2017 Journal

ag

California Polytechnic State University San Luis Obispo

Technical Association of the Graphic Arts 2016 – 2017

taga Š 2017 by California Polytechnic State University, San Luis Obispo Technical Association of the Graphic Arts (TAGA) Student Chapter First published in the United States of America by Cal Poly SLO TAGA Student Chapter 1 Grand Avenue San Luis Obispo, CA 93407 USA Printed at the Graphic Communication Department at California Polytechnic State University, San Luis Obispo All rights reserved. No part of this book may be reproduced in any form without written permission of the copyright owners. All images in this book have been reproduced with the knowledge and prior consent of the artists concerned, and no responsibilty is accepted by producer, publisher, or printer for any infringement of copyright or otherwise, arising from the contents of this publication. Every effort has been made to ensure that credits accurately comply with information supplied. We apologize for any inaccuracies that may have occurred.

Packaging. Designing. g. We Learn by Printin Binding. Coding. Lead ing. Marketing. Drawin g. Developing. Envision ing. Screening. Embos sing. Foiling. Trimmin eveloping. Interacting mping. Fundraising. Co mmunicating. Format ng. Planning. Doing. Le Innovating. Researchi ng. Experiencing. Deve 3

04 Table of Contents

Presidential Letters

Trends in Gravure Printing Lucas Tran Can Gravure Successfully Lead the Printed Electronics Market in Printing OLEDs? Breanna Rittmann Testing the Feasibility of Screen and Flexographically Printed Hall-Effect Sensors Bryce Beatty Patterned Photonic Curing of Copper Oxide Inks Using Metal Masks Tyler Weseman

06 11 23 37 55

A “Learn by Doing” Case Study The Cal Poly Phoenix Challenge Team

67

Meet the Team

96

Colophon

104

Thank You

106

06

Presidential Letters

6

Dear Reader, It is my honor to present California Polytechnic State University Student Chapter’s 2017 Technical Journal.

Cal Poly’s philosophy has inspired our chapter to embrace the true “Learn

by Doing” motto in this year’s theme. Throughout the collaborative and ideation phases of constructing our journal, the Design, Digital, Marketing and Production Executives embodied a true team with constant and constructive feedback. Our board of leaders spearheaded events, facilitated general meetings, and mentored their teams with support and education.

To us, it was important to have clear communication between our chapter and our department.

While exemplifying Cal Poly’s motto, our team worked diligently and effectively during each production process in order to present our entirely student driven technical journal to you.

We are very proud to say we have the resources and capabilities to create, print, and bind our entire journal in-house. Not only are we able to get hands-on experience and develop new sets of skills by operating a variety of presses we have never used prior to TAGA, but we have also grown as well-rounded individuals to become the industry’s future leaders.

We would like to extend our gratitude to our gracious donors, our advisors and professors who have enlightened us with their knowledge, our dedicated and highly valued members, and our friends and family for their support. This journal would not have been made possible without you.

Sincerely,

Mayra Mejía Chapter President | Cal Poly TAGA

7

8

A note from President Armstrong Cal Poly TAGA captures the essence of “Learn by Doing.” This chapter engages in “experiential learning,” in which our students take what they learn from their lectures and apply them in their labs and in competitive clubs, like TAGA. Education experts have developed an approach to learning they call “discovery learning.” This type of learning allows students to discover a solution for a problem where a solution is not already known or evident, through processes such as research and development, and trial and error.

TAGA students have engaged in the necessary experiential learning that gave them the expertise to write, design, and produce their very own technical journal. They also have the opportunity to engage in discovery learning through the research they conduct for their technical papers, the branding of this year’s aesthetic and the marketing strategies they developed to fundraise throughout the year.

The value of hands-on learning is evident in the success our students experience when they leave Cal Poly and make their contributions as professionals in the industry. They obtain technical knowledge, as well as the transferable critical thinking and communication skills they need to problem solve in the real world.

I am heartened by the initiative of the students in TAGA, many of whom, but not all, are Graphic Communication majors. Graphic Communication offers an education that gives its students every possible opportunity it can through its curriculum and faculty support. I am proud to serve in a university with a strong liberal arts college that values and provides the hands-on, “Learn by Doing” education we find in departments such as Graphic Communication.

Sincerely,

Jeffrey D. Armstrong President | California Polytechnic State University, San Luis Obispo

9

10

11

Trends in Gravure Printing

Awarded Undergraduate First Place Winner for the 2016 Gravure Association of the Americas Technical Writing Contest

Lucas Tran

11

Abstract Gravure printing is a high-speed, high-quality printing process. It is utilized for products ranging from publications to packaging, and recently, printed electronics. Historically, the trade-off for printing gravure is its high cost due to complicated set-up, makeready, and maintenance. New technology has been developed and adopted to make gravure more cost effective and thus a more attractive process for commercial printing jobs. Gravure is one of the most versatile printing processes because it can print on a wide range of substrates, from paper to plastics to film and it is often printed in large webs, leading to its high speed. Furthermore, the capability to print fine details at the level of microns has made gravure a contender in fabricating printed electronics such as organic solar cells and labels. Present technology has made gravure a diverse field of interest, due in no small part to its versatility. This paper will explore those fields and how gravure has affected the modern print market.

12

Introduction The past decade has been a period of growth in the gravure printing industry.

Printed electronics comes to mind as the most obvious growth area, but there has also been continuing advancement in familiar areas, namely packaging.

Emergent technology has led to advancements in printing such as glowing bottles, temperature sensitive packages, and decorative solar cells. Within a handful of years, it may become common to see supermarket shelves lined not only with products printed with ornate inks, but eye-catching light-up displays as well. Meanwhile, gravure is still commonly utilized for magazines, food packaging, wallpaper, and many other high quality printed products.

Gravure has historically been a popular choice for the mentioned commercial products due to the exceptional quality and versatility. It is being chosen to print long-run jobs where tight quality tolerances are needed. It is capable of producing unique features such as: implementing metallic inks, fabricating organic solar cells, and transferring graphics to plastics for packaging.

Its niche in the commercial marketplace will be further explored, as well as areas for growth. This paper will analyze the current state of the gravure printing industry, including its strengths and weaknesses, as well as take a look at the opportunities for future growth.

Methodology Secondary research was conducted in preparation of this research paper.

Sleeves Traditionally, gravure has been a cost prohibitive process in both dollars and time. Unlike offset processes, which use plates wrapped around cylinders, gravure printing requires the cylinder itself to be engraved. After printing is complete, the cylinder’s shell is stripped, with the image unable to be transported or used again afterward. If a different location needs to print the same image or if a customer requests reprints after the shell has been stripped the only option would be to engrave the cylinder again. Furthermore, cylinders need to be periodically electroplated to refresh the outer layer. This process can only be performed in specially equipped facilities. With these considerations in mind, it is easy to see why gravure is known as such a costly process.

However, new technology in the past decade has led to the development and adoption of gravure sleeves. Sleeves are a type of outer shell that are wrapped around a cylinder and can be removed, stored, reused, and transported. Industry

13

professionals have high praise for the sleeves. “Gravure printing presses used to be dominated by large and heavy cylinders that had to be transported around in a factory or between factories,” says Claus Larsen, market support manager for Nilpeter. “Today, heavy cylinders have been replaced by sleeve technology, which makes transport and changeover much easier and operator friendly” (as cited in Sartor, 2007). In some ways, the technology intersects gravure with offset printing, bringing some of the portability, ease of use, and cost efficiency of plates to gravure. Now, if an image needs to be transported to another facility, or even within the same location, a sleeve weighs in the range of single digit pounds instead of hundreds. The saved weight also makes changing images far easier than the old process of stripping and re-engraving the cylinder. Instead, the sleeves themselves are re-plated, so a printer only has to send their sleeve to be electroplated instead of the entire cylinder as before (Rothtec).

Metallic Ink One of gravure’s greatest strengths and the reason why it is so attractive for commercial packaging printing is its ability to lay down metallic inks. Customers have two primary options when choosing their printing process: add the additional step of finishing or print the metallic ink in-line. Although finishing has its time and place, using gravure can save an extra step. As Larsen says, “The gravure ink is the best alternative for metallic effects if one wants to avoid the downsides of hot foiling in very large volume runs” (as cited in Sartor, 2007).

While gravure cannot achieve the level of detail or spectacle as dedicated foil stamping or embossing, it is still an attractive offering for many retail products.

Metallic gravure inks can commonly be seen in the beauty aisle, on products such as shampoo and conditioner bottles, creams, deodorant, perfumes, and cologne. It is popular for other types of packaging, such as Halls cough drops, protein powder, and a variety of foods and drinks. The use of these inks give a brilliance effect and make features of a product stand out. On the aforementioned beauty products, it is common to see a set of art elements printed with metallic ink. For example, a shampoo bottle may have ribbons or stripes printed metallically or with a metallic gradient. The eye-catching nature of these specialty inks make gravure printing more and more attractive to commercial customers; but perhaps the most exciting development in gravure is still ahead.

Solar Cells Gravure is not limited to just high quality design for consumer products. Gravure is among several print processes currently being explored with the objective of printing organic solar cells. This paper will not be exploring the complete nature

14

of organic solar cells, as it will instead focus on gravure printing’s significance on the subject. However, for the sake of clarity, organic solar cells differ from inorganic solar cells due to their carbon based construction rather than silicon.

Lower cost and ease of manufacturing are among the benefits making organic solar cells more attractive than inorganic cells. “Inorganic solar cells show higher energy conversion efficiency than organic photovoltaic devices, but typically require expensive equipment and large amount of energy during fabrication,” say Korean researchers Jiyeon Lee, Aran Kim, Sung Min Cho, and Heeyeop Chae of Sungkyunkwan University. “Organic photovoltaic devices are of interest due to their low manufacturing costs and flexibility, despite having lower power conversion efficiency.” Their research has tested the effects of various solvents on the fabrication of organic solar cells and the resulting power conversion efficiency. A variety of print processes have been explored, including screen and inkjet printing. However, gravure is the most practical process for the manufacture of printed electronics. “Interest in gravure for PE is strong and growing in relation to an increased understanding of gravure’s inherent benefits,” says Eric Serenius, vice president of Daetwyler R&D. “These benefits include the simplicity of the process, the ability to transfer a variable amount of ink volume, the robustness of the image carrier and its resistance to harsh solvents that are used for printed electronics and its capability to print long runs at high speeds” (as cited in Savastano, 2011). The researchers favor roll-to-roll gravure due to its capability to “produce resolutions of a few tens of micro-meters” and its relatively low cost compared to manufacturing traditional inorganic solar cells. Furthermore, the cells leave a smaller environmental footprint, using and wasting fewer materials (Lee et al., 2011). The benefits of these cells, and gravure’s role in manufacturing them, have led to extensive research in optimizing organic solar cells for power conversion efficiency.

Presently, cells printed with gravure have low power conversion efficiency, in the realm of 8% or greater (Lee et al., 2011). However, the nature of gravure printing organic solar cells allows them to be manufactured in much greater quantities, with the added flexibility to use them for more applications. Just this past year, the VTT Technical Centre of Finland has developed a new production method that “enables designers to create interior design elements from organic solar panels (OPV, organic photovoltaics), harvesting energy from interior lighting or sunlight for various small devices and sensors that gather information from the environment” (Printed Electronics World, 2015).

Previously, cells were limited to printed stripes, but now the new method has opened the capability of printing decorative panels. The image from VTT

15

showcases a metallic leaf as just one of the possibilities. Other potential uses include, “windows, walls, machines, objects and advertisement billboards.”

Furthermore, gravure adds the feature of printing graphics on the cells themselves. According to the article in Printed Electronics World, one square meter of organic solar panels can generate approximately 10 watts, enough to power small lights. Although the current output is limited, there is still potential for the possible applications of these solar panels. Billboards and signage could have lit elements without requiring an external power source, similar to solar powered street lights. The compact size and flexibility of VTT’s cells can also allow the panels to be incorporated into the design itself. Gravure is instrumental in the production of these solar panels because it is printed from webs, allowing for the high speed necessary for mass production. A key feature of gravure, and the reason for it being a viable print process for solar cells, is its capability to print on a wide array of substrates, particularly flexible substrates.

Flexible Containers One of the most easily recognizable examples of this type of substrate is seen in flexible consumer packaging. Pouches for juice, baby food, wine, and others are common retail items printed with either flexographic or gravure processes.

According to Cory Francer of PackagePrinting, “flexible packaging provides decoration opportunities that are not available with other options.” Whereas bottles and boxes can be limited to a small design area, such as a label, packages like pouches can be printed on nearly their entire surface. Greater surface area allows for larger, more complex graphics. “We can apply a matte varnish in register, so some of the graphics can have a matte finish and other areas, a glossy look,” says Tom Triggs, liquid market manager at American Packaging Corporation. “That way you can have a picture of a bowl of fruit that is very glossy, while areas around the bowl can have a matte, natural look to them” (as cited in Francer, 2015). Gravure printing is desirable for achieving these effects and when “large-volume jobs and those where very high quality graphics are required” (Francer, 2015). For these jobs, gravure can achieve the tighter tolerances necessary for eye-catching goods.

Beyond design and aesthetics, gravure printing on pouches allows for easier shipping and end-user portability. Rigid bottles are inefficient in terms of storage and, in the case of glass, heavy. Flexible packaging means lower shipping costs. The benefit is not just to the supplier, however. Consumers also get to enjoy the portability and lighter weight, making the product more convenient overall. Marla Donahue, President of the Flexible Packaging Association,

16

highlights the advantages of flexible pouches, “They are convenient, lightweight, non-breakable, easy to ship and store, and have a smaller environmental footprint, especially when you consider the reduced weight in transportation.” (as cited in Francer, 2015).

Smart Labels Gravure is not just limited to packaging design, however. Beyond solar cells, gravure is significant in the manufacture of printed electronics. One such example is the smart label developed by Thin Film Electronics ASA. The smart label is primarily intended for perishable goods like groceries and medicine.

For example, smart label technology can detect the temperature of a bag of salad, a gallon of milk, or vials in a pharmaceutical cooler. Including electronic information on packaging could help stores maintain an optimal environment for their perishable products and keep consumers informed on their purchases.

Furthermore, the smart labels are not confined to packaging. Labels can be applied to the physical shelves to display real-time pricing data, making adjustments, sales, and clearance easier to retail stores (Embree, 2013). Whereas presently employees must manually remove and replace price labels, often weekly in the event of sales, in the future stores will be able to instantly change price tags. As with solar cells, gravure is a reasonable choice because it can print fine details as small as 2 μm at a printing speed of ~1 m/s (Cen et al., 2014).

