Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM
Fraunhofer Institute for Manufacturing Technology and Advanced Materials IFAM

Process stability in industrial printing processes

Optimize printing processes, ensure quality, and reduce production costs

Thermal image of a powder bed in a binder jetting process to verify homogeneity.
© Fraunhofer IFAM
Thermal image of a powder bed in a binder jetting process to verify homogeneity.
Optical trace measurement for quality control and cross-sectional area calculation.
© Fraunhofer IFAM
Optical trace measurement for quality control and cross-sectional area calculation.

Industrial printing processes are an important part of modern manufacturing. Whether used for printed electronics, functional coatings, or additive manufacturing, the quality of the final product depends largely on how stable and reproducible the overall process is.

Variations can arise from a wide range of factors. The consequences can range from quality deviations and rework to scrap and rising production costs. A stable and reproducible process therefore not only helps ensure consistent product quality but can also reduce scrap and rework, lower production costs, and improve manufacturing cost efficiency.

Fraunhofer IFAM helps companies systematically analyze and optimize printing processes and stabilize them for production at scale. To achieve this, we combine process and materials expertise with analytical methods, measurement technology, data analysis, and hands-on training.

 

What makes a manufacturing process stable?

Consistent product quality requires relevant influencing factors to be controlled throughout the entire process chain. These include, for example, print quality, layer thickness, line resolution, adhesion, drying, and material properties.

These factors can interact with one another and affect the quality of the printed result. Systematic process analysis helps identify critical influencing factors and develop appropriate control strategies.

The goal of process stabilization is to achieve reproducible production with greater process reliability, even at high production volumes.

 

Identifying quality variations and determining their causes

When a printing process produces inconsistent results, a variety of underlying causes may be responsible. Potential influencing factors include:

  • Material properties
  • Unsuitable process parameters and unstable process windows
  • Equipment and environmental conditions
  • Inadequate process monitoring
  • Insufficient or inadequate personnel training

At Fraunhofer IFAM, we identify influencing factors and determine optimal process windows to reduce defective parts, increase equipment availability, and significantly improve reproducibility. Companies can benefit from lower production costs and greater process reliability.

 

From analysis to production at scale: services offered by Fraunhofer IFAM

Fraunhofer IFAM supports companies throughout the various stages of process optimization and stabilization, offering services such as:

  • Analysis and evaluation of existing printing processes
  • Identification of root causes of defects and quality deviations
  • Development of stable process windows
  • Implementation of quality management and inspection concepts
  • Implementation of in-line and off-line monitoring
  • Reduction of scrap and rework
  • Optimization of material usage and equipment availability
  • Transfer of developed processes to production at scale
  • Employee training through practical, hands-on seminars

Both individual process steps and the entire process chain can be evaluated.

 

In which printing processes does Fraunhofer IFAM have in-depth expertise?

Fraunhofer IFAM has expertise in a range of printing and manufacturing processes, including:

This expertise makes it possible to address a wide range of requirements for industrial printing and additive manufacturing processes.

Our training program

Seminar »Printed Electronics using Screen Printing Technology«

Certificate Program: “Industrial Specialist in Additive Manufacturing (Design Engineer)”

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  • One approach is to reduce scrap and rework while optimizing material usage and equipment availability. A systematic analysis of the printing process can reveal which factors affect production costs and where there is potential for improvement.

  • The first step is to identify the root causes of defective parts. Potential causes include unstable process windows, unsuitable parameters, material properties, or insufficiently controlled process conditions. Process analysis, inspection methods, and monitoring can help detect quality deviations early and enable corrective action.

  • Quality variations can have several causes. In addition to process parameters, factors such as materials, equipment conditions, the surrounding environment, and process control can play a role. A systematic investigation of the process chain helps identify the relevant influencing factors.

  • Changes in print quality can result from a variety of influencing factors, including material properties, process parameters, layer thickness, adhesion, and drying. Analyzing the relevant process parameters and material properties can help narrow down the cause of the quality deviation.

  • Reproducible production at scale requires relevant process parameters and influencing factors to be understood and controlled. Establishing suitable process windows and implementing inspection and monitoring concepts can help detect quality deviations early and stabilize processes in a targeted manner.

  • Fraunhofer IFAM has expertise in a range of printing and manufacturing processes. These include screen printing, pad printing, inkjet and aerosol jet printing, as well as additive manufacturing methods such as Metal Binder Jetting, Laser Powder Bed Fusion, Selective Laser Sintering, and stereolithography.