Abstract: Systems and methods disclosed herein are directed towards flexographic printing of microscopic high resolution conductive patterns (HRCP). These HRCP may be printed using one or more formulations for high polarity and stable viscosity inks for use in the flexographic printing process. The inks may be water permeable, UV curable, and configured to resist loss of integrity when exposed to water and atmospheric moisture.

Abstract: Disclosed herein are systems methods for using ink comprising organometallics in a flexographic printing process using engraved anilox rolls to transfer ink to an impression roll that prints a pattern on a substrate. A banded anilox roll with more than one geometry and/or volume of cells may be used in these production systems and methods. The pattern printed may comprise a plurality of lines which are each from 1 micrometer-25 micrometers wide and may be part of an electronics application such as a touch screen sensor or an RF antenna that requires microscopic conductive patterns such as touch screen displays or antennas.

Abstract: A method of manufacturing a flexographic printing plate includes designing a photomask patterned design. The photomask patterned designed is laser-ablated into a thermal imaging layer. The laser-ablated thermal imaging layer is laminated to a top side of a flexographic printing plate substrate. A bottom side of the flexographic printing plate substrate is exposed to UV-A radiation. The top side of the flexographic printing plate substrate is exposed to UV-A radiation. The thermal imaging layer is removed. The flexographic printing plate substrate is developed. A flexographic printing system for printing a photomask includes an ink roll, an anilox roll, a printing plate cylinder, a flexographic printing plate disposed on the printing plate cylinder, and an impression cylinder. The flexographic printing plate comprises embossing patterns corresponding to a photomask patterned design. The flexographic printing plate may be used in a flexographic printing system to manufacture a photomask with flexography.

Abstract: A method of fabricating a conductive pattern includes disposing an image of the conductive pattern on a substrate. The image includes material capable of being electroless plated. The image is electroless plated with a first metal forming a plated image. The first metal includes copper. The plated image is bathed in an immersion bath that includes a metal ion source of a second metal that reacts with the first metal. The second metal includes palladium. The conductive pattern includes a first metal layer having a first metal thickness, an intermetallic first metal-second metal interface layer, and a second metal layer having a second metal thickness.

Abstract: In a flexographic printing system, both the process parameters and equipment setup and configuration may play a role in producing the desired printed pattern. One component of the equipment setup is the printer roller assembly which may comprise a roller and a flexoplate as well as tape. The properties of the flexoplate and the tape as well as the relative dimensions of each in the assembly may affect the geometry and quality of the transferred pattern, as well as the ability of the system to produce a pattern on a repeatable, consistent basis.

Abstract: A method of printing uniform line widths with angle effect includes transferring ink to a flexo master comprising printing patterns disposed at an adjusted angle relative to a directional printing axis and transferring ink from the flexo master to a substrate. A flexographic printing system includes an ink roll, an anilox roll, a plate cylinder, a flexo master, and an impression cylinder. The flexo master is disposed on a plate cylinder. The flexo master includes printing patterns disposed at an adjusted angle relative to a directional printing axis.

Abstract: A system and method of preparing a reinforced flexoplate comprising a base support structure and a printing surface. The method includes controlling the curing conditions of the reinforced flexoplate, thereby controlling the properties of the flexoplate such as floor thickness, printing and base support pattern cross-sectional geometry, repeatability of printed features during the printing process, and durability of the reinforced flexoplate during the printing process.

Abstract: A method of manufacturing a flexographic printing plate includes designing a patterned design that includes a plurality of lines and a plurality of support structures and laser-ablating the patterned design into a thermal imaging layer. A support structure of the plurality of support structures is disposed at an offset relative to a line of the plurality of lines.

Abstract: Systems and methods disclosed herein are directed towards flexographic printing of microscopic high resolution conductive patterns (HRCP). These HRCP may be printed using one or more formulations for high polarity and stable viscosity inks for use in the flexographic printing process. The inks may be water permeable, UV curable, and configured to resist loss of integrity when exposed to water and atmospheric moisture.

Abstract: Systems and methods of flexographically printing a pattern comprising a plurality of lines or a first antenna loop array on a first side of a substrate, wherein printing the first antenna loop array comprises using an ink and at least one flexomaster. The ink comprises an acrylic monomer resin and a catalyst which may be an organometallic acelate or oxolate at a concentration from 1 wt %-20 wt %. The substrate may have one pattern on one surface of the substrate or may be printed as a double-sided substrate with at least one pattern on each side of the substrate. The ink is cured to dissociated the catalyst in the ink prior to electroless plating, this may be done using one curing process on each side, using one curing process in total, or by performing a partial cure on a first pattern and then curing the second pattern.