Other Printed Electronics Gravure is also being explored as the manufacturing method for other products in the printed electronics market. “We see gravure as an area where major manufacturers will be playing,” says John Lettow, President of Vorbeck Materials, manufacturer of a graphene-based conductive ink. “We see primary opportunities being RFID antennas as well as high volume consumer applications” (as cited in Savastano, 2011). RFID, or radio-frequency identification, is used for tracking applications such as with livestock, merchandise, or transponders like FasTrak. Gravure printing has the potential to make these products cheaper in the future and more widespread, like barcodes that do not have to be scanned directly. Gravure might start lighting up homes and offices soon. According to David Savastano from Printed Electronics Now, “Add-Vision has developed a strong partnership with Daetwyler R&D to create world’s first commercial scale sheetfed gravure printer for printing OLEDs.” Organic light emitting diodes are carbon based films that produce bright light with less energy consumption than traditional LEDs (Tarantola, 2014). With the new printer from Add-Vision and Daetwyler, sheets of these arrays can be printed with the gravure process.

17

Products that might feature these printed arrays include phone displays and LCD televisions and monitors. Currently, the trade-off for the increased performance of OLEDs are prohibitively high costs, about three times higher than LEDs (Tarantola, 2014). However, gravure printed electronics might be the breakthrough needed to make them an economical choice within the decade. ď ˇ

18

Results and Concluding Remarks Gravure allows manufacturers to produce high quality imaging that is being adapted for emerging technologies. The gravure process is capable of applying unique inks and textures, making it extremely popular for retail packaging.

Manufacturers can achieve eye-catching graphics and designs on a variety of substrates that are otherwise impossible to recreate with print processes like lithography, inkjet, or even flexography in some cases. Looking ahead, printed electronics is perhaps the most exciting field, with gravure being one of the leading processes. Organic electronics, printed with conductive carbon ink on plastic films, is where most researchers and manufacturers seem to be focusing their attention. Gravure printing is being seriously explored as a means to economically bring products such as solar cells, smart labels, RFIDs, OLEDs, and more to market. Gravure in printed electronics is moving out of its stages of infancy and is maturing quickly, with significant development likely within the next few years. Keeping these trends in gravure will set the printing process up to be a viable, if not ideal, choice for a variety of alternative printing solutions.

19

References Cen, Jialiang, Rungrot Kitsomboonloha,, and Vivek Subramanian. “Cell Filling in

Gravure Printing for Printed Electronics.” Langmuir (2014): 13716-3726. Web.

5 Oct. 2015. <http://pubs.acs.org/doi/pdfplus/10.1021/la503180a>.

Embree, Kari. “Breakthrough in Printed Electronics.” Packaging Digest. N.p., 15 Oct.

2013. Web. 21 Nov. 2015. <http://www.packagingdigest.com/smart-packaging/ breakthrough-printed-electronics>.

Francer, Cory. “Flexible Refreshments - Package Printing.” Package Printing. N.p., 23 Apr.

2015. Web. 06 Oct. 2015. <http://www.packageprinting.com/article/flexible refreshments-2/>.

“Gravure Sleeves - Printing Sleeves - ROTHTEC.” Rothtec. N.p., n.d. Web. 21 Nov. 2015. <http://rothtec.com/electroforming/gravure-sleeves/>.

Koidis, C., S. Logothetidis, S. Kassavetis, C. Kapnopoulos, P.g. Karagiannidis, D.

Georgiou, and A. Laskarakis. “Effect of Process Parameters on the Morphology

and Nanostructure of Roll-to-roll Printed P3HT:PCBM Thin Films for Organic

Photovoltaics.” Solar Energy Materials and Solar Cells 112 (2013): 36-46. Web.

5 Oct. 2015. <http://www.sciencedirect.com/science/article/pii/ S0927024813000044>.

Lee, Jiyeon, Aran Kim, Sung Min Cho, and Heeyeop Chae. “Solvent Effects on Gravure printed Organic Layers of Nanoscale Thickness for Organic Solar Cells.” Korean

Journal of Chemical Engineering Korean J. Chem. Eng. 29.3 (2011): 337-40.

Web. 5 Oct. 2015. <http://link.springer.com/article/10.1007%2Fs11814-011 0174-6#page-2>.

“Printers Find Opportunities In Printed Electronics.” Printed Electronics

Now. Ed. David Savastano. N.p., 7 Nov. 2014. Web. 06 Oct. 2015. <http:// www.printedelectronicsnow.com/issues/2013-04/view_features/printers-find opportunities-inprinted-electronics/>.

“Printing Technologies for Manufacturing Decorative Solar Panels.” Printed

Electronics World. N.p., 29 Jan. 2015. Web. 06 Oct. 2015. <http://www. printedelectronicsworld.com/articles/7346/printing-technologies-for manufacturing-decorative-solar-panels>.

Sartor, Michelle. “Gravure Printing.” Label & Narrow Web. Rodman Publishing, Oct.

2007. Web. 5 Oct. 2015. < http://shows.labelandnarrowweb.com/

articles/2007/10/gravure-printing >.

Savastano, David. “Gravure Makes Inroads in Printed Electronics.” Printed

Electronics Now.. N.p., 23 Feb. 2011. Web. 06 Oct. 2015. < http://www. printedelectronicsnow.com/contents/view_online-exclusives/2011-02-23/

gravuremakes-inroads-in-printed-electronics/ >.

Tarantola, Andrew. “Why Is OLED Different and What Makes It So Great?”

Gizmodo. N.p., 6 Nov. 2014. Web. 24 Nov. 2015. <http://gizmodo.com/why-is oled-different-and-what-makes-it-so-great-1654102034?sidebar_promotions_ icons=testingoff&utm_expid=6686609067.9PWeE2DSnKObFD7vNEoqg.

1&utm_referrer=https%3A%2F%2Fwww.google.com%2F>.

20

Lucas Lucas Tran Tran Lucas Tran is a graduating senior majoring in Graphic Communication, and is concentrating in Web & Digital Media. He is from the San Francisco Bay Area and intends to return home for his post-graduation career. In his free time, Lucas enjoys videography, movies, and video games.

21

22

23

Can Gravure Successfully Lead the Printed Electronics Market in Printing OLEDs? Awarded Undergraduate Second Place Winner for the 2016 Gravure Association of the Americas Technical Writing Contest

Breanna Rittmann

Abstract This paper aims to explore whether gravure printing processes are capable of producing Organic Light Emitting Diodes (OLED). Current secondary research was compiled, showing the breakdown of both the gravure market as well as the printed electronics market as it pertains to OLED displays and lights. The benefits and drawbacks associated with gravure were exposed and compared to other processes like ink-jet printing. The research showed that gravure was not capable of being the best printing method at producing high-quality OLEDs and instead ink-jet is leading the way. Gravure is still able to produce OLEDs but not as high of quality and not as efficiently, but there is room for improvement.

24

Introduction OLEDs are primarily manufactured using ink-jet processes that are non-contact. Gravure, on the other hand, is a direct-contact process that has unique characteristics to contribute to successfully printing on thin, flexible substrates which are ideal for printed electronics. While gravure is more popular among more non-U.S. markets, it is starting to gain momentum in the states as its capabilities prove to deliver higher quality and greater sustainability. Secondary research was used in preparation of this research paper.

Methodology The market share captured by gravure is only a fraction of the $76.7 billion dollar print industry (Moldvay, 2012). At 4.1%, commercial gravure printing is primarily used for advertising (about 28.4% of product revenue), catalogs and directories (22.5%), labels and wrappers (20.4%) and magazines and periodicals (17.8%) (Moldvay, 2012). Core competencies associated with gravure, according to lecture materials derived from Cal Polyâ&#x20AC;&#x2122;s Web Offset and Gravure Printing Technologies class include: high-quality photo reproductions, extremely fast printing speeds, excellent low-key detail, light-weight flexible substrates, dry-trapping, larger press forms, and consistency. However, its disadvantages of expensive make-ready, along with a misalignment in the trend towards shorter print runs in the US, are a result of its decline. Flexography and rotary offset have seen huge gains in improving their quality and turnaround time that they have more often than not, pushed gravure out of many markets (Daniel, 2013). Manoj Garg, the general manager of Gulf Scan (the Middle Eastâ&#x20AC;&#x2122;s largest provider of imaging and prepress solutions), says otherwise that gravure is more popular when it comes to the ratio of flexo to gravure in specific regions: Asia-Pacific has flexo to gravure at 20:80 respectively, Europe 55:45, North America 75:25, and Middle East and Africa have lost little to flexo and web offset so gravure still dominates in this region (Daniel, 2013).

Commercial printers such as Gulf Scan in the Middle East and G3 Enterprises in Modesto, CA implement the strengths associated with rotogravure in their current equipment because its advantages will continue to deliver high-quality more consistently than other processes as well as remain the superior, easier-to-use technology for many regions (Daniel, 2013). According to the newest findings in the drupa 2016 report, gravure and flexography are both seeing a significant growth in the packaging sector with flexo growing +18% and gravure a modest but stable +3%. Although packaging is a stable sector for rotogravure, there is still much more room for growth in other markets

25

such as printed electronics and other multifunctional technologies. These technologies that demand a significant threshold for high-quality combined with thin, flexible substrates (Figure 1), will continue to request gravure as its go-to printing process.

The market for multifunctional technologies, such as printed electronics, is estimated to be $40.2 billion by 2020 (Markets and Markets, 2016). This number includes materials (substrates and inks), technology (screen, gravure, inkjet, and flexography), and applications (displays, sensors, OLEDs & PVs) (Markets and Markets, 2016). The industry breakdown shows OLEDs as making up the majority of the market in both displays and lights as shown in Figure 2 (Das & Harrop, 2015).

OLED technology can be found in the many products that have 1: A flexible display using organic light emitting made their way into the market Figure diodes, OLED-info.com today, like Samsungâ&#x20AC;&#x2122;s OLED TV displays and its Galaxy S6 mobile phone (OLED-info, 2016). Over 3,000 companies in the world are pursuing printed, organic, and flexible electronics because this new technology has the capabilities to be extremely efficient, yield low-cost, execute improved performance, and retain better environmental credentials (Das & Harrop, 2015). Currently, industry leaders are calling for a focus in developing the markets for printed electronic wearables (as shown in Figure 3), and printed electronic products for the automotive industry (OE-A News, 2015). These market segments, specifically for automobiles, will benefit mainly from OLED displays such as pop-up warnings on windshields, and other interior, â&#x20AC;&#x153;smartâ&#x20AC;? displays that engage the customer and enhance their vehicle properties. There is a high potential for OLEDs to be implemented into these markets, and the demand for multifunctional, low-cost, printed electronic products will need to be required to manufacture. Therefore, finding the best processes to manufacture OLEDs inexpensively, while delivering high-quality with high-volume, will be essential for the success of OLEDs in the future.

OLEDs are currently manufactured in a variety of different ways. Specifically in the conventional print market, OLEDs are primarily manufactured through an ink-jet process. Inkjet is common because the high-precision nozzle is capable

26

of controlling deposition of a solution in specific locations on a substrate and can “provide easy and fast deposition of polymer films over a large area” (GE Global Research, 2008). Another characteristic for manufacturing OLEDs are the roll-to-roll processes as they are ideal for cost savings involved with high volume production. Researchers at the Holste Centre were able to successfully produce over 2.5km of roll-to-roll barrier film (Flex-o-Fab, 2015). The project manager Date Moet said, “Roll-to-roll production will be essential to bring flexible OLEDs to market at an afford4.1% commercial 3.3% able price. By demonstrating the first gravure quick printing printing OLEDs on a high performance R2R 5.3% book printing produced flexible barrier foil, we have taken a major step towards commercial 6.6% production” (Flex-o-Fab, 2015). Another digital printing characteristic that OLEDs will benefit 54.7% from is an additive process. Traditional commercial 7.6% lithographic printing commercial manufacturing methods of electronics printing require a subtractive process, which is very wasteful. However, printing is an 9.1% additive process, which allows for just commercial screen printing the right amount of solution without the 9.3% Total $76.6 billion excess amount of waste. This knowledge other printing opens the door for the printing industry Figure 2: Products and Services Segmentation to enter the new and exciting market (2012), The printing industry market segments, Das & Harrop, 2015

of printed electronics as it relates to the production of OLEDs. In order to understand which printing processes would best suit the production of OLEDs, it is important to dissect the layers of what makes an OLED function. According to Figure 4, many different layers are laid on a substrate to a total thickness of about 100-500 nano- Figure 3: A wearable printed electronic, appleinsider.com meters thick (200 times smaller than a human hair) (Freudenrich, 2016). OLEDs work by emitting light through a process of electrophosphorescence (Figure 5). An electric current flows from the cathode to the anode, passing through the organic layers, which creates movement among the electrons. When the electrons bond with other elements, they give off

27

Cathode Emissive Layer (organic molecules or polymers)

Anode

Conductive Layer (organic molecules or polymers) Substrate

Figure 4: OLED structure, Freudenrich, 2016

energy in the form of light, depending on the amount of electrical current being sent through the OLED (Freudenrich, 2016). Given this basic summary of how an OLED works, it still is quite complex and this is all happening at the microscopic level.

Therefore, each layer must contain the highest precision of quality and must not have any gaps or particles that could corrupt its performance.

Combining gravure printing processes with the manufacturing of OLEDs is the proposed question of this research. Understanding the significance, core competencies, and drawbacks from each technology is vital when deciding if the pair should be mated into one. They must be able to complement each other in order to achieve the desired success of a low-cost, light-weight, flexible, and more durable OLED. The attributes that gravure can bring to the production of OLEDs are many. As mentioned before, the roll-to-roll process is a key element associated with gravure and it will also be beneficial for making OLEDs. By using a substrate in roll form and running it continuously throughout a press, output is greatly increased due to high speeds and decreased waste, which means higher cost savings and lower costs per printed unit which is extremely important in order for OLEDs to remain competitively priced (Gaspar, 2015). Utilizing gravureâ&#x20AC;&#x2122;s roll-to-roll drives prices down to make OLEDs more affordable for everyone. Another attribute associated with gravure

28

cathode

cathode

cathode

anode

1.

Conductive Layer Emissive Layer

Electrical current flows from the cathode to the anode through the organic layers, giving electrons to the emissive layer and removing electrons from the conductive layer.

electrons from the 2. Removing conductive layer leaves holes that

need to be filled with the electron in the emissive layer.

holes jump to the emissive layer 3. The and recombine with the electrons.

