PicoJet Bonding Method

Since 1997, PicoJet’s engineering team has been developing the process for bonding metal laminates together using ultrasonic energy. PicoJet printheads are assembled using multiple stainless steel laminates each having a unique architecture which when bonded together form the inner architecture of the printhead. By applying the correct temperature, pressure, and vibration to the stainless steel laminates; a highly durable and hermetically sealed weld is created without allowing the bonding alloy to spread into the printhead’s fluid channels. This manufacturing process breakthrough allows for the creation of an all metal ink channel capable of jetting more diverse inks than previously thought possible.

Epoxy Bonded Printhead Disadvantages

The ultrasonic metal bonding process also eliminates the need for epoxies in the ink channel. Organic adhesives have historically caused significant problems in printhead manufacturing. First, adhesives are difficult to apply since adhesives must wet in order to bond. This wetting process can result in adhesive oozing into the ink channel. Any uncontrolled adhesive in the small ink channel can alter or block the flow characteristics of the printhead. This can negatively affect the ink jetting operation. Any adhesive debris released into the ink channel can cause blockage in the ink channel or the smaller nozzle.

Exposed adhesive in the printhead can also interact with ink. Adhesive interaction with ink can cause changes in the ink chemistry and the integrity of the adhesive bond. This in turn affects the reliability and performance of the printhead device. To prevent this interaction between the ink and adhesive, printhead manufactures are required to find compatible adhesives for each ink used in the printhead. This effort adds cost and time to the introduction of new ink chemistries.