Abstract: A system and method of preparing a flexoplate so it is suitable for the printing of high resolution patterns. The method includes controlling the curing conditions of the flexoplate, thereby controlling the properties of said flexoplate such as floor thickness, pattern cross-sectional geometry, repeatability of printed features during the printing process, and durability of the flexoplate during the printing process.

Abstract: An ink composition for flexographic printing having an acrylic polymer at a viscosity of 100 cps to 10,000 cps and an organometallic catalyst at a concentration of 1 wt % to 12 wt %.

Abstract: Disclosed herein are systems methods for using ink comprising organometallics in a flexographic printing process using engraved anilox rolls to transfer ink to an impression roll that prints a pattern on a substrate. A banded anilox roll with more than one geometry and/or volume of cells may be used in these production systems and methods. The pattern printed may comprise a plurality of lines which are each from 1 micrometer-25 micrometers wide and may be part of an electronics application such as a touch screen sensor or an RF antenna that requires microscopic conductive patterns such as touch screen displays or antennas.

Abstract: A method of manufacturing a flexographic printing plate includes designing a patterned design that includes a plurality of lines and a plurality of support structures and laser-ablating the patterned design into a thermal imaging layer. A support structure of the plurality of support structures is disposed at an offset relative to a line of the plurality of lines.

Abstract: In a flexographic printing system, the both the process parameters and equipment setup and configuration may play a role in producing the desired printed pattern. One component of the equipment setup is the printer roller assembly which may comprise a roller and a flexoplate as well as tape. The properties of the flexoplate and the tape as well as the relative dimensions of each in the assembly may affect the geometry and quality of the transferred pattern, as well as the ability of the system to produce a pattern on a repeatable, consistent basis.

Abstract: A method of manufacturing a flexographic printing plate includes exposing a bottom side of a flexographic printing plate substrate to UV-A radiation for a first exposure time. A top side of the flexographic printing plate substrate is exposed to UV-A radiation through a thermal imaging layer. The bottom side of the flexographic printing plate substrate is exposed to UV-A radiation for a second exposure time. The flexographic printing plate substrate is developed. The flexographic printing plate is cured. A sum of the first and second exposure times set a relief depth.

Abstract: A method of manufacturing a flexographic printing plate includes designing a photomask patterned design. The photomask patterned designed is laser-ablated into a thermal imaging layer. The laser-ablated thermal imaging layer is laminated to a top side of a flexographic printing plate substrate. A bottom side of the flexographic printing plate substrate is exposed to UV-A radiation. The top side of the flexographic printing plate substrate is exposed to UV-A radiation. The thermal imaging layer is removed. The flexographic printing plate substrate is developed. A flexographic printing system for printing a photomask includes an ink roll, an anilox roll, a printing plate cylinder, a flexographic printing plate disposed on the printing plate cylinder, and an impression cylinder. The flexographic printing plate comprises embossing patterns corresponding to a photomask patterned design. The flexographic printing plate may be used in a flexographic printing system to manufacture a photomask with flexography.

Abstract: A method of manufacturing a high-resolution flexographic printing plate includes exposing a back side of a flexographic printing plate substrate to a first UV radiation. A top side of the flexographic printing plate substrate is exposed to a second UV radiation through a photomask that includes a patterned design. The flexographic printing plate substrate is developed. The flexographic printing plate substrate is cured. A flexographic printing system includes an ink roll, an anilox roll, a printing plate cylinder, a high-resolution flexographic printing plate disposed on the printing plate cylinder, and an impression cylinder. The flexographic printing plate includes embossing patterns corresponding to a patterned design. The embossing patterns are patterned into the flexographic printing plate using a photomask.

Abstract: In a flexographic printing system, the both the process parameters and equipment setup and configuration may play a role in producing the desired printed pattern. One component of the equipment setup is the printer roller assembly which may comprise a roller and a flexoplate as well as tape. The properties of the flexoplate and the tape as well as the relative dimensions of each in the assembly may affect the geometry and quality of the transferred pattern, as well as the ability of the system to produce a pattern on a repeatable, consistent basis.

Abstract: A method of manufacturing a low volume transfer anilox roll includes depositing a first coating material over a contact surface of a cylinder. A plurality of cells are patterned into the contact surface of the cylinder. A second coating material is deposited over the patterned contact surface of the cylinder.