As the electrons drop into their holes, they release their extra energy as light.

Figure 5: The OLED process, Freudenrich, 2016

is its precision and high resolution print cells. “Gravure has the ability to print a variety of functional materials and fine lines with resolutions below 30μm” (Hösel, 2013). Dry-trapping is another positive attribute that gravure passes along to manufacturing OLEDs. Since gravure ink is typically solvent-based, the dry time between each pass of a cylinder is greatly reduced, allowing for optimum registration necessary for OLEDs. “Inks need to be contained within the designated area during the drying step, remaining so located during subsequent processing steps” (Gaspar, 2015). Since printing OLEDs involves putting down as fine of details to that of pixels, gravure can get close to offering those high resolution “dots” with its microscopic cells. Researchers at Sungkyunkwan University in Korea said, “We were able to achieve a 51 nm thick and 3.7 nm rough MEH-PPV layer with the gravure printing process and subsequent solvent printing treatment and an OLED was fabricated using the gravure printed organic layers. An improvement of the brightness and efficiency was observed due to the improved roughness of the organic layers” (Kim, 2010). Here in this example, due to gravure’s laser-engraved print cylinder, high resolution can be achieved with microscopic sized print cells, an attribute required to print OLEDs. Thin, flexible substrates are also vital in the production of flexible OLEDs, which are gaining demand in the wearable printed electronics market. Gravure is able to deliver printed matter on a wide variety of substrates, including super thin materials. Its process, as shown in Figure 6, shows substrates feeding between two cylinders with the ink almost jumping out of the cell onto the substrate. This process allows the substrate to remain smooth, not be stretched or compressed too tightly between the cylinders. An ESA (electrostatic assistant) is a novel innovation that has allowed gravure to improve its processes dramatically with delivering homogeneous ink deposition, ideal for the manufacture of OLEDs where gaps in circuitry lines are impermissible.

Some drawbacks associated with gravure printing are its direct-contact attributes.

OLED functions can be significantly reduced if any dust or particulates become deposited on the substrate or between the layers. “Depending on the size and nature, they can destroy deposited layers, cause leaks after encapsulation, and become nucleation points that cause faster aging and destruction of OLED pixels” (MBRAUN, 2015). Since ink-jet is the only printing process that is non-contact, it minimizes contamination risks that are associated with other printing methods (Gaspar, 2015). Some of the main challenges that gravure faces is its low emission efficiency (Gaspar, 2015). The VTT Technical Research Centre in Finland found that “The luminosity of [gravure and screen printed] OLED (lm/W) amounts up to around one third of an LED’s luminosity. It has

29

pap e

rb

oar d

one advantage in that OLED emits electrode light throughout its entire surface, (charging bar) whereas LED is a spotlight tech+ + lonisator nology” (Ford, 2015). So trade-offs - semiconductive layer (discharging bar) 0 + do happen when it comes to new + + 0 0 0 + technology. Because OLEDs cre0 0 + 0 + ate light at the source, they don’t impression roller + 0 + need a backlight that conventional + 0 + LEDs would need. However, this 0 + + means that sometimes OLEDs ar++ + + + + + en’t as effective at performing as + + + + + + + + well or even better than traditional, -- -- -- -thicker, LEDs. However, the auelectrostatic field thor of OLED Fundamentals says printing cylinder that even though gravure printed OLEDs lack efficiency, “recent ad- Figure 6: The gravure printing process, Iggesund.com vances show promise of improvement” (Gaspar, 2015). Since gravure uses primarily solvent-based inks, this can cause “wash-out”. Gaspar says that, “during solution deposition of one organic layer on top of another, the solvent penetrates into the underlying layer and leads to swelling or even “wash-out” (where the underlying layer is actually removed)”. Since gravure uses solvent-based inks for fast dry time, they may have to make some trade-offs in order to achieve maximum manufacturing abilities when it comes to high-quality OLEDs. The biggest issue that gravure faces when successfully printing OLEDs is perfect registration. Because gravure is a traditional printing process that uses cylinders for each different ink, there are many variables to how those inks line up with one another. According to Cal Poly lecture materials, there are many different registration techniques used in gravure: side-lay registration, lateral registration, and circumferential registration. In order for a roll to be aligned throughout the press, controls with the side-lay of the actual roll-stand need to be adjusted. Moving cylinders within the printing unit are controlled with lateral registration instruments. Circumferential registration can be controlled by packing the cylinder to increase the diameter of the printing cylinder. All these registration variables increase the risk of mis-registration and timely makeready. Where uniformity from pixel-to-pixel is of the utmost importance when manufacturing OLEDs, gravure may struggle to achieve perfect registration and deposition (Gaspar, 2015). Creating plates for gravure cylinders require a laser engraver that is capable at running at extremely high speeds. However,

30

ink-jet does not require a plate, “…this makes inket printing one of the most cost-efficient ways of producing complex patterns” ( Gaspar, 2015). The noted author again adds, “Not surprisingly, the displays industry has initially focused on ink-jet printing as the preferred method for the production of OLED displays” (Gaspar, 2015). While initially this may be the case, changes are frequent in this industry and those preferences could easily change. 

31

Results and Concluding Remarks When looking at the attributes and setbacks that gravure printing faces when attempting to produce high-quality OLEDs, the consolidated research suggests that gravure may not be the best printing method for OLED manufacture.

Ink-jet seems to be the leading printing method for producing high-quality OLEDs since it is non-contact and has a high-precision nozzle that can deposit material onto a variety of substrates at extremely high resolutions with high levels of control. The barriers gravure faces outweigh the benefits it currently brings to the OLED market. There are too many risks for contamination with direct contact printing, incapable of higher resolutions offered by ink-jet, too many trade-offs between inks and registration controls, and costly make-ready.

Although its roll-to-roll features are whatâ&#x20AC;&#x2122;s driving the market for printed electronics in order to make it affordable and competitive, it will have to be stripped from its native printing process and instead applied to other, more suitable processes, like roll-to-roll ink-jet processes. As traditional print loses sales to other forms of digital media, the industry is looking for ways to rejuvenate its presses and get them running again. Printed electronics is a huge opportunity for the print industry, and processes like gravure, ink-jet, screen-printing, and flexography still have opportunities to individually contribute to the printed electronic industry. Gravure, while unable to successfully lead the market in manufacturing high-quality OLEDs, still has the capabilities to produce lower-cost printed displays in things like posters and other one-time-use products that can be thrown away, recycled, and printed all over again. Otherwise, gravure needs to continue its research and development in order to improve in the areas itâ&#x20AC;&#x2122;s weakest in when it comes to manufacturing OLEDs. Extensive secondary research was done to support this project and to adequately answer the question of whether gravure printing methods could be successfully married to OLED technology. The solution to answering the question was simply a concern of pooling the most up-to-date research into one consolidated paper. Secondary sources were all very up-to-date, with 10 of the 18 resources published from 2015 and 2016. This research needed to be as up-to-date as possible because of the nature of this technology and how rapidly it is changing in the market.

32

References Angel, B. (2008). The Analysis of the Viability of Electronics Printed by Gravure and Web

Offset Lithography. Gravure Association of the Americas. Retrieved from: http://www.gaa.org/tech-articles/analysis-viability-electronics-printed-gravure and-web-offset-lithography Cal Poly, (2016). Web Offset and Gravure Printing Technologies. Graphic Communication

Department. http://catalog.calpoly.edu/collegesandprograms/collegeofliberalarts/ graphiccommunication/#courseinventory Daniel, B. (2013). Gravure’s Bright Future in Middle East Packaging: Manoj Garg of

Gulfscan. Packaging MEA. Retrieved from: http://www.packagingmea.com/ 2013/12/gravure-in-the-middle-east-interview-with-manoj-garg/ Das R., Harrop, P. (2015). Printed, Organic, & Flexible Electronics Forecasts, Players &

Opportunities 2016-2026. IDTechEx. Retrieved from http://www.idtechex.com/ research/reports/printed-organic-and-flexible-electronics-forecasts-players-and opportunities-2016-2026-000457.asp Flex-o-Fab (2015). Lighting by the Mile. OPE Journal. 10.

Ford, J. (2015). Traditional Printing techniques combine in OLED display manufacture.

The Engineer. Retrieved from http://www.theengineer.co.uk/traditional-printing -techniques-combine-in-oled-display-manufacture/ Freudenrich, C. (2016). How OLEDs Work. How Stuff Works: Tech. Retrieved from http://electronics.howstuffworks.com/oled1.htm Gaspar, D. (2015). OLED Fundamentals: Materials, Devices, and Processing of Organic

Light-Emitting GE Gilboa, R. (2016). Info Trend’s Rob Gilboa Reports on the Digital Transformation of

Industrial Printing.

Global Research, (2008). GE Demonstrates World’s First Roll-to-Roll Manufactured

OLEDs. Gravure Magazine. 22(2), 30.

Hösel, M. (2013). Gravure Printing. Plastic Photovoltaics.org. Retrieved from http:// plasticphotovoltaics.org/lc/lc-fabrication/lc-printing/lc-gravure.html Kim, A. (2010). Nanoscale thickness and roughness control of gravure printed MEH-PPV

layer by solvent printing for organic light emitting diode. PubMed.gov Retrieved

from http://www.ncbi.nlm.nih.gov/pubmed/20358949 Markets and Markets, (2016). Printed Electronics Market Worth $40.2 Billion by 2020.

Retrieved from http://www.marketsandmarkets.com/PressReleases/printed electronics-market.asp MBRAUN, (2015). Enclosure with laminar flow and inert atmosphere. OPE Journal.10.

Moldvay, K. (2012). Printing in the US Industry Report. IBISWorld. Retrieved from: http://www.morrisanderson.com/images/uploads/documents/32311_Printing_ in_the_US_industry_report.pdf

33

References Continued OE-A News, (2015). Moving from 2015 to the year 2016 – OE-A is going abovbe and

beyond to bring the organic and printed electronics industry to the next level.

OPE Journal. 13.

Oled-info (2016). OLED Technology: introduction and basics. Retrieved from http:// www.oled-info.com/oled-technology Package Printing. Retrieved from http://www.packageprinting.com/article/infotrends-ron gilboa-reports-on-the-digital-transformation-of-industrial-printing/ PNEAC (N.D.). Gravure Printing. Retrieved from http://www.pneac.org/printprocesses/ gravure/ Printing Impressions. (2016). Third drupa Global Trends Report Shows Optimism for

Growth in 2016. PIWorld. Retrieved from: http://www.piworld.com/article/ third-drupa-global-trends-report-2016-available-soon/

Images

Figure 1 – OLED-info.com.introduction/ Figure 2 – www.IBISWorld.com Figure 3 – http://appleinsider.com/articles/13/05/20/rumor-apple-testing-15-oled-displaysfor-wearable-iwatch Figure 4 – Freudenrich, 2016 Figure 5 – Freudenrich, 2016 Figure 6 – https://www.iggesund.com/en/knowledge/the-reference-manual/printing-andconverting-performance/Gravure-printing/

34

Breanna Rittmann Breanna Rittmann is originally from Livermore, California. She is a fifth year student at Cal Poly majoring in Graphic Communication and concentrating in Graphic Communication Management. She is a student-athlete on the Cal Poly Womenâ&#x20AC;&#x2122;s Soccer team and was a captain during her senior year.

Her favorite Graphic Communication topics are estimating and flexography.

35

36

37

Testing the Feasibility of Screen and Flexographically Printed Hall-Effect Sensors Bryce Beatty

Abstract Hall-Effect sensors were printed using carbon ink and then tested by the Van der Pauw method and a Helmholtz coil. The results show that both a screen-printed carbon sensor and a flexographically printed carbon sensor are responsive to a magnetic force; however, more testing is needed to produce the repeatable results needed for mass production, particularly for commercial use. Traditional printing technology may someday replace traditional manufacturing of Hall-Effect sensors. This paper focuses on sensor design, carbon ink properties, printing techniques for both screen and flexographic printing and recommended solutions.

38

Introduction A Hall-Effect sensor can be used in many different applications: automobiles, consumer electronics, and medical equipment such as a pacemaker. The small device can act as a switch and, with the addition of computer logic, can expand the functions of electronic devices. For example, St. Jude Medical recently developed a cardiac pacemaker with a Hall-Effect sensor for the purpose of safely controlling the device during MRI screening. This paper explores the challenges that traditional printing technology faces in manufacturing this common sensor.

Flexographic (flexo) and screen-printing are two different printing processes that were used to print the samples. The samples were then tested in the presence of a magnetic force. Leonardo Frem, an Electrical Engineering (EE) graduate student at Cal Poly, assisted in the development of this printed sensor. Mr. Frem applied his EE background to help predict the best printing parameters needed to produce a successful sensor.

If a magnetic force affects the printed Hall-Effect sensor and the sensor reacts in a consistent repeatable way, the experiment is success. The goal of this research paper was to produce a viable, consistent carbon printed version of a Hall-Effect sensor.

Related Literature The Hall-effect was first discovered in 1879 when Edwin H. Hall observed a change in electron paths when a magnetic force was applied (Thurber, 2016).

Hall further investigated and discovered that this phenomenon can be measured and predicted. This magnetic force, also referred to as the Lorentz force, pushes the electrically-charged particles perpendicular to the normal flow of voltage (Sun, 2012). When there is no magnetic force, the electrons travel across the conductive sample on the least resistive path. When a magnetic force is applied, the electrons are forced to deviate from the normal path, causing an accumulation of charged electrons on the edges of the sample. The cross shape of a Hall-Effect sensor is designed so it can easily measure this voltage change (see figure 1 & 2), and the volt- Figure 1: Proposed cross designs that show how the voltage across age differential, in millivolts. the design will change hen a magnetic force is applied (Sun, 2012)

39

The design proposed for this experiment uses the same cross shape as seen in figure 1 and 2. Two different sizes I+ Iand three cross patterns were created for VH each printing method to test the effect of a magnetic force. Conductivity of the x ink used will also influence a Hall-effect Vsensors behavior. The sensor needs to be y made of conductive material, yet studI ies have shown that material with metFigure 2: How the proposed cross design al particles will not act as a Hall-Effect will be measured for voltage and voltage sensor around a magnetic force (Ramsden, differential (Sun, 2012) 2011). Due to the metal particles being very conductive, the electrons move too quickly and are not defelected by the magnetic force. Current Hall-Effect sensors are made from semiconductor material such as silicon and germanium, which is then doped (Thurber, 2016).

