Lubrication-related residue as a fundamental process scaling limit to gravure printed electronics

In gravure printing, excess ink is removed from a patterned plate or roll by wiping with a doctor blade, leaving a thin lubrication film in the nonpatterned area. Reduction of this lubrication film is critical for gravure printing of electronics, since the resulting residue can lower device performance or even catastrophically impact circuit yield. We report on experiments and quantitative analysis of lubrication films in a highly scaled gravure printing process. We investigate the effects of ink viscosity, wiping speed, loading force, blade stiffness and blade angle on the lubrication film, and further, use the resulting data to investigate the relevant lubrication regimes associated with wiping during gravure printing. Based on this analysis, we are able to posit the lubrication regime associated with wiping during gravure printing, provide insight into the ultimate limits of residue reduction, and, furthermore, are able to provide process guidelines and design rules to achieve these limits.