Addressing Environmental Imperatives in Marking Systems

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Addressing Environmental

Imperatives in Marking Systems

Santokh Badesha PhD, D.Sc. (Hon.)

Xerox Fellow and Manager Open Innovation Xerox Corporation

800 Phillips Road, Mail Stop: W207-01Z Webster, NY 14580

Phone# 585-422-3428

Email: [email protected]

• Introduction to Xerox printing technologies –2D and 3D printing

• Role of Nanos (tech & matls) to address environmental challenges

• Additive Manufacturing/3D Printing

• Some thought starters for collaborative research.

October 12, 2018

Focus:

Power Savings, light weight

for Transportation, and EH&S

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Armonk Group

2

Nanotech &

Materials

High

Performance Computing & IT

Life Sciences Skills and Talent Energy Services Innovation

Collaboration + Investment = Innovation & Jobs

Overarching Synergy: A Must Have

Collaborate and Invest in 4 Strategic Growth Areas To Restart Economic Growth in NYS

http://www.state.ny.us/governor/reports/pdf/IHETF_Report_FINAL.pdf

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NANO 2:Nanotechnology Research Directions 2020

(http://www.wtec.org/nano2/)

Chapter 1. Enabling and Investigative Tools: Theory, Modeling, and Simulation Mark Lundstrom, Purdue U. (slides presentation pdf)

Chapter 2. Enabling and Investigative Tools: Measuring Methods, Instruments, and Metrology, Dawn Bonnell, U. PENN (slides presentation pdf)

Chapter 3. Synthesis, Processing, and Manufacturing of Nanoscale Components, Devices, and Systems, Mark Tuominen, U Mass (slides presentation pdf)

Chapter 4. Nanotechnology Environmental, Health, and Safety Issues, Andre Nel, UCLA (slides presentation pdf)

Chapter 5. Nanotechnology for Sustainability: Environment, Water, Food, and Climate, Mamadou Diallo, Cal Tech (slides presentation pdf)

Chapter 6. Nanotechnology for Sustainability: Energy Conversion, Storage, and Conservation, Jeff Brinker, SNL (slides presentation pdf)

Chapter 7. Applications: Nanobiosystems, Medicine, and Health, Chad Mirkin, Northwestern U (slides presentation pdf) Chapter 8. Applications: Nanoelectronics and Nanomagnetics,

Jeff Welser, IBM and Nanoelectronics (slides presentation pdf)

Chapter 9 Applications: Photonics and Plasmonics, & Chapter 10 Applications: Nanostructured Catalysts, Evelyn Hu, Harvard U. (slides presentation pdf) (slides presentation pdf)

Chapter 11. Applications: High-performance Nanomaterials and Other Emerging Areas, Mark Hersam, Northwestern U. (slides presentation pdf)

Chapter 12 . Preparation of People and Physical Infrastructure, James Murday, USC (slides presentation pdf)

Chapter 13. Innovative and Responsible Governance, Mike Roco, NSF (slides presentation pdf)

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Xerox Company Introduction

Global leader in document management & outsourcing with superior technology, solutions and innovation

capabilities.

~$10.3B

Revenue

70%

Annuity- driven

revenue

160 Countries

$90B

Estimated market

opportunity

~35K

Employees

#1 Equipment revenue market share &

Managed Print Services

Global R&D Centers

RD&E Spending

~$1B

Xerox and Fuji Xerox Active Patents

11,500+ U.S.

$

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Hot air/IR/

UV lamp Print

head

Media transport Me

dia

Aqueous Ink Jet

Xerox Technologies Meeting Market Trends

Xerographic Process: Toner Path

Broad spectrum of Scientific and Engineering Skills and supporting infrastructures are required .

. .

FFuse & Fix Development

Image Generation

Toner Composition: Polymer, Pigments, Additives, Flow Aides, Charge Control Agents.

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6

Xerox Devices Competency played a key role in marking innovation of the past …

ColorQube

Production Inkjet CiPress

Xerography Solid InkAqueous Ink Jet Devices Innovation Of the Future

Desktop SOHO

iGen Nuvera 288

Print Head

TBD

Technologies

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Digital Color Technology – iGen Digital Press

Image fully constructed on rigid belt

Shuttle vacuum feeder

600 X 4800 pixels/inch Closed loop process controls

Automatic adjusting decurler

6 servos steer paper to image Gripperless

paper handling

Wide radius turns

Straight paper path

Standard Document Finishing

Architecture (DFA) All 4 colors

transfer at once

• 85 microprocessors

• 192 sensors

• 5M lines of software

• 3.5 miles of wires

• 102 motors

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• Most intelligent Press ever

• SmartPress

^™

Sentry watches

over every subsystem

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Design for Light Weight

• Xerox spends hundreds of millions of

dollars in Transporting, warehousing, and rigging.

• Xerox almost a factor of 2 overweight over competition.

