = 13) | 2.31 | 0.05 (n = 9) |
300 | Q | 20 000 × 1 | 48.1 | 0.7% (n = 13) | 1.87 | 0.03 (n = 10) |
500 | Q–T | 20 000 × 1 | 48.9 | 1.0% (n = 21) | 1.78 | 0.03 (n = 12) |
2000 | T | 20 000 × 1 | 61.2 | 1.1% (n = 14) | 1.48 | 0.03 (n = 9) |
3226 | R | 20 000 × 1 | 71.4 | 1.2% (n = 13) | 1.65 | 0.02 (n = 9) |
4545 | S | 20 000 × 1 | 73.5 | 1.4% (n = 13) | 1.56 | 0.05 (n = 9) |
5556 | A | 20 000 × 1 | 59.8 | 1.4% (n = 13) | 0.77 | 0.02 (n = 9) |
10 000 | R | 20 000 × 1 | 127.4 | 1.6% (n = 14) | 4.22 | 0.02 (n = 9) |
10 989 | S | 20 000 × 1 | 82.8 | 1.6% (n = 14) | 2.90 | 0.04 (n = 9) |
20 000 | R | 20 000 × 1 | 106.3 | 0.8% (n = 13) | 7.63 | 0.03 (n = 9) |
500 | Q–T | 5 × 1000 | 48.8 | 0.6% (n = 6) | ||
20 000 | R | 5 × 1000 | 95.7 | 0.9% (n = 8) |
Q, quiescent; T, transitional; A, antiresonant; S, slope; R, resonant.
Uncertainty Evaluation
Conclusions
Supporting Information
(I) The reservoir headspace pressure control system; (II) reproducibility of isopropanol printing; (III) validation of eq 1; and (IV) attenuation of droplet velocity by air resistance. This material is available free of charge via the Internet at http://pubs.acs.org.
Terms & Conditions
Most electronic Supporting Information files are available without a subscription to ACS Web Editions. Such files may be downloaded by article for research use (if there is a public use license linked to the relevant article, that license may permit other uses). Permission may be obtained from ACS for other uses through requests via the RightsLink permission system: http://pubs.acs.org/page/copyright/permissions.html.
Acknowledgment
We gratefully acknowledge the Science & Technology Directorate of the U.S. Department of Homeland Security and the NIST Office of Law Enforcement Standards for sponsoring this work. We also wish to acknowledge Dr. Hans Jochen Trost of MicroFab Technologies for valuable discussions during preparation of this manuscript.
References
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Abstract
Figure 1
Figure 1. System for drop-on-demand generation of microdrops and gravimetric/optical characterizations. To move precisely between the balance and camera, the PZT device and fluid reservoir were mounted together on an x–y–z stage and rotating armature (not shown). The pressure control system for the reservoir headspace is shown in Supporting Information (I).
Figure 2
Figure 2. Idealized schematic of acoustic wave propagation in a DOD dispensing device.
Figure 3
Figure 3. Characteristics of IBA microdrops across ejection cycle periods from 42 μs to 400 ms (ejection frequencies from 24 kHz to 2.5 Hz, top scale) using a single driving waveform and constant fluidic pressure. Droplet formation characteristics demarcate three regions: resonant (24 kHz to 3 kHz); transitional (3 kHz to 500 Hz); and quiescent (<500 Hz). Short-term analytical imprecision (standard deviation) is within the size of the markers. Long-term reducibility for each characteristic was measured at selected ejection periods noted by multiple crosses on the mass plot. See text for further description.
Figure 4
Figure 4. Sensitivity of IBA droplet mass, velocity, and kinetic energy to fluidic pressure at four ejection frequencies. Uncertainties are within the sizes of the data markers.
Figure 5
Figure 5. Profiles of average and differential droplet mass ejected at 5556 and 500 Hz as a function of burst size. Fluid was isobutanol ejected from a PZT device using a single waveform and a constant fluid pressure. Error bars are expanded uncertainties about the means of replicated measurements.
Figure 6
Figure 6. Images of IBA droplets ejected at 5556 Hz. Images a–e depict a four-droplet burst sequence, with each image separated in virtual time by 180 μs, the ejection cycle period. Lines were added to identify a particular droplet across the sequence. Because 5556 Hz is an antiresonance frequency, the first droplet traveled at a greater velocity than the following droplets, which eventually reached a minimum steady-state velocity as depicted by the continuous ejection image at right. This steady-state condition required continuous ejection of at least 100 droplets as measured by mass; see Figure 5.
Figure 7
Figure 7. Profiles of average and differential droplet mass ejected at 20 kHz as a function of burst size. Fluid was isobutanol ejected from a PZT device using a single waveform and a constant fluid pressure. Error bars are expanded uncertainties about the means of replicated measurements.
Figure 8
Figure 8. Images of IBA droplets ejected at 20 kHz. Each row of images depicts a 2-droplet, 3-droplet, or 5-droplet burst sequence, with each image separated in time by 50 μs, the ejection period. Lines were added to identify a particular droplet across each sequence. Note that the 2-droplet burst includes a satellite from the last droplet, while the 3-droplet and 5-droplet bursts include a satellite plus superfluous ejecta emerging after the last droplet. Because 20 kHz is a resonance frequency, the first droplet traveled at a slower velocity than did the following droplets, which overtook and coalesced with that droplet. The steady-state condition is depicted by the image at right, which was reached after continuous ejection of about 100 droplets as measured by mass; see Figure 7.
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Supporting Information
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ARTICLE SECTIONS(I) The reservoir headspace pressure control system; (II) reproducibility of isopropanol printing; (III) validation of eq 1; and (IV) attenuation of droplet velocity by air resistance. This material is available free of charge via the Internet at http://pubs.acs.org.
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