The doped material is not as conductive as a metallic material, allowing the electrons to be moved by a magnetic force exerted on them. Fabricated graphene material can also be grown on silicon, and has been shown to display results similar to a traditional Hall-Effect sensor (Matveev, 2015). Carbon ink acts similar to doped semiconductor material, and can easily be printed via traditional flexo or screen-printing methods. Little has been published about using traditional printing methods to create a Hall-Effect sensor, but there have been many advances in printing of various electronic components in the past several years. The Hall-Effect force exerted on a single carrier can be expressed as F = q(E + (v x B)) H

V+

where F is the force on the carrier, q is the charge of the carrier, E is the electric field applied, v is the drift of the electrons, and B is the magnetic field vector (Sun, 2012). Additional equations are used to simulate the Hall-Effect voltage; knowing the thickness and resistance of the ink is also needed for an accurate prediction of the drifting electrons. When possible these data were collected from the printed samples and then used to simulate the Hall voltage.

Before testing with a magnetic force, all samples were subject to the Van der Pauw method. The Van der Pauw method is used to determine resistance and the Hall coefficient for the carbon material. By testing the samples using this method first, the user can determine if the samples are stable

40

with consistent resistance in all directions, before applying a magnetic force.

There are several conditions that must be met before testing a sample: 1. The sample must have a flat shape of uniform thickness 2. The sample must not have any isolated holes 3. The sample must be homogeneous and isotropic 4. All four contacts must be located at the edges of the sample 5. The area of contact of any individual contact should be at least an order of magnitude smaller than the area of the entire sample (Van der Pauw).

As stated by the Van der Pauw Method: A Helmholtz coil was used to produce a consistent magnetic force for all tested samples. Each coil has 400 turns of copper wire and can power up to 1 amp of current to create a magnetic field. A Helmholtz coil was chosen because the magnetic force can be easily controlled and predicted when preforming simulations. Each sample was connected with alligator clips and centered between the coils prior to testing.

I. Screen Printing Methods Using screen-printing equipment, a Hall-Effect sensor can be printed on glass and then successfully measured to react when in contact with a magnetic force is hypothesis one (H1). Several initial experiments were conducted to test different substrates, inks, and mesh on traditional screens. The results helped to outline the final experiment levels that would produce a viable Hall-Effect sensor. Two sizes and three patterns (solid, diamond, and circle) were tested. The cross leg lengths are 3mm, and 6mm, resulting in sensors that are 9mm x 9mm and 18mm x 18mm wide respectively.

Gwent Group heat curable carbon ink (C2050425P1) was chosen for the Hall-Effect sensor because the characteristics resemble doped silicon electrical properties. The heat curable carbon ink has a sheet resistance of 120 Ί/sq., at a thickness of 25Οm (Gwent 2015). This yields a sheet resistance of 3x10-3 ohm meter per square inch of printed material. These data points were used along with graphite material properties to simulate the printed sensor. Graphite material properties were used in place of carbon properties to simulate the Hall

41

voltage because of the similarities between the materials. It was assumed that the graphite material would have similar properties to carbon material for simulation purposes.

Sensors were designed (see figure 3) and printed on several different types of substrates: paper, polyethylene terephthalate (PET), and coated and uncoated paperboard. For all sensors, the resistance was calculated and recorded using a power supply and digital multimeter. The sensor was initially tested with the use of a hand magnet for the Hall voltage differential. None of the first sensors provided any conclusive results. It is possible that the thickness of the ink and flexibility of the substrate impacted the results.

Figure 3: Designs for the screen-printed sensor. Similar designs for both screen-printing and flexo printing were chosen to test how the sensors react differently

Further trials show that the printed Hall-Effect sensor functions best with the lower ink thickness and a rigid substrate. Glass sheets were obtained and screen-printed with the solid cross shape to test again. The glass substrate was chosen to reduce the ink surface roughness and thickness. A 156 thread-per-inch (TPI) screen was used to print the carbon ink onto both acrylic and glass surfaces. After printing, the carbon material was heated in an oven for a recommended 30 minutes to remove non-conductive solvents. The Van der Pauw Method was first used to test the resistances of the samples before testing with a Helmholtz coil for the Hall-Effect. Finally the hole mobility and hole concentration were calculated and compared to the values of graphite that were previously stated (see table 1).

Findings

Van der Pauw Method

The screen-printed samples were connected to the power supply through two adjacent terminals, while measuring voltage in another two terminals. The results are shown in table 2. Note that the percent difference between testing of different leads is less than 3%, which conveys property value unit consistency in both ink thickness and cm 2 electron mobility 20 x 10 resistance across the printed sensor. v s

hole mobility

15 x 10

cm 2 vs

electron concentration

5 x 10

cm -3

hole concentration

5 x 10

cm -3

Table 1: Graphic material properties (Saada 2000).

42

The percentage difference shown in table 2 confirms that the samples were consistent and also fairly conductive. The resistance of all samples tested conveyed promising results for testing with the

Helmholtz coil. The samples were validated using the Van der Pauw Method, and then tested using the Helmholtz coil.

The hole mobility and hole concentration of the screen-printed carbon material deviated considerably I (mA) V (mV) R( ) from the graphite reference 1 -22.916 22.916 properties. Hall-Effect sim1 -23.072 23.072 ulations were repeated using 1 -22.14 22.14 the updated information. The 1 -22.632 22.632 samples were still tested using 1 -23.926 23.926 1 -23.637 23.637 a Helmholtz coil to test for 1 -23.825 23.825 any consistent reaction to a 1 -23.353 23.353 magnetic force.

Helmholtz Coil Test

Table 2: Resistance measurements on screen-printed cross design on glass using the Van der Pauw method. The first column (Configuration) refers to the terminals of the Hall sensor tested (see Figure 5). The last column shows the calculated percent difference between each terminal configuration.

Each sample was tested using a Helmholtz coil to reduce excess outside noise and unnecessary movement from the user. The coil was powered by 1 amp of power, while multiple configurations of the sample were tested. Results for the glass samples are shown in table 5.

The Hall-Effect voltage measurements were difficult to keep consistent. Every sample was prone to drift, in either the positive or negative direction. The glass samples showed less reaction to the magnetic force with each magnetic charge applied. It proved difficult to connect the samples accurately with alligator clips at the center of the Helmholtz coil. The samples scratch easily, which changed how the electrons move, causing an in-balance across the sensor. This is measured as a voltage-offset measurement, which should be kept as close to zero as possible. It was difficult to determine 1 if the offset variation was due to temperature, stress, or outside noise. To help reduce any issues caused by 4 2 connecting the samples, several attempts were made to achieve better contact with the printed sensor test.

Some of the solutions included using conductive copper tape, soldering tape to the edges of the sensors, 3 and applying conductive gel. None of the solutions Figure 5: Outline of the cross helped to connect the sensor with more accuracy. design with the numbering system used for the Van For future testing, a better method of interconnecder Pauw method and tion is needed for commercial applications. calculations.

Figure 5: Outline of the cross design with the numbering system used for the Van der Pauw method and calculations.

43

The resulting Hall voltage for the glass substrate samples was calculated for every configuration of leads (see table 5). The collected data points were also analyzed in JMP to be independent and normal (see table 4).

The Hall voltage calculated in table 3 was very inconsistent. These numbers convey that the sensor was not stable when measured. This could be due to temperature changes, inefficient interconnects, or inconsistencies of the ink itself. The sensor showed inconsistent measurements, and should not be considered concrete proof that the printed sensor works. The sensor did react to a magnetic force, but was not reliable and the reaction could not be predicted easily. It was thought that the unreliable connection was the main cause of the inconsistent readings (see figure 8).

II. Flexo Printing Methods Hypothesis two (H2) is using traditional Flexo printing technologies; a HallEffect sensor can be printed roll to roll (R2R) and then successfully measured to react when in contact with a magnetic force. A basic concept for the design was created and tested using a flexo proofer to find the optimal printing Figure 8: Damaged sensors from connection issues parameters. The design of a Hall-Effect sensor can be seen as a cross, with leg segments of 3mm and 6mm resulting in sensors that are 9mm x 9mm and 18mm x 18mm respectively. The patterns that were used during screen-printing testing were repeated (see figure 10).

Carbon ink, suitable for flexo printing was utilized for this experiment. Although not available to the public for commercial printing, the ink has a sheet resistivity of <35Ί per sq. The sensors were printed on polyethylene terephthalate (PET) material using a Mark Andy flexo printing press located in the Graphic Communication department at California Polytechnic State University (CPSU).

Two units were used on the press: one for the carbon ink and one for the silver traces added to the cross pattern for lead connections. DuPont Cyrel DFQ plates were produced at CPSU by the Graphic Communication Department. Steel doctor blades were used for both the carbon and silver inks. The carbon ink

44

Property

Estimated Value

Experimental Results

Unit

Hole mobility

15x103

279.4

Hole concentration

5x1018

118x1015

cm2 Vs cm-3

Sheet resistance

120

105

Resistivity

2.50x10 to 5.00x10-6 // basal plane 3.00x10-3 basal plane

/sq

1.89x10

-6

-3

m

Table 3: The hole mobility and hole concentration of graphite material compared to the results calculated from testing the screen-printed samples.

Table 4: Normal distribution of resistance for carbon samples printed on glass substrate

P(uV)

N(uV) VH(uV)

418

391

27

351

355

-4

-314

-354

40

-310

-356

46

Table 5: Hall voltage measurements when using the Helmholtz coil test setup. The first column refers to the terminals, which were used for measuring current. The second and third column refers to positive and negative fields applied, respectively. The last column represents Hall voltage for that particular configuration. The final Hall voltage for the glass samples was 13.6 ÎźV

45

was applied using two anilox rollers, 440/3.33 and 360/6.53. A 2^k factorial design analysis of the resistance data showed that the data are normal, and that most levels effect the resistance of the sensor (see table 8).

Findings

Van der Pauw Method

The Van der Pauw method was attempted to test for consistent resistances across the flexo printed sensor. The sensors were difficult to measure the resistance of just the carbon material because of the silver traces that were printed to connect to each leg of the cross. By placing the silver traces Figure 10: Designs for Flexo print at the edges of the carbon sensor the 5th con- experiment. Blue represents the silver ink printed, and black the dition of the Van der Pauw method is violated; carbon ink. see Related Literature for details on using the Van der Pauw method. The sensor also showed visible striations or scratches from the press direction during printing. These striations, or scratches, are a common challenge with roll-to-roll printing, as any defects from ink particles on transfer and idler rolls can show up in the printing. The striations are the main cause for the resistance of the sample to be unbalanced when measured using the Van der Pauw method. The flexo printed samples did not show an even ink thickness, nor as consistent resistance across the samples compared I (mA)

V (mV)

R( )

3

-1.802

600.82

3

-1.755

584.86

3

-1.77

590.01

3

-1.732

577.47

3

-2.052

684.12

3

-2.002

667.45

3

-2,034

678.93

3

-2.052

683.88

Table 6: Resistance measurements of flexo cross design on PET using the Van der Pauw method.

The first column (Configuration) refers to the terminals of the Hall sensor tested (see figure 5). The last column shows the calculated percent difference between each terminal configuration.

46

Property

Estimated Value

Hole mobility

15x10

279.4

8.86

Hole concentration

5x1018

118x1015

4.47x1018

Sheet resistance

120

105

105

Helmholtz Results Neodymium/Ag Results Unit

3

cm2 Vs cm-3 /sq

Table 7: The hole mobility and hole concentration of graphite material compared to the results calculated from testing the flexo printed samples.

Source

Analysis of Variance DF Sum of Squares Mean Square F Ratio Prob > F

Model Error C. Total

11 12 23

Source Nparm A B A*B C A*C B*C A*B*C

1 1 1 2 2 2 2

58.389746 1.925450 60.315196

5.30816 0.16045

33.0821 <.0001*

DF

Sum of Squares

F Ratio

Prob > F

1 1 1 2 2 2 2

2.686704 30.307537 0.001204 21.255908 1.333908 2.443075 0.361408

16.7444 188.8859 0.0075 66.2367 4.1567 7.6130 1.1262

0.0015* <.0001* 0.9324 <.0001* 0.0425* 0.0073* 0.3563

A = 3 mm (-1) 6mm (1) B = 440 anilox (-1) 360 anilox (1) C = Solid (-1) circle (0) square (1)

Table 8: Normalcy plot and P-values associated with the different levels from printing the sensor via flexo. Notice that the low P-values for A, B, C, A*C, and B*C convey a significant change in resistance when testing.

47

9 mm Ag Sensor/Hall Response at 5 mA 460 458 456 454 452 450 448

446 444 -800

-600

-400

-200

0

2004

00

6008

00

Table 9: Response from measuring the 9mm sensor printed on PET. This curve is an interesting response because it does not follow the predicted path of a Hall-Effect sensor. It clearly shows that there is an interaction between the magnetic force and the flexo printed sensor, however it is unclear how to interpret the results.

P(mV) N(mV) VH(mV) 150.092 156.806

-6.714

-149.982 -157.476

7.494

138.361

5.721

132.64

-145.978 -140.262

-5.716

Table 10: Hall voltage measurements when using the Helmholtz coil test setup. The first column refers to the terminals, which were used for measuring current. The second and third column refers to positive and negative fields applied, respectively. The last column represents Hall voltage for that particular configuration. The final Hall voltage for the PET samples was 98 ÎźV at 527 G.

48

to the screen-printed samples. This could be due to the flexo carbon ink used, the anilox roll, or the printing method. The Van der Pauw method was tested by removing the silver leads, and the results show a difference of less than 3%.

Notice that although there are visible press striations and uneven printing, the resistance of these sensors is much higher when compared to screen-printing.

It was decided to continue testing the samples even though the Van der Pauw conditions were not completely met by the samples.

Neodymium Magnet Tests

The flexo printed samples were first analyzed using JMP for levels that directly effect resistance. A 2k factorial design was conducted to test the sensors in several ways. Two sizes (3mm and 6mm), two anilox rollers, and three patterns were printed and then resistance tested using a digital multimeter. The data were also shown to be normal, equal variance, and independent. The results are shown in table 8.

Further testing the samples revealed immediately that the substrate of flexible PET proved too flexible to be effected by a magnetic force consistently.

By attaching the sensor to a more rigid substrate, the Hall-voltage showed promising results. Both the solid 3mm cross design and the 6mm design were chosen to test between two cube magnets. The other patterned samples were disregarded because of high resistance when testing for the Van der Pauw method and violation of condition 2. When the sensor was affixed to a rigid carrier, the magnetic force applied showed a significant and steady reaction by the printed sensor. This response was tested on over 50 flexo printed samples of the 3mm cross and 13 flexo printed samples of the 6mm. Only the 3mm sensor had a consistent reaction to the magnetic force, despite having a higher resistance than the screen-printed sensors.