• Light weight materials, components, and subsystems can result in reduction in

weight & size.

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Adhesive Properties -Adhesion forces - Wetting behavior -(surface energy) - Topography

Component

Thermal Properties -Tg - CTE

-Conductivity -Thermal mass -Emissivity

Component

Foundations of a Multifunctional Components

Mechanical

-Strength & modulus -Toughness/durability -Wear resistant

-Stress relaxation - creep resistance -Resiliency

Goal: Predictability, Consistency,& Stability of traditionally difficult to combine properties.

Split the function via multilayered design

Chemical Soluability -Reactivity -Homogenity -Hydophobicity

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iGen3 Fuser Sub System: Biggest Energy Hog

10

Fuser Roll X Roll

#1

X Roll

#2

Pressure Roll Media

Impacts the Environment:

• Consumes ~50% of total power from plug.

• Inefficient heat flow through interfaces.

• Expensive Recycle, Reuse, Disposal

Material System Interactions:

• Toner components, fuser surface, oil, paper surface chemistry, RH, T.

Fuser Impacts Customer Satisfaction:

• Print quality, cost of ownership, paper jams

• Impacts finishing (binding, collating, folding,

assembling, …).

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Wide Particle Size Distribution

Conventional: Attrition

Uncontrolled Breakage

Chemical: Growth

Controlled Growth

Narrow Particle Size Distribution

Marking Materials Design: Transition from Conventional to Chemical Methodology

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1

1 10 100

Diameter (um)

Normalized Count

Volume Differential Number Differential

0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1 1.1

1 10 100

Diameter (um)

Normalized Count

Volume Differential Number Differential

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Titanium dioxide with enhanced whiteness and

environmentally safe

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NYSERDA/NYSTAR-ESD Initiative: Additive Manufacturing/3DP Consortium

• Consortium

• Theme: “Needs Driven Capability Building via Connecting Industry/University Research for Economic Development”.

• Task: First establish a Consortium and then go for a NAMI – America Makes in NY State

• Steering Committee

• Comprised of industry (large and small), academia, and NY State funding agencies.

• Xerox an active and founding member.

• Process

• Needs: Identify Industry needs

• Capabilities: Identify NY State, academia and industry combined capabilities

• Map: capabilities and needs

• Identify common and executable activities.

• Status

•

Steering committee in place, industry needs compiled, mapping capabilities on-going

•

RIT-AMPrint Center funded as a CAT (www.rit.edu/amprint)

•

In policy book, Cuomo proposes 3D printing consortium

•

NYSERDA website: 17-12 Status of and Vision for the Additive Manufacturing Ecosystem

in New York State

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3D Printing : Current Challenges

Manufacturing

Materials Design &

Analysis

Design for 3DP / AM Best Practices Analysis of 3DP / AM

Designs

Multifunctional Materials Build Rate

Build Volume Geometry Tolerances

Surface Finish

Material Qualification Mechanical Properties Economics

Environmental and Political: Being sold as Green

Reprinted with permission from Fred Herman of Advanced Additive Manufacturing

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3DP: Additive Manufacturing

• Piezoelectric Printhead technology using extrusion and metal jetting for 3DP and Xerographic process for 3D-EP.

• Multi-Nozzle Extruder developed addressing shortfalls of FFF (speeds, surface quality, porosity, & mechanicals)

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Some thought starters for collaborative research

• Nano-materials and Composites:

• Enhanced color gamut for inks & toner designs.

• Titanium dioxide with enhanced whiteness and environmentally safe.

• IR absorbing materials.

• Polymeric Composites with enhanced thermal conduction

• Aqueous Ink Jet:

• Drying fundamentals (process, speed, efficiency--)

• Thermal modeling,

• Additive Manufacturing:

• High Temp Ceramics for metals jetting.

• Sensing: In-situ thermals monitoring during build process.

• Modeling: Predictive models for mechanical, thermal, electrical

stability, Melter Modeling, Dynamic flow model.

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Thank you!

17 Innovation is not about the idea Innovation is about connecting

The network is the innovation

Innovation requires seeing, building and managing new networks

(

Adapted from Andrew Hargadon, ‘How Breakthroughs Happen)

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5 Technologies Meeting Market Trends

Offset Quality Document Appearance

– Image Quality, Color, Document Thickness, Custom Color

Reliability at Low Cost (TCO)

– UMC / AMPV, Productivity, Run Cost, Long Life Components

Broad Substrate Latitude

– Type / Range, Width, Web/Sheet

Customer Friendly

– Miniaturization, Light Weight, Consistency, Jam Free

Meeting Green Requirements

– Low Power/Emissions, Recycle, Noise

– Simplify Multinational Sales

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Printing Technologies: Continue--

Printing Drum

[imaging plate

^]

Cleaning Subsystem

Impression Cylinder

Imaging Substrate Dampening

Imaging Ink development

Transfer

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