Statistical analysis for the manufacturing of multi-strip patterns by roll-to-roll single slot-die systems

• Correlation between operation conditions and topography of patterned strip was examined in roll-to-roll single slot-die printing.
• Mathematical model and its limitation to estimate the thickness and width of single slot-die patterned strips were analyzed.
• Full factorial experiment was conducted to screen the effective parameters for the thickness and width of patterned strip.
• A strategy to determine the R2R operating conditions was proposed for fabrication of multi-strips with desired thickness and width by single slot-die systems.

Roll-to-roll (R2R) slot-die coating systems are mostly devoted to the mass manufacture of printed electronics. This study examined the correlation among the operating conditions, thickness, and width of the patterned strip fabricated by the R2R slot-die system. A full factorial experiment was conducted to screen for effective parameters. The velocity of a moving substrate was found to be the most dominant parameter affecting the thickness and width of the patterned strips. The flow ratio of the supply to the slot-die, and gap between substrate and slot-die did not affect the width of the strip, but affected the thickness; therefore, the flow ratio and gap can be employed for the independent patterning of thickness against width. In addition, it was proposed to determine the R2R process conditions, such as gap, velocity, and flow ratio for the desired thickness and width of the patterned strips.