Finally, the Hall voltage for the flexo printed PET samples was calculated (see table 10). Similar to the screen-printed sample, the sensor did react to a magnetic force, but not in an expected way. These data shows a much more consistent reaction to the magnetic force, but were still unpredictable. ď ˇ

49

Conclusions Printing a functional Hall-Effect sensor is possible. Whether the sensors can be produced for extended shelf life applications using these methods and materials is yet to be proven. The goal of this research is to show that traditional printing equipment using carbon ink can produce a Hall-effect sensor that does react when in the presence of a magnetic field. Flexo printing can greatly reduce the cost of producing a Hall-Effect sensor while increasing production because it is a R2R process. Flexo printing also delivers a thin ink thickness and can easily print other conductive traces in line with the carbon sensor. This is key for integrating the sensor into new products. Screen-printing provides a consistent ink coverage that allows the sensor to be controllable and easily measured. Sheetfed screen-printing also allows the sensor to be printed directly onto a ridged or stiff substrate, without needing to mounted after printing. This allows the use of glass, or acrylic material, which provides a smooth surface to create an evenly printed sensor. To determine an ideal printing process, the user first must define the goals for the project. The flexo sensors did show a consistent reaction to the magnetic force applied, however the results were not what was expected. The unique curve of data, seen in table 9, conveys that there is an interaction between the sensor and the magnetic force, however it is not a predictable or expected one. This could be due to the hole mobility being unstable in the tested carbon ink. Similarly the screen-printed sensors showed consistence resistances, yet were unable to achieve consistent results when tested with a magnetic force. There are many improvements that can be made for either producing the flexo printed sensor or the screen-printed sensor.

Both printing methods can be a valid way of producing the Hall-Effect sensor in the future, but both processes need some alterations to be more successful.

There are several needed improvements for flexo to improve the functionality and reliability of the sensor. For flexo printing, the image needs to have a more consistent ink thickness. First, using a larger anilox roller during printing, or using two units to print two layers of ink on top of each other may achieve this. Second, the sensor needs to rotate at a 45 degree bias to reduce the impact of printed striations that cause the sensor to be less effective. Third, an in-line process to mount the sensors on a rigid surface should be introduced after printing to keep the process R2R. For screen-printing the sensors, continued use of glass or acrylic for the main substrate is recommended. The main improvement for using screen-printing for Hall-Effect sensor production is to discover a better way to connect the

50

leads to the sample. The methods used for testing proved too damaging to the sensor for long term testing or usage. Discovering a better way to connect conductive material to each leg of the cross design will greatly improve the performance of the screen-printed sensor. Screen-printing the sensors is a slower process than printing R2R, however the benefits of printing directly onto a glass substrate will create a more stable sensor.

51

References D. Saada (2000, June 22). Diamond and Graphite Properties. Retrieved June 6, 2016 from http://phycomp.technion.ac.il/~david/thesis/node3.html.

Gwent Group (2015, May). Curable Carbon Ink. Retrieved March 10, 2016.

Hanks, A. (n.d.). Magnetic Fields of Coils. Retrieved June 9, 2016, from http://course1. winona.edu/fotto/physics222/labs/Lab_10_HH_Coils.pdf Matveev, V. , Levashov, V. , Kononenko, O. , Matveev, D. , Kasumov, Y. , et al. (2015).

Hall effect sensors on the basis of carbon material. Materials Letters, 158, 384-387.

Paun, M. , Sallese, J. , & Kayal, M. (2013). Hall effect sensors design, integration and

behavior analysis. Journal of Sensor and Actuator Networks, 2(1), 85-97.

Ramsden, Edward (2011). Hall-Effect Sensors. ProQuest ebrary. Chapter 1.

Retrieved April 20, 2016.

Sun, Jian, Kosel, JĂźrgen (2012). Finite-Element Modelling and Analysis of Hall Effect and

Extraordinary Magnetoresistance. New Trends and Developments. Chapter 10.

Retrieved February 10, 2016, from http://www.intechopen.com/books/finite element-analysis-new-trends-and-developments/finite-element-modelling-and analysis-of-hall-effect-and-extraordinary-magnetoresistance-effect Thurber, R. W. (n.d.). I. Introduction. Retrieved March 10, 2016, from http://www. nist.gov/pml/div683/hall_intro.cfm Van der Pauw method. (n.d.). Retrieved May 03, 2016, from https://en.wikipedia.org/wiki/ Van_der_Pauw_method Woodford, C. (2015, April 21). Hall-effect sensors. Retrieved March 10, 2016, from http:// www.explainthatstuff.com/hall-effect-sensors.html

52

Lucas Bryce Tran Beatty Bryce is a Cal Poly Graphic Communication alumni, as well as a graduate from the Printed Electronics program. She enjoyed teaching lab classes in the Graphic Communication field and getting to know both the students and faculty. She currently lives in Madison, Wisconsin and works for a digital printing start-up, ePac LLC.

53

54

55

Patterned Photonic Curing of Copper Oxide Inks Using Metal Masks

Tyler Weseman

Abstract Copper ink is an effective, low-cost alternative to silver or gold ink in printed electronics applications. However, commercial inks quickly oxidize and become non conductive. By curing the oxidized copper ink, which involves using short, intense bursts of ultraviolet light, it is possible to reduce the oxidation, return copper to a conductive state, and make it more resistant to future oxidation. By only curing certain sections, it is possible to pattern specific traces by utilizing the uncured copper oxide as an effective dielectric, preventing traces from crossing or shorting. Utilizing a specificallydesigned metal mask, it was possible to cure two traces as close as 76 microns apart without any shorting.

56

Introduction Cost reduction is an integral part of any industry, including printed electronics.

Copper ink has long been considered as a cost-saving replacement for silver ink in printed traces, with the main drawback being the fact that copper ink quickly oxidizes and becomes non-conductive. Photonic curing has been shown to cause a reduction of oxidation, and make copper conductive again, while also protecting the ink from reoxidizing. In this process, ultraviolet light rapidly heats up the copper oxide ink, activating the reduction agent present in the ink, and allowing the remaining copper to bond together into a conductive copper film.

This leads to the purpose of this experiment — using photonic curing to create patterns on a layer of copper oxide ink to determine the viability of photonic curing as an innovative production method in the field of printed electronics.

This was done primarily by testing how different factors impacted the reduction of copper oxide ink, and how small of a feature size could be obtained through the use of photonic curing using specially crafted metal masks.

Related Literature This experiment was based on a previous research project conducted by Kang et al., titled “Direct Intense Pulsed Light Sintering of Inkjet-Printed Copper Oxide Layers within Six Milliseconds.” In this experiment, Kang et al. demonstrated “intense pulsed light (IPL) sintering of inkjet-printed CuO layers” (Kang, 2014, p. 1). Using this process, Kang et al. were able to sinter copper oxide inks in under a second on PET, while traditional sintering methods took hundreds of times longer and could not be used with thermally fragile substrates. This experiment was designed to expand upon that research, to see if the patterning process, which is normally separate from sintering, could be combined into a single step, and to see if unreduced copper oxide could still be useful as a dielectric.

Use of copper ink, in spite all of its drawbacks, instead of silver or gold is primarily about lowering costs. It has been reported on average, “one ounce of gold and silver costs about $1100 and $17, whereas one ounce of copper and nickel are about 20 cents and 53 cents, respectively” (Park, 2014, p. 1). Moreover, copper demonstrates the best conductivity values (Bell, 2016). It is easier to formulate it for inks as well, due to its ductility. Using copper as the base material and further developing it into its more conductive state would be a viable option.

When analyzing Copper [II] Oxide under magnification, the presence of oxygen increases the number of large-sized pores, contributing to high resistance.

57

Even if those oxygen atoms were removed under normal room conditions, the ink will remain to function as an insulator. Only through sintering can the bonds between the copper atoms form, shrinking the size and the number of the pores (Paglia, 2015).

Traditional sintering involves high temperatures and long heating times, which is detrimental in processes involving thermally fragile substrates, such as paper or PET. By utilizing short, intense bursts of ultraviolet light, it is possible to quickly raise the temperature of the metallic nanoparticles without affecting the substrate it is printed on (Schroder, 2006, p. 1). This process activates the reduction agent present in the copper oxide ink, removing the oxygen from the copper and leaving behind a conductive copper film. The reduction agent used in NovaCentrixâ&#x20AC;&#x2122;s Metalon ICI-021 Copper Oxide ink is proprietary, and the information is not readily available. H2 is used as a common reduction agent and, when activated, would cause the following reaction: Cu2O + H2 g Cu2 + H2O. While information on the reducing agent used in the Novacentrix ink is not available, one can assume a similar reaction occurs resulting in the reduction of copper metal and an oxide molecule, likely in a vapor form.

Methods and Materials For this experiment, the material used was NovaCentrix Metalon ICI - 021 Cu(II)O ink. This material was selected as it is similar to the material used in the research conducted by Kang et al. and because it was a readily obtainable, commercially available copper oxide ink. The mask used was made from nickel using a laser engraving process by MET Associates. The substrate used was Arjowiggins Powercoat brand coated paper, 129 g/m2, 8.5x11â&#x20AC;? in size. This was used as it was specifically designed for use in printed electronics, and the smooth coating allowed for an even ink film thickness.

The samples were produced on an ATMA screen printing press using two separate screens, one with a 90 line screen, and one with a 156 line screen, then dried in an oven set to 900 degrees F. This was done to determine if the ink film thickness had an effect on the conductivity and/or the minimum viable width between cured traces. The samples printed with a 90 line screen had an ink film thickness of 50 microns, while the samples printed with a 156 line screen had an ink film thickness of 29 microns. The samples printed were large, solid rectangular patterns of copper oxide ink. 15 prints were made with each line

58

screen. 8 prints of each line screen were used as makeready, with a total of 7 samples of each line screen used for testing.

The samples were then photonically cured on a NovaCentrix Pulseforge 1200, covered with the metal mask with the design shown in Figure 2. The Pulseforge was set to 400 V, and released light in one main pulse at 400 nanoseconds and four micropulses at 150 nanoseconds, each pulse separated by 250 nanoseconds. The mask was made from a laser-etched nickel sheet at 0.005 inches thick. The metal mask blocked ultraviolet light from affecting most of the copper oxide ink, except for the areas under the laser-etched mask gaps. The revealed areas are Figure 2: The mask design. Black areas are metal, white subjected to high-frequency pulses of areas are laser etched gaps. ultraviolet light which removes the oxidation from the copper, making those areas conductive again. Once all of the samples were cured, the samples were tested for three main factors - resistance across individual traces, sheet resistance of each sample, and shorts between the large squares.

After the samples were tested, the resistance of each trace was recorded, and separated by ink film thickness, width of trace, and length of trace. Each group of traces of one ink film thickness was compared to those of the same length/ width on the other line screen using one-way analysis of variance, or ANOVA. This was used to see if there is any statistically significant difference between the resistance of cured traces based on ink film thickness differences related to line screen of the screen used. In addition, the sheet resistance of each sample was tested using a four-point probe, and compared using one-way ANOVA. The hypotheses being tested is that different ink film thicknesses will have different resistances across traces of the same length and width.

The large squares were cured in such a way as to test the minimum possible distance between two cured traces that would still properly isolate. The squares on the mask were separated by bars of varying widths as seen in figure 3, to a minimum of 76 microns. This was the minimum possible width that a bar could be etched into a metal mask by the mask supplier. The metal bar would,

59

if successful, block ultraviolet light from electrically connecting the two squares together, and the uncured copper oxide would act as an effective dielectric to prevent squares from shorting.

Findings and Results The NovaCentrix Pulseforge 1200 secures metal masks to the samples via magnets to the sides of the curing dock. Since the metal mask was so thin, the magnets only secured the sides, and caused the mask to bend towards the center, allowing light to flood under the bars, exposing areas of the samples that were meant to remain unexposed. This was likely caused by the fact that the NovaCentrix Pulseforge 1200 has a parabolic reflector as part of the ultraviolet light source, which equalizes and focuses the energy across a large area, but causes a majority of the light to strike the samples at an angle. This caused more light to strike under the bent mask, resulting in shorts between the traces. This was remedied by using additional metal sheets made from a thicker, more rigid material holding the entire testing mask and sample down, curing a small section of the sample, then moving the sheet and repeating the process until the entire sample was properly cured.

The maskâ&#x20AC;&#x2122;s interaction with parabolically reflected light also caused a problem when curing the thin traces. Since the gaps are in the mask are both narrow and did not come perfectly into contact with the sample, much of the light did not strike the ink, resulting in low or no oxidation reduction. Out of all of the samples cured, only one resulted in an adequate trace produced by the 1mm wide mask gap, with a resistance of 2.7 ohms. On the same sample, the trace produced by the 0.8mm wide mask gap also showed some conductivity, but with a resistance of 3.4 Kohms, likely caused by minor pinholes in the trace.

Figure 3: Square gaps cut into the mask, separated by bars of varying widths; from left to right, the widths are 200 microns, 150 microns, 100 microns, and 76 microns.

60

Due to the issues caused by the mask deformation or lack of intimate contact with the printed copper oxide, an accurate comparison of various line lengths and widths between samples produced with differing ink film thicknesses was unobtainable.

Therefore, data were collected based on the resistance of the squares that were used to test for conductivity across narrow lines of unreduced copper oxide. The resistance was tested from the top left corner to the

bottom right corner of each of the eight squares on each sample, and the overall conductivity of the sample was recorded based on the average of those eight tests. The results were then compared between the two different thread mesh counts using one way ANOVA. A one-way ANOVA was completed on the two sets. Based on the ANOVA of the resistance of each sample, there is no evidence to suggest that a different ink film thickness has an effect on the conductivity of cured copper traces. Based on a total of 14 samples, both ink film thicknesses produced an average resistance of 643 mOhms across the trace, giving a P-Value of 1.0. The main difference between the two sample groups was that the 90 line screen samples had a larger variance than those of the 156 line screen group.

A four-point probe was used to measure sheet resistance of the two sample sets.

An ANOVA of the sheet resistance showed that there is sufficient evidence to conclude a difference in sheet resistance between the sample printed with a 90 line screen and those with a 156 line screen, at a 95% confidence level (P = 0.0385). Based on the data collected, the samples printed with a 156 line screen, which produced a thinner ink film thickness, had a lower overall sheet resistance.

