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Comparative reliability of inkjet-printed electronics packaging

Comparative reliability of inkjet-printed electronics packaging

Tilford, Tim ORCID: 0000-0001-8307-6403, Stoyanov, Stoyan ORCID: 0000-0001-6091-1226, Braun, Jessica, Janhsen, Jan Christoph, Patel, Mayur K. and Bailey, Chris ORCID: 0000-0002-9438-3879 (2021) Comparative reliability of inkjet-printed electronics packaging. IEEE Transactions on Components, Packaging and Manufacturing Technology, 11 (2). pp. 351-362. ISSN 2156-3950 (Print), 2156-3985 (Online) (doi:

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This article compares the thermomechanical behavior of 3-D inkjet-printed microelectronics devices relative to those fabricated from traditional methods. It discusses the benefits and challenges in the adoption of additive manufacturing methods for microelectronics manufacture relative to conventional approaches. The critical issues related to the design and reliability of additively manufactured parts and systems stem from the change in the manufacturing process and the change in materials utilized. This study uses numerical modeling techniques to gain insight into these issues. This article is an extension of the same topic presented at the 2018 IEEE Electronics Packaging Technology Conference. An introduction providing an overview of the area, covering salient academic research activities and discussing progress toward commercialization is presented. The state-of-the-art modular microelectronics fabrication system developed within the EU NextFactory project is introduced. This system has been used to manufacture several test samples, which were assessed both experimentally and numerically. A full series of JEDEC tests showed that the samples were reliable, successfully passing all tests. The numerical model assessing the mechanical behavior of an inkjet-printed structure during layer-by-layer fabrication is presented. This analysis predicts that the stresses induced by the UV cure process are concentrated toward the extremities of the part and, in particular, in the lower layers which are constrained by the print platform. Subsequently, a model of a multilayer microelectronics structure undergoing JEDEC thermal cycling is presented. The model assesses the differences in mechanical properties between a conventional FR4/copper structure and an inkjet-printed acrylic/silver structure. The model identified that the influence of the sintering process on subsequent material properties, behavior of the inject-printed structure, and reliability of the inject-printed structure is significant. Key findings are that while stresses in the conventional and inkjet boards are relatively similar, the inkjet-printed board exhibits significantly greater deformation than the standard board. Furthermore, the mechanical stresses in the inkjet fabricated board are strongly dependent on the elastic modulus of the sintered silver material, which, in turn, is dependent on the sintering process.

Item Type: Article
Uncontrolled Keywords: additive manufacturing, inkjet printing, microelectronics fabrication, reliability, numerical analysis
Subjects: Q Science > QA Mathematics > QA75 Electronic computers. Computer science
Faculty / School / Research Centre / Research Group: Faculty of Engineering & Science
Faculty of Engineering & Science > Centre for Numerical Modelling & Process Analysis (CNMPA)
Faculty of Engineering & Science > Centre for Numerical Modelling & Process Analysis (CNMPA) > Computational Mechanics & Reliability Group (CMRG)
Faculty of Engineering & Science > School of Computing & Mathematical Sciences (CMS)
Last Modified: 10 Mar 2022 09:31

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