A high-adaptability nozzle-array printing system based on a set covering printing planning model for printed display manufacturing

Inkjet printing technology is expected to enhance printed display mass production technology in the future. Nozzle-array printheads form the basis for printed display mass production applications. However, jet instability caused by air bubble entrapment and nozzle wettability changes during the printing process is a major challenge in the application of this technology. To adapt to possible nozzle abnormalities, a high-adaptability nozzle-array printing system based on a set covering printing planning (SCPP) model for printed display manufacturing is designed in this study. The study consists of two parts. First, a printing system based on multistep visual inspection and closed-loop feedback is proposed to accurately detect and screen abnormal nozzle positions. Notably, the inkjet printing system can identify nozzles with abnormal ejection characteristics and ensure that the remaining nozzles work accurately and stably. Then, an SCPP model is established for display pixel printing planning by using the remaining normal nozzles on the nozzle-array printhead. This model can output the most efficient printing path and nozzle printing action and can adapt to any pixel pattern, nozzle type, and abnormal nozzle distribution. The system and technology are highly adaptable and scalable for fabricating large-area printed display devices.