When testing for conductivity between large squares, the samples produced by both the 156 line screen and the 90 line screen maintained an unbroken barrier between the two cured sections at the smallest tested width of 76 microns.

This occurred with high consistency across all samples, with only two samples showing any conductivity between the squares, both occurrences resulting from the mask moving or otherwise insufficiently contacting the sample. ď ˇ

61

Oneway Analysis of Resistance By Thread Mesh Count

Thread Mesh Count Error C. Total

0.9 0.8

Sheet Resistance

DF

Source

Analysis of Variance Sum of Squares Mean Square

1

0.000000

0.000000

12 13

0.19428571 0.19428571

0.016190

0.7

Prob > F

0.0000

1.0000

Tests that the Variances are Equal

0.6

0.15

90

0.10

Std Dev

0.5 150 Thread Mesh Count

0.05 0.00 90

Oneway Anova Rsquare Adj Rsquare Root Mean Square Error Mean of Response Observations (or Sum Wgts)

0.000000 -0.08333 0.127242 0.642857 14.000000 t Test

156-90 Assuming equal variances 0.000000.0 6801 -0.14819 -0.14819 0.95

t Ratio DF Prob > | t | Prob > t Prob < t

0 12 1.0000 0.5000 0.5000

Level

Count

Std Dev

MeanAbsDif to Mean

MeanAbsDif to Median

7 7

0.1618347 0.0786796

0.1346939 0.0612245

0.1285714 0.0428571

90 156

Test O’Brien [.5] Brown-Forsythe Levene Bartlett F Test 2-Sided

-0.1

0.00

0.1

DF Num 1 1 1 1 6

F Ratio 3.2301 3.3750 5.5227 2.6609 4.2308

p-Value 0.0975 0.0911 0.0367 0.1028 0.1027

DF Den 12 12 12 6

Welch’s Test Welch Anova testing Means Equal, allowing Std Devs Not Equal DFNum 1

F Ratio 0.0000

-0.2

156 Thread Mesh Count

Summary of Fit

Difference Std Err Dif Upper CL Dif Lower CL Dif Confidence

F Ratio

DFDen 8.6863

Prob > F 1.0000

t Test 0.0000

0.2

Figure 5: The analysis of variance of resistances.

Oneway Analysis of Sheet Resistance by Thread Mesh Count 0.25

Thread Mesh Count Error C. Total

0.225 Sheet Resistance

DF

Source

0.2

Analysis of Variance Sum of Squares Mean Square

1

0.00638579

0.006386

12 13

0.01419857 0.02058436

0.001183

Prob > F

5.3970

0.0385*

Means for Oneway Anova

0.175 Level

0.15

90 156

0.125 0.1

90

Count

Mean

Std Error

Lower 95%

Prob > F

7 7

0.201571 0.158857

0.01300 0.01300

0.17324 0.13053

0.22990 0.18718

Std Error uses a pooled estimate of error variance

150 Thread Mesh Count

Tests that the Variances are Equal

Summary of Fit Rsquare Adj Rsquare Root Mean Square Error Mean of Response Observations (or Sum Wgts)

0.310225 0.252744 0.034398 0.180214 14.000000

Std Dev

Oneway Anova

0.05 0.04 0.03 0.02 0.01 0.00

90

156 Thread Mesh Count

Count

Std Dev

MeanAbsDif to Mean

MeanAbsDif to Median

7 7

0.0176244 0.0453410

0.0146531 0.0352653

0.0144286 0.0335714

t Test Level

156-90 Assuming equal variances Difference Std Err Dif Upper CL Dif Lower CL Dif Confidence

F Ratio

-0.04271 0.01839 -0.00265 -0.08277 0.95

t Ratio DF Prob > | t | Prob > t Prob < t

-2.32314 12 0.0385* 0.9807 0.0193v*

90 156

Test O’Brien [.5] Brown-Forsythe Levene Bartlett F Test 2-Sided

F Ratio 3.0622 2.6294 4.4722 4.3476 6.6184

DF Num 1 1 1 1 6

DF Den 12 12 12 6

p-Value 0.1056 0.1309 0.0561 0.0371* 0.0368*

Welch’s Test Welch Anova testing Means Equal, allowing Std Devs Not Equal -0.06

-0.02

0.00

0.02

0.06

F Ratio 5.3970

DFNum 1

DFDen 7.7727

Figure 6: The analysis of variance of the sheet resistance.

62

Prob > F 0.0496*

t Test 2.3231

Conclusion Based on the results obtained in this experiment, it appears that photonic curing could be used as a viable production method of producing electronics using copper oxide ink for larger feature sizes such as 100 micron gaps and 1 mm traces. A feature size of 76 microns was obtained using a specially-formed metal mask, and at that size, the unreduced copper oxide ink consistently acted as an effective dielectric, preventing any shorts from occurring between the two exposed, cured traces.

The results of the sheet resistance analysis were unexpected. Since both ink film thicknesses produced the same amount of resistance on average and the ink film thickness of both groups of samples is quite low, the sheet resistances should have been the same as well. This may be related to the fact that the calculation for sheet resistance made by a four point probe assumes a nominal ink film thickness. Since the ink film thicknesses for each set of samples was different, that may have altered the results.

The inability to create intimate contact between the mask limited the ability to get finer features. The problems that arose with the mask bending at the center could have been resolved by distributing the gripping magnets across the entire sample dock, instead of just the sides.

A collimated light source may also aid in greater fidelity in reducing small features in the copper oxide ink. Further research should be done involving photonic curing using collimated light instead of parabolically reflected light.

Since collimated light travels in a straight line, it would be able to strike the samples precisely through the gaps etched into the metal mask. Lasers use a collimated light source, providing a more accurate and directed curing process over a smaller area. With accurate laser sintering technology, it may be possible to reduce the feature size even further, getting the conductive traces even closer together while still maintaining an unbroken barrier of dielectric copper oxide ink, as well as creating thin and effective traces. Additionally, the technology behind shaping the metal masks could be improved to design a thinner metal mask with an even smaller feature size.

63

References Bell, T. [2016]. Copper Applications. Retrieved March 11, 2016, from http://metals.about.

com/od/properties/a/Copper-Applications.htm. About.com, 2016 Das, R. (October 15, 2009). The Game Changer From NovaCentrix: Copper Oxide Ink.

Printed Electronics World. Retrieved June 6, 2016.

Das, R. SEM image of copper oxide ink [Online Image]. Retrieved June 6, 2016 from http://www.printedelectronicsworld.com/articles/1765/the-game-changer-from novacentrix-copper-oxide-ink Dharmadasa, R., Jha, M., Amos, D., & Druffel, T. (November 27, 2013). Room

Temperature Synthesis of a Copper Ink for the Intense Pulsed Light Sintering of

Conductive Copper Films. ACS Applied Materials & Interfaces.

Retrieved June 6, 2016.

Kang, H., Sowade, E., & Baumann, R. R. [2014]. Direct Intense Pulsed Light Sintering of

Inkjet-Printed Copper Oxide Layers within Six Milliseconds. ACS Applied

Materials & Interfaces. Retrieved June 6, 2016.

Kim, Y., Lee, B., Yang, S., Byun, I., Jeong, I., & Cho, S., (2011). Use of copper ink for

fabricating conductive electrodes and RFID antenna tags by screen printing.

Science Direct. Retrieved June 6, 2016.

Lee, B., Kim, Y., Yang, S., Jeong, I., & Moon, J. (2009). A low-cure-temperature copper

nano ink for highly conductive printed electrodes. Science Direct.

Retrieved June 6, 2016.

Paglia, F., Vak, D., Embden, J. V., Chesman, A. S., Martucci, A., Jasieniak, J. J., &

Gaspera, E. D. (2015). Photonic Sintering of Copper Through the Controlled

Reduction of Printed CuO Nanocrystals. ACS Applied Materials & Interfaces.

Retrieved June 6, 2016.

Park, B., Kim, D., Jeong, S., Moon, J., & Kim, J. (2007). Direct writing of copper

conductive patterns by ink-jet printing. Science Direct. Retrieved June 6, 2016.

Park, S., Chung, W., & Kim, H. [2014]. Temperature changes of copper nanoparticle ink

during flash light sintering. Journal of Materials Processing Technology, 214[11],

2730-2738. Retrieved March 11, 2016.

Schroder, K., McCool, S., & Furlan, W. (2006). Broadcast Photonic Curing of Metallic

Nanoparticle Films. NSTI-Nanotech. Retrieved from http://www.novacentrix.

com/sites/default/files/pdf/Schroder-NSTI-2006.pdf on June 6, 2016.

64

Tyler Weseman Tyler grew up in San Diego, California. He graduated from Cal Poly with a Bachelor of Science in Graphic Communication in June of 2013 and then returned for his Masters in Printed Electronics in 2015. He currently works as a print estimator for Oâ&#x20AC;&#x2122;Neil Data Systems in Los Angeles. Outside of his work, he enjoys playing video games, reading, and exploring.

65

66

67

A â&#x20AC;&#x153;Learn by Doingâ&#x20AC;?

Case Study Awarded first place for the Phoenix Challenge College (PCC) competition, a year long, problem-solving team project which culminates in a formal presentation to a panel of industry judges at the annual FTA Forum. The intent of the PCC is to engage college-level students in creatively solving a current, industry-relevant flexographic problem which would allow them to practice and showcase their research, problem solving, design, and print production skills. The goal is to inspire academic programs to grow and improve their level of instruction and research.

The Cal Poly Phoenix Challenge Team

Message from the Project Advisor Cal Poly’s motto is “Learn by Doing”. Students are expected to not only learn and be assessed on materials, but apply that knowledge and think critically in a variety of project based learning environments. The Phoenix Challenge competition project at Cal Poly is Learn by Doing defined.

Students work on real-life projects with actual clients, create relationships with the supply chain in the flexographic industry, conduct market research, in addition to designing, preparing files, printing and executing a packaging job from scratch. They present their findings to a panel of industry professionals and must be prepared for very scrutinizing questions.

This project counts as Cal Poly Graphic Communication senior project, and the level of effort, rigor, and achievement (Learn by Doing) is amazing.

The students are self motivated: they learn technology, software, color management, how to run a press, and estimate budgets for real-world production.

More than 10 Universities from the US and Canada compete in this challenge each year, and the bar is continuously raised. From a personal perspective, this yearlong project is lots of blood, sweat, and tears; but some of the most satisfying engagement takes place when all the students from the different universities meet each other, compete — and by the end of the competition are friends.

Colleen Twomey Assistant Professor, Phoenix Challenge Advisor

Letter from the Editor This is an abridged version of the original document, and therefore is not what the Cal Poly Phoenix Challenge team sent to the board last year.

However, this document was rewritten in collaboration with the team with the help of one of our faculty advisors, Dr. Xiaoying Rong, in order to describe the team’s process in a more technical aspect, and to better fit the format and theme of this journal.

Jacqui Luis Editor

68

Chapter 1: The Scope of the Project This project was to rebrand and repackage a startup company. The team chose a local family-owned startup B.R.A.T. Diet Drink.

The B.R.A.T. Diet Drink (an acronym that stands for Bananas, Rice, Applesauce, and Toast) is a diet regimen often recommended by doctors for individuals experiencing stomach flu or other digestive related discomfort.

The combination of nutrients offered by the diet is effective because these foods are “binding foods”. This means they are “low-fiber foods that can make stool firmer” and “replace nutrients [the] body has lost because of vomiting or diarrhea” (B.R.A.T. Diet: Recovering From an Upset Stomach, 2011).

The founders of the company, Greg and Ilsa Toepfer, began developing the official B.R.A.T. Diet Drink formula with the help of food scientists. The result of their efforts was a rehydrating beverage that is organic, kosher, and free of most allergens. By 2009, B.R.A.T. DIET LLC was established.

Original, vanilla, and chocolate flavored B.R.A.T. Diet Drink entered the market in 2010. However, the product faced tough competition from large corporations including Abbott Laboratories (makers of Pedialyte® and Ensure®) and PepsiCo (makers of Gatorade®).

This project included a redesigned logo, two new forms of packaging, a P.O.P. (point-of-purchase) display, and an interactive app. Printing of the mockups was done in Cal Poly’s Flexo Lab. The team also collaborated with Pacific Southwest Container (PSC) for POP production.

With this project, the team entered the Phoenix Challenge accomplished the following goals: • Apply design and print technical knowledge to an emerging brand • Investigate market trends and competition, while researching industry packaging regulations, for a food product • Engineer innovative packaging and interactivity to create a competitive edge for our client • Design eye-catching graphics that follow both FIRST Specifications and standard design principles • Collaborate with flexographic print professionals to execute our products to industry production standards

69

Chapter 2: Market Research Competitors on the Market The team overviewed the related products on the market in four different aspects: • • • •

Structure of the package Packaging and branding of similar products Overall design Structural and conceptual impact on purchase decision

The focus of the market research was in the following concepts: • How purchase decisions are made for the target audience of children and parents • How important point of purchase display (POP) is to making purchase decision • The need for individual and large serving options • How to implement retort pouch or innovative juice pouch (individual serving) • Unique plastic bottle (large serving) as a valid option for this particular product • The benefits of implementing tactile inks • Attracting the target audience with an interactive game and glow in the dark inks • Exploring beacon technology and its impact on purchasing decision at retail stores • Using QR codes as a virtual tool to engage the target market • Creating a billboard effect at retail stores The team used two common market research tools to clarify the position B.R.A.T. on the market. A strengths, weaknesses, opportunities and threats analysis (Figure 1) showed that B.R.A.T. is a special product that will benefit the consumers who have specific allergies. The product uses more natural ingredients compared to its competitors. The perceptual map (Figure 2) showed that B.R.A.T. was perceived as a higher quality product with a relatively lower price. These two analyses helped the team to design the package and determine the market position of the product.

70

Strengths Organic, Vegan, Soy and Gluten-free, Rehydration drink, Soothes and Nourishes, Pediatrician Recommended.

Threats Abbott Laboratories owns several of the nutritional diet drinks, as well other medical products.

Large competition with pricing.

Weaknesses Lack of funding, Not yet established, Branding does not stand out, Competing with large brands, Product is only in one retailer

Opportunities Only a few companies are in nutritional electrolyte drink market.

Benefits consumers who have specific allergies.

Figure 1: SWOT analysis

High Quality

High Price

Low Price

Low Quality

Figure 2: Perceptual Map

71

Market Demand An online survey to parents and adults was conducted to better understand the purchasing decisions of the potential target market; and pinpoint what packaging, graphics, and interactivity would resonate best with this audience.

