Blister-actuated laser-induced forward transfer (BA-LIFT) is a versatile printing technique in which fine jets of ink are ejected from a thin donor film onto an acceptor substrate, enabling high-resolution patterns to be formed. Fluid ejections are initiated by the rapid expansion of micrometre-sized blisters that form on a polymer film underneath the ink layer. Recent work has demonstrated that these ejections exhibit novel flow phenomena due to the unique dimensions and geometry of the BA-LIFT configuration. In this work, we study the dynamics of BA-LIFT printing using a computational model in which fluid is forced by a boundary that deforms according to experimental time-resolved measurements of an expanding blister profile. This allows the model's predictions to be unambiguously correlated with experimental blister-actuated ejections without any fitting parameters. First, we validate the model's predictive capabilities against experimental results, including the ability to accurately reproduce the size, shape and temporal evolution of the jet as well as the total volume of ink released. The validated model is then used to interrogate the flow dynamics in order to better understand the mechanisms for fluid ejection. Finally, parametric studies are conducted to investigate the influence of ink density, surface tension, viscosity and film thickness as well as the size of the blister used. These results provide key insights into avenues for optimization and better control of the BA-LIFT process for improved resolution and repeatability of the printed features.
When a solid boundary deforms rapidly into a quiescent liquid layer, a flow is induced that can lead to jet formation. An asymptotic analytical solution is presented for this flow, driven by a solid boundary deforming with dimensionless vertical velocity V b (x, t) = (1 + cos x) f (t), where the amplitude is small relative to the wavelength and the time dependence f (t) approaches 0 for large t. Initially, the flow is directed outwards from the crest of the deformation and slows with the slowing of the boundary motion. A domain-perturbation method is used to reveal that, when the boundary stops moving, nonlinear interactions with the free surface leave a remnant momentum directed back towards the crest, and this momentum can be a precursor to jet formation. This scenario arises in a laser-induced printing technique in which an expanding blister imparts momentum into a liquid film to form a jet. The analysis provides insight into the physics underlying the interaction between the deforming boundary and free surface, in particular, the dependence of the remnant flow on the thickness of the liquid layer and the deformation amplitude and wavelength. Numerical simulations are used to show the range of validity of the analytical results, and the domain-perturbation solution is extended to an axisymmetric domain with a Gaussian boundary deformation to compare with previous numerical simulations of blister-actuated laser-induced forward transfer.
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