Hybrid machine learning method to determine the optimal operating process window in aerosol jet 3D printing

Aerosol jet printing (AJP) is a three-dimensional (3D) noncontact and direct printing technology for fabricating customized microelectronic devices on flexible substrates. Despite the capability of fine feature deposition, the complicated relationship between the main process parameters will affect...

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Main Authors: Zhang, Haining, Moon, Seung Ki, Ngo, Teck Hui
Other Authors: School of Mechanical and Aerospace Engineering
Format: Article
Language:English
Published: 2021
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Online Access:https://hdl.handle.net/10356/148676
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Institution: Nanyang Technological University
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spelling sg-ntu-dr.10356-1486762021-05-04T07:07:53Z Hybrid machine learning method to determine the optimal operating process window in aerosol jet 3D printing Zhang, Haining Moon, Seung Ki Ngo, Teck Hui School of Mechanical and Aerospace Engineering Engineering::Mechanical engineering Aerosol Jet Printing Direct Writing Aerosol jet printing (AJP) is a three-dimensional (3D) noncontact and direct printing technology for fabricating customized microelectronic devices on flexible substrates. Despite the capability of fine feature deposition, the complicated relationship between the main process parameters will affect the printing quality significantly in a design space. In this paper, a novel hybrid machine learning method is proposed to determine the optimal operating process window for the AJP process in various design spaces. The proposed method consists of classic machine learning methods, including experimental sampling, data clustering, classification, and knowledge transfer. In the proposed method, a two-dimensional design space is fully explored by a Latin hypercube sampling experimental design at a certain print speed. Then, the influence of the sheath gas flow rate (SHGFR) and the carrier gas flow rate (CGFR) on the printed line quality is analyzed by a K-means clustering approach, and an optimal operating process window is determined by a support vector machine. To efficiently identify more operating process windows at different print speeds, a transfer learning approach is applied to exploit relatedness between different operating process windows. Hence, at a new print speed, the number of line samples for identifying a new operating process window is greatly reduced. Finally, to balance the complex relationship among SHGFR, CGFR, and print speed, a 3D operating process window is determined by an incremental classification approach. Different from experiment-based approaches adopted in 3D printing technologies for quality optimization, the proposed method is developed based on the theory of knowledge discovery and data mining. Therefore, the knowledge in different design spaces can be fully explored and transferred for printed line quality optimization. Moreover, the data-driven-based characteristics can help the proposed method develop a guideline for quality optimization in other 3D printing technologies. Nanyang Technological University National Research Foundation (NRF) Accepted version This research work was conducted in the SMRT-NTU Smart Urban Rail Corporate Laboratory with funding support from the National Research Foundation (NRF), SMRT, and Nanyang Technological University under the Corp Lab@ University Scheme. 2021-05-04T07:07:53Z 2021-05-04T07:07:53Z 2019 Journal Article Zhang, H., Moon, S. K. & Ngo, T. H. (2019). Hybrid machine learning method to determine the optimal operating process window in aerosol jet 3D printing. ACS Applied Materials & Interfaces, 11(19), 17994-18003. https://dx.doi.org/10.1021/acsami.9b02898 1944-8244 0000-0003-2132-8091 0000-0002-2249-7500 https://hdl.handle.net/10356/148676 10.1021/acsami.9b02898 31012300 2-s2.0-85065755987 19 11 17994 18003 en ACS Applied Materials & Interfaces This document is the Accepted Manuscript version of a Published Work that appeared in final form in ACS Applied Materials & Interfaces, copyright © American Chemical Society after peer review and technical editing by the publisher. To access the final edited and published work see https://doi.org/10.1021/acsami.9b02898. application/pdf
institution Nanyang Technological University
building NTU Library
continent Asia
country Singapore
Singapore
content_provider NTU Library
collection DR-NTU
language English
topic Engineering::Mechanical engineering
Aerosol Jet Printing
Direct Writing
spellingShingle Engineering::Mechanical engineering
Aerosol Jet Printing
Direct Writing
Zhang, Haining
Moon, Seung Ki
Ngo, Teck Hui
Hybrid machine learning method to determine the optimal operating process window in aerosol jet 3D printing
description Aerosol jet printing (AJP) is a three-dimensional (3D) noncontact and direct printing technology for fabricating customized microelectronic devices on flexible substrates. Despite the capability of fine feature deposition, the complicated relationship between the main process parameters will affect the printing quality significantly in a design space. In this paper, a novel hybrid machine learning method is proposed to determine the optimal operating process window for the AJP process in various design spaces. The proposed method consists of classic machine learning methods, including experimental sampling, data clustering, classification, and knowledge transfer. In the proposed method, a two-dimensional design space is fully explored by a Latin hypercube sampling experimental design at a certain print speed. Then, the influence of the sheath gas flow rate (SHGFR) and the carrier gas flow rate (CGFR) on the printed line quality is analyzed by a K-means clustering approach, and an optimal operating process window is determined by a support vector machine. To efficiently identify more operating process windows at different print speeds, a transfer learning approach is applied to exploit relatedness between different operating process windows. Hence, at a new print speed, the number of line samples for identifying a new operating process window is greatly reduced. Finally, to balance the complex relationship among SHGFR, CGFR, and print speed, a 3D operating process window is determined by an incremental classification approach. Different from experiment-based approaches adopted in 3D printing technologies for quality optimization, the proposed method is developed based on the theory of knowledge discovery and data mining. Therefore, the knowledge in different design spaces can be fully explored and transferred for printed line quality optimization. Moreover, the data-driven-based characteristics can help the proposed method develop a guideline for quality optimization in other 3D printing technologies.
author2 School of Mechanical and Aerospace Engineering
author_facet School of Mechanical and Aerospace Engineering
Zhang, Haining
Moon, Seung Ki
Ngo, Teck Hui
format Article
author Zhang, Haining
Moon, Seung Ki
Ngo, Teck Hui
author_sort Zhang, Haining
title Hybrid machine learning method to determine the optimal operating process window in aerosol jet 3D printing
title_short Hybrid machine learning method to determine the optimal operating process window in aerosol jet 3D printing
title_full Hybrid machine learning method to determine the optimal operating process window in aerosol jet 3D printing
title_fullStr Hybrid machine learning method to determine the optimal operating process window in aerosol jet 3D printing
title_full_unstemmed Hybrid machine learning method to determine the optimal operating process window in aerosol jet 3D printing
title_sort hybrid machine learning method to determine the optimal operating process window in aerosol jet 3d printing
publishDate 2021
url https://hdl.handle.net/10356/148676
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