Of the 82 individuals surveyed via Cal Poly Parent Facebook Page (a venue specifically created for all parents of Cal Poly students), 58.54% responded that they were the Mother of the household while the others indicated Decline to State (24.39%), Father (15.85%) and Guardian (1.22%) (Figure 3). From the same group of respondents, 71.95% stated that they were the primary shopper in the household.

Figure 3: Primary Household Shoppers

58.54%

24.39%

15.85%

1.22%

Mother

Decline to State

Father

Guardian

When asked which aisle of the grocery (or other store) they shop in when sick, the majority of responses were the “medicinal” or “pharmaceutical” aisles. A majority of survey respondents had children within the ages of four to eight years, in addition to college age children as old as twenty-two. Using demographic information provided by B.R.A.T., it was noted that the main purchasers of B.R.A.T. products are most often female caregivers. B.R.A.T. positioned their company to “directly target households with children between the ages of one and ten” (“B.R.A.T. Diet Drink Marketing Plan”, 2012).

When asked which major retailer they were most likely to purchase health products, respondents reported CVS (41.25%), Target (27.5%), Rite Aid (16.25%), Walmart (8.75%), and Walgreens (6.25%). In the past, B.R.A.T. Diet Drink was sold in several different retail stores, but later reported a major decrease in sales. This drop in sales was possibly a result of their move to an alternative retailer, CVS, and that the product design did not stand out from other major competitors. With this information, the market demand

72

for this product was oriented toward drug stores due to their large volumes of health and nutrition products.

When asked to rank the factors that would influence their purchasing decision, survey respondents listed the following factors in order from most compelling to least: doctor recommendation, product quality, brand recognition, and package design. From this ranking, the team decided that the graphic designs needed to focus on a medicinal look with all of the nutritional benefits as the key selling points.

Using Cal Poly’s ASI Children’s Center as a survey population, the team presented groups of 4-6 year old boys and girls with juice boxes and juice pouches with different designs. The children were asked about their preference between juice box or juice pouch. Based on the survey, 44% of the children preferred a juice box whereas 56% preferred the juice pouch. Although it was not by a large majority, more children preferred the juice pouch to the juice box. The Tetra Wedge Aseptic, which the team ultimately chose, serves as a perfect medium between both a pouch and juice box.

In the past, the only packaging for all B.R.A.T. flavors was a 32 fluid oz.

Tetra Brik Aseptic™ package. Tetra Pak served as a co-packer for B.R.A.T. products, manufacturing the packaging, processing the product through filling lines, then transporting the finished products to retailers. One of the main benefits of using a Tetra Pak Brik Aseptic was the support of B.R.A.T. shelf-life and the longevity of its ingredients (brown rice, banana puree, apple puree), which were all products that have a minimal shelf-life once the Tetra Pak packaging is opened, giving the product 7-10 day shelf-life.

The Tetra Pak Brik Aseptic is an innovative type of packaging for liquid products. It includes a polyethylene layer for moisture protection, aluminum foil to protect against oxygen and light absorption, and paperboard for stability, strength, and a smooth printing surface. The Tetra Pak Brik Aseptic is an advanced type of package for the beverage industry. However, the cost per unit of the Tetra Pak Brik Aseptic was too expensive for B.R.A.T. at USD $1.23 each (filled). After running a cost analysis, the team’s strategic decision was to move to the smaller Tetra Pak Wedge Aseptic.

73

This packaging transition allowed the product to implement a single serve option in addition to the larger serving option the B.R.A.T. currently offers, thereby increasing their marketing mix.

The team made a choice for B.R.A.T. to take on a new package; a shrink sleeve form 16 oz. high-density polyethylene (HDPE) natural, square bottle.

The 16 oz. shrink sleeve package would serve as the large serving option for B.R.A.T. fans. The Tetra Wedge Aseptic (6.5 fluid ounce) would serve as the company’s single-serve package offering.

Chapter 3: Research on Rebranding The previous branding strategy was toward a childcentric target market.

However, B.R.A.T. Diet wanted their brand to appeal to parents for its nutritional value. Although the previous survey conveyed all of the facts and benefits, the design was overwhelming and cluttered. Their color palette consisted strictly of vibrant primary colors. Their logo was formed from a messy handwritten typeface that mimicked a young child’s handwriting.

In addition, the logo incorporated a silhouette of an ambiguous building resembling either a school or hospital. Their purpose of the building’s placement was to showcase the product’s target market while simultaneously conveying the drink’s medicinal benefits. Unfortunately, because the previous design had an unnecessary large quantity of text, an abstract logo, and a limited selection of portion sizes, it discouraged many consumers from buying this nutritional product.

Product Logo Redesign In addition to the packaging choices, the children at the ASI Children’s Center were also presented with two sets of designs to choose from, composed of three different color choices per set. The two designs were the circle logo and the bar logo (Figure 4).

Figure 4: Two logo design concepts for surveying

74

The circle logo color choices were black, orange/black, and orange/blue, while the bar logos came in orange, red, and blue. The children were asked which logos and colors they preferred.

Results indicated that the children were more accepting of the bar logo due to the softer presence it evokes. One of the female respondents stated that she “liked the rounded edges and it looks happier.” Children were more attracted to the bar logo that had a single solid color rather than multiple colors within the logo. The team then decided focus the design on solid colors to reinforce design simplicity.

Furthermore, 4-6 year olds rated the more colorful designs as more favorable than the less colorful alternatives.

Out of the three color choices for the circle logo (black, orange/black, orange/blue), three-quarters of the children preferred the orange/blue while the remaining quarter preferred the orange/black. None of the participants preferred the solid black color scheme. Out of the three color choices for the bar logo (orange, red, blue), a majority of the children chose blue (56%), while others chose red (25%) and orange (19%). Based on these results, the team concluded that children prefer vibrant color combinations, also noting that a large majority preferred blue. Since blue is a color that resonates more within the medicinal industry, the redesigned logo used blue as the primary color for B.R.A.T.’s product line.

Choice of Logo Type It was important to redesign the logo to be clean and memorable, but enticing for a children-target market.

The font selected was Avenir, for the name of the product, a sans-serif appeals to a larger demographic. However, the new logo also included a secondary handwritten font, Enduratize, to incorporate the child-like essence and appeal.

The periods in B.R.A.T. proved to be unattractive and unbalanced in many of the design sketches. However, keeping the logo as “B.R.A.T.” without the periods, would give a negative and misleading connotation to the product. The problem was solved by enclosing the name with the periods in a rectangular box with rounded corners.

75

To further convey the nature of the product, graphics were used above the letters to blatantly display what each letter stood for: bananas, rice, applesauce, and toast. Though the B.R.A.T. diet is universally known in the medical field, it is not as known to the public. The team considered this incorporation of the graphics would aid consumers in associating the drink with the original diet.

Redefined Spot Color Children are drawn to vibrant colors. Their visual senses are still forming, they are unable to fully identify varying shades in colors and prefer bright, vivid hues. This concept was implemented in the original design to utilize bright primary colors. Unfortunately, the orginial design was not effective in stores and B.R.A.T. product sales did not accurately reflect the concept.

For cost purposes, it was important that the rebrand didn’t use more colors than the original branding (4 colors). Accordingly, the redesign mock up was processed with varying replications of a primary color palette. However, the redesigned logos that used primary colors were receiving little positive impact on prospective consumers after presented to the target audience.

Since B.R.A.T. is pediatrician recommended and is often encouraged as a medical treatment, the change in the redesign would reflect this aspect of the product. The finalized redesign logo used a bright teal—a tone that acknowledged children’s visual senses while also being a tone of “medical blue” that established trust in the consumers.

The finalized redesign color palette was Pantone 121C, as the vanilla flavor identifier, Pantone 732C as the chocolate flavor identifier, and Pantone 7459C, as the main color. Incorporating only three main colors in all the redesigns helped establish a successful brand recognition among all the products as well as decrease the number of different inks used to print the product.

Figure 5: Finalized redesigned logo incorporating color palette, font and illustrations as discussed

B. R. A. T.

Feels good. Tastes better.

76

Chapter 4: Execution of Various Packaging Forms There were four different redesigned packaging forms associated with B.R.A.T. products, which included a Tetra Pak Wedge, a plastic bottle with a shrink sleeve label, a carrier tray and a POP display. The overall goal was to meet the needs of the target audience, stand out from the competition using various design elements, provide the consumer with confidence in the product and create emotional connection with the product.

Tetra Pak Wedge Aseptic The Tetra Wedge Aseptic, also known as the Tetra Wedge, is an “aseptic carton package [that] provides [companies] with a great billboard for promoting [their] brand” while “its lightweight board keeps food safe and fresh for a long time” (TetraPak Wedge Aseptic website). The Tetra Wedge’s triangular shape and slim profile, combined with its rigid, multi-layer structure, would provide the best features of both juice pouches and juice boxes to be an innovative package that would help the B.R.A.T. Diet Drink standout from the competing products.

The Tetra Wedge has the same structural make-up as the Tetra Pak Brik, the package used by the original products, and would give the B.R.A.T. Diet Drink the same trusted protection at a lower cost. Like the Tetra Pak Brik, the Tetra Wedge uses a multilayer structure, including a polyethylene layer for moisture protection, paperboard for stability and strength as well as for a smooth printing surface, and aluminum foil to protect against oxygen and light absorption. Producing the Tetra Pak Wedge Aseptic would be overall more cost efficient for the redesigned product line, and allow them to produce both an individual and larger serving option.

Furthermore, since B.R.A.T. Diet Drink had an established relationship with Tetra Pak packaging, B.R.A.T. would simply replace their original large package Tetra Pak Brik to the smaller solution of the Tetra Wedge. Another benefit of working with Tetra Pak packaging for B.R.A.T. Diet Drink was the ability of co-packing. Co-packing enables B.R.A.T. Diet Drink more flexibility since production is all in house, reducing any production stress onto B.R.A.T.. Since B.R.A.T. Diet Drink is a startup, the manufacturing process must be as simple as possible making the Tetra Pak packaging a great solution. Essentially, this was convenient for B.R.A.T. due to the fact that Tetra Pak is an all inclusive co-packing manufacturer, limiting the need to resource the filling and packaging to other third-party manufacturers.

77

With the Tetra Pak Wedge, photoluminescent (aka glow-in-the-dark) ink was used to provide an interactive game for children drinking B.R.A.T. from the wedge. A case study from the journal Young Consumers showed that packaging can have an influence on a child’s preferences (Ike-Elechi & Johnson, 2010). From that point, a child can influence the parent’s purchase decision. Oftentimes the child’s “pestering” is to buy unhealthy foods high in fat, salt, and sugar. Since B.R.A.T. is a healthier product, parents may be more inclined to listen to their child’s pestering and make a purchase.

Another article from the peer reviewed Qualitative Market Research explores “personally meaningful packaging-related experiences” (Ryynänen, Joutsela, & Heinonen, 2016). Some packaging elicits a sense of nostalgia. The use of a glow-in-the-dark ink could be an opportunity to create a lasting memory in the minds of children drinking B.R.A.T. This memory could resonate later in life, and an adult who had B.R.A.T. as a child may search for the drink later in life.

Kurt Hudson, Global Director Digital Printing, Director of Strategic Accounts and System Partner Relationships of Actega WIT assisted the team with the choice of anilox roll cell volume for printing the photoluminescent ink. The UV inks used were photoluminescent and pearlescent OPV. Kurt advised the team to use the deepest anilox volume possible in order to transfer the highest amount of ink.

The Tetra Wedge format was printed on white coated one side (C1S) paperboard. In order to get the most vibrant colors to appeal to the children, the image files were set up with reverse type principles. Knocked out, trapped text, and graphics followed FIRST specifications. The design of the photoluminescent and OPV interactivity was crafted to be at an unexpected location on the packaging and provided a slight challenge for the children.

Placing the OPV on the sides of the wedge enabled the use of the full real estate of the product package, as well as obtain the brightest contrast for the photoluminescent ink.

The C1S paperboard used for the Wedges, is recyclable as well as nonhazardous for the environment. The majority of the inks used for printing are water-based. The recyclability of the Wedge prototype was a huge part of the brand promise for B.R.A.T., a sustainable and health diet drink alternative that upholds their motto of “Tastes Good, Feels Better.”

78

The goal for the new wedge packaging was to create an innovative structural design that not only provides single serve options but also be fun and interactive for children. The wedge-shaped stand up carton would provide a stronger shelf presence and the ability to act against the competitors of B.R.A.T. Digital proofs were made to set a standard of L*a*b* values to control the quality of flexo printed Tetra Wedges. In Cal Polyâ&#x20AC;&#x2122;s Flexo Pressroom, an Epson 9800 inkjet large format printer was used for accurate digital proofing. The proofs were used for other redesigned packaging forms during production printing. The printed results were qualitatively compared with the proof to make sure good quality of color reproduction.

The Wedge itself was created from a design standard from Tetra Pak. The original B.R.A.T. drinks used the larger Tetra Pak carton. The transition to the wedge format would strengthen the relationship between B.R.A.T. and the Tetra Pak brand and ease the transition from the new prototype to full scale production. This single serve concept was new to B.R.A.T., and by partnering with a company that specializes in single serve, it is promising to ensure success in the medicinal beverage market.

The substrate used for the wedges is a C1S 10 point Avery Dennison paperboard. The biggest challenge in printing the Tetra Wedge was registering the photoluminescent inks, which are colorless during application. An LED blacklight was used to assist registration and ink coverage to the designerâ&#x20AC;&#x2122;s specification. The Graphic Communication Department at Cal Poly does not have Aseptic forming and filling capabilities, so the team hand-laminated and assembled the Tetra Wedge prototypes. A 5 mil PET/EVA film was laminated to the surface, using a roll laminator. This emulated the look and feel of a Tetra Wedge, and also avoided any potential cracking in the paperboard during wedge forming. The inside of the wedge was adhered to a metalized BOPP (biaxially-oriented polypropylene) after printing to protect the beverage from contacting any inks or coatings that may set off onto the inside of the wedge, as well as other barrier properties BOPP provides. After the laminations of PET/EVA and BOPP to the printer paperboard, the Esko Kongsberg i-Cut table was used to cut and score according to the printed register marks. The team then manually assemble the wedges as mockups.

79

Unit 1: PMS 121C Unit 2: PMS 732 C Unit 3: PMS 7459 C RAD Glow UV UV Curing Station

Figure 6: The configuration of the press setting for printing the wedge

INKS

PLATES

•

DuPont DFM (medium durometer)

•

0.067" thick

•

0.023” - 0.025" relief

•

RIP: 4,000 dpi

•

10 series sticky back (3M)

• • • •

ANILOX • Station 1: PMS 121C, Anilo x Roll #6, 600 line count, Vol = 2.24, Angle = 60 • Station 2 : PMS 732C, Anilo x Roll #3, 800 line count, Vol = 1.62, Angle = 60 • Station 3 : PMS 7459C, Anilo x Roll #4, 800 line count, Vol = 1.99, Angle = 60 • Station 4 : RadGlow, Anilo x Roll #12, 140 line count, Vol = 12.-, Angle = 60

Figure 7: Wedge prototyping conditions

80

PMS 121C (Yellow) : Viscosity 21.5 sec with #3 Zahn, pH 9. 4 PMS 732C (Brown) : Viscosity 23 sec with #3 Zahn, pH 9. 3 PMS 7459C (Blue) : Viscosity 24 sec with #3 Zahn, pH 9. 3 RadGlow UV ink : cosity 45 sec with #3 Zahn, pH N/A

Vis-

The water-based PMS colored inks were donated by Flint Group The UV photoluminescent ink was donated by ActegaWIT

SUBSTRATES

Figure 8: Finalized wedge design

To the left is the summary of prototyping conditions while producing the wedge (Figure 7).

The finalized Tetra Pak Wedge package provided: • • • •

Unique shape for a drink container — ­ ergonomic Interactive and engaging for children Individual portion servings Medicinal yet attractive graphics and structure

Carrier Tray For B.R.A.T. Diet Drink’s individual serving option, the Tetra Wedge needed a carrier that could hold multiple wedges not only for shipping purposes, but for consumer preference as well. After finalizing the wedge dimensions, a paperboard tray was engineered to hold four Tetra Pak Wedges in a curved arrangement. For finishing with tray filling, each of the four wedges were glued to each other with a small amount of adhesive to prevent possible shifting during shrinking wrapping and transportation. Once the wedges were assembled, arranged, and glued in sets of four, they were shrink wrapped into the 10-point paperboard carrier tray. The purpose of shrink wrapping

81

Unit 3: PMS 7459 C Unit DVP Silver Pearlescent OPV UV Curing Station

Figure 9: The configuration of the press setting for printing the carrier trays

INKS

PLATES •

DuPont DFM (medium durometer)

•

0.067" thick

•

0.023” - 0.025" relief

•

RIP: 4,000 dpi

•

10 series sticky back (3M)

• •

PMS 7459C (Blue) : Viscosity 24 sec with #3 Zahn, pH 9. 1 DVP Silver Pearlesc ent (OPV) : Viscosity 2 min 36 sec with #3 Zahn, pH 5. 0

The water-based PMS colored inks were donated by Flint Group ANILOX

• Station 3: PMS 7459C, Anilo x Roll #4, 800 line count, Vol = 1.99, Angle = 60 • Station 6 : Pearlesc ent OPV, Harper 12 Anilox Roll, 140 line c ount , Vol = 12, Angle = 60

Figure 10: Carrier tray prototyping conditions

82

SUBSTRATES

• Avery Dennison 10p t C1S paperboar d

Figure 11: Prototype for carrier trays

was so that the consumer would still have the ability to see the design of the product which was considered as one of the key selling points. The billboard effect can still be receptive with the carrier tray as well. When stacked next to each other on the POP display, the carrier tray helped illustrate a billboard effect to further strengthen the B.R.A.T. brand recognition.

In order to offer consistent branding to the consumers of B.R.A.T., the design of the carrier tray and the Tetra Wedge are highly similar. The tray was designed using PMS 7459C to keep the product versatile for any flavor, and included the use of a pearlescent OPV. The OPV was set to overprint over a 50% line screen tint in the design. The team was very cautious when placing the QR code on the tray to ensure that the pearlescent OPV would not be near the QR code. While the OPV offers excellent rub resistance, it also has a reflective surface and may affect the scannability of the QR code had it been overprinted.

To the left is the summary of prototyping conditions while producing the carrier tray (Figure 10).

83

The finalized carrier tray provided: • Aesthetically pleasing 4-pack carrier targeted toward children • Functional QR code for customer interaction and brand/identity building HDPE Bottle with Shrink Wrap Label The reason for the change from the original 32 ounce Tetra Pak Brik to a 16 ounce high density polyethylene (HDPE) bottle with a shrink sleeve was due to the fact that B.R.A.T. Diet Drink is in an obligatory contract with Tetra Pak packaging for co-packing. This contract limited B.R.A.T. Diet Drink to only a few options for packaging alternatives. Not only did the contract limit B.R.A.T. Diet Drink’s packaging options, but the pricing was no longer feasible for B.R.A.T. Diet Drink if switched to other packaging types other than Tetra Pak. The team suggested that the shrink wrap with HDPE bottle could be the low cost solution for bigger volume packaging. It is well known that the growth of shrink sleeve packaging is on the rise due to the 360° graphic opportunity on the containers, the ability to apply tamper-evident packaging, and the low cost compared to other traditional packages.

The price per unit for the shrink sleeve plastic bottle was drastically less expensive than the Tetra Pak Brik option. However, another reasoning behind the alternative shrink sleeve method was that B.R.A.T. Diet Drink has the alternative of using any retailer of their choosing. B.R.A.T. Diet Drink is a small, family owned business, so having a plethora of packaging manufacturer options was highly sought after. Also, the owners of B.R.A.T. Diet Drink wanted to have the option of visiting the manufacturer for quality checks of their products. Local packaging manufacturers offers plastic bottle manufacturing and product filling were ideal.

Industry professionals guided the team through the process of prototyping the shrink wrap. A 3D scan of mockup bottle was provided by Sun Chemical and the Esko DeskPak plug-ins for Adobe Illustrator was used to view the designs rendered on a realistic bottle. Designing for shrink sleeves called for understanding the “behavior of the shrink sleeve production process” and “pre-distorting the artwork to compensate for production” (Stitzel, S., 2010). Understanding this importance, the file was set to reverse print and accounted for “no text” and high distortion zones.

A quick test on Cal Poly’s 7” press revealed that the orientation of distortion from the shrink film was opposite of the press in the lab. The press width was

84

not sufficient to cover the full body of the bottle as the orientation of the film shrunk in the vertical direction as opposed to the horizontal direction that the press was capable of handling. The size of the product did not fit with the orientation of the press.

Edwards Label and AmeriSeal—companies who specialize in shrink sleeve production located near Cal Poly­— educated the team in following layflat standards (prepress specific design standards for shrink), considered high distortion and no text zones, paid attention to the seals and seams of the sleeve, and avoided any text or graphics on the corners of the bottles.

Edwards Label is within a 3 hours drive of B.R.A.T., and has 30 years experience in the label industry. Edwards was gracious enough to donate their press time and consumables to produce the actual bottle labels so that the shrink sleeve could be applied onto the HDPE bottles as the mock up by the team.

Before the press run at Edwards Label, the same file was run in the lab using the Polyethylene Terephthalate shrink material from Avery Dennison, as well as PMS 121C (yellow) and PMS 7459C (blue), with an opaque white. It was a reverse-print job. Yellow was put down first, followed by blue, finally opaque white. It was an extreme challenge to maintain registration on this very thin material. The tension was minimized, and stations were skipped to allow for better drying by used blowers, but no heat was used. Several team members visually approved registration before and after the opaque white was put down during press run.

In conceptualizing this product, a single-serve wedge option for B.R.A.T. was targeted toward the adult market. A bottle was the most mature packaging solution for adults (as opposed to the wedge for children). It would give consumers a larger, resealable option. One of the biggest concerns with this product was the opacity of the bottle itself. The product may deteriorate rapidly with continued exposure to UV light, so it is very important that the product be sheltered as much as possible. Using a shrink sleeve for B.R.A.T. Diet Drink was a reasonable choice for product integrity. Shrink sleeves using an opaque white ink can block UV light which can affect nutrients and vitamins of the product in addition to taste (Connor, D., 2004).

At the time of processing the project, it was difficult for the team to obtain a 16-oz opaque white bottle. So the team decided to pursue a full shrink sleeve

85

around a semi-opaque, natural HDPE (high density polyethylene) plastic bottle for added UV protection as well as high density-to-polymer strength ratio for additional structural stability. Since a clear shrink material was used, it needed to print a primary layer of opaque white on the labels to prevent excessive light from filtering through the transparent inks on top. The newly designed sleeve covers more surface area of the bottle than a simple label would, and the full shrink around the cap allows for a tamper-evident seal.

An IL440 (International Light meter), was used to measure the UV light transmission difference with the HDPE bottle and the printed shrink in the photopolymer plate exposure unit. The UV intensity of the exposure unit with warm bulbs is 20 milliwatts/cm2. The UV transmission through the bottle with shrink wrap sleeve dropped to 11 milliwatts/cm2. It proved that the shrink wrap sleeve with white opaque ink dropped the UV transmittance in half.

Along with the design of a shrink wrapped label, the team also developed an interactive online community for those enduring chemotherapy or related treatments and disorders that impact their diets. The purpose of the blog was to create an outlet of discussion on a personal and helpful level.

B.R.A.T. is a clean, organic, and simple diet that is frequently recommended as a meal supplement for chemotherapy patients. Because chemotherapy generally causes side effects of nausea, vomiting, and stomach irritation, the soothing properties of B.R.A.T. Diet Drink benefit patients during their treatment and recovery period.

The blog is responsive and mobile compatible so it is easily accessible on a phone. This way, when the patients are waiting and/or receiving treatment, they have a selection of updated inspirational and relatable content readily available. In addition, users can share their positive experiences. Each blog post allows users to post comments and ask questions. These user experiences add value to the product while also providing B.R.A.T. insights for product development (Kelleher & Helkkula, 2010).

By hosting a blog, B.R.A.T. has a means of communication between themselves and consumers. This communication helps the company to establish a relationship and build trust with their customers.

Blogging also gives B.R.A.T. an opportunity to collect data through a program such as Google Analytics. Analytics are essential to all businesses

86

Original

Redesign

Figure 12: Finalized redesigned website with blog

and are especially useful for young companies. By tracking blog analytics, B.R.A.T. could measure information about viewer locations and search queries that led viewers to the site. This data also would help B.R.A.T. to assess their digital marketing strategy and decide what content draws the most attention.

This blog is accessible by a QR code placed on the shrink-wrapped bottle and on the tray housing the Tetra Wedges.

It was important to establish a complete multi-channel marketing plan. The website carried the same redesigned color palette, graphics, and new slogan in order to provide cohesion with their productâ&#x20AC;&#x2122;s marketing. The website was created using HTML, CSS, and JavaScript.

The next page reads summary of prototyping conditions while producing the HDPE bottle and shrink wrap sleeve.

Unit 1: PMS 121C Unit 3: PMS 7459 C Unit 5: Opaque White

Figure 13: The configuration of the press setting for printing the shrink wrap label

87

INKS

PLATES •

DuPont DFM (medium durometer)

•

0.067" thick

•

0.023” - 0.025" relief

•

RIP: 4,000 dpi

•

10 series sticky back (3M)

• • •

ANILOX

PMS 121C (Yellow) : Viscosity 21.5 sec with #3 Zahn, pH 9. 4 PMS 7459C (Blue) : Viscosity 24 sec with #3 Zahn, pH 9. 3 Opaque White Viscosity 55 sec with #3 Zahn, pH 9. 1

The water-based PMS colored inks were donated by Flint Group

• Station 1: PMS 121C, Anilo x Roll #6, 600 line count, Vol = 2.24 BCM • Station 3 : PMS 7459C Anilo x Roll #3 , 400 line count, Vol = 1.99, BCM

SUBSTRATES

• Station 5 : Opaque White Anilox Roll #5, 360 line count, Vol = 6.53, BCM

Figure 14: Shrink wrap label prototyping conditions

The finalized HDPE bottle with shrink wrap label provides: • • • •

88

Larger, mature-look, and resealable Shrink sleeve and opaque white layer for UV protection Tamper-evident shrink seal “Banner effect” on panels

Figure 15: Finalized HDPE bottle with shrink wrap label

Point of Purchase Display Point of purchase (POP) displays have steadily developed to become a popular marketing tool for retailers seeking a value-added packaging display solution. According to a POPAI 2014 Mass Merchant Study (Point of Purchase Advertising International), 82% of consumer purchases are made in store (2014). The whole move behind POP displays comes from years of statistical analysis comparing the increase in sales of product to the implementation of highly attractive and innovative displays that showcase a productâ&#x20AC;&#x2122;s functionality, aesthetics, and highlights the brand promise.

The POP display could also be very cost effective for the product because there is no additional fee for floor space from retailers B.R.A.T is contracted with. Since B.R.A.T. is a startup, capital had to be utilized as efficiently as possible. With no additional cost needed for floor space, a POP would not only give B.R.A.T. products a competitive advantage, but it would also be within B.R.A.T.â&#x20AC;&#x2122;s budgetary needs.

89

By creating a POP display for the retail stores, B.R.A.T. would be able to further expand their products, market, and brand as well as display in the retailer aisles giving B.R.A.T. Diet Drink an upward advantage against its competitors. The main goal for this project was to ensure the competitive capability against brands like Pedialyte and Ella’s Kitchen by reaching the consumer before they walk down the medicinal aisle—and see the other competitive brands. Essentially, the POP would act as an eye-catching, instore billboard, as well as an additional structure to hold B.R.A.T. Diet Drink products—which would positively increase B.R.A.T.’s sales.

The POP display could also be very cost effective for the product because there is no additional fee for floor space from retailers that B.R.A.T is contracted with. With no additional cost needed for floor space, a POP would not only give B.R.A.T. products a competitive advantage, but also be within B.R.A.T.’s budgetary needs.

Moreover, based on a KDM POP Solutions Group study, the “merchandising and point of purchase displays can provide an emotional connection with the shoppers” (Del, 2014). Since B.R.A.T.’s target market is focused on sick children and their parents who purchase their products, the emotional connection that B.R.A.T. tries to convey was crucial to the startup’s branding effort. This emotional attachment to the product and the mission of B.R.A.T. Diet Drink would be present when consumers view the newly rebranded B.R.A.T. Diet Drink products.

The POP display would be highly effective in giving the family-owned B.R.A.T. Diet Drink a chance to compete evenly with other well known nutritional drinks.

When designing the POP display for B.R.A.T., three aspects for a successful product display were incorporated, which include: • aesthetically pleasing principles and interactivity from the youth demographic • scientifically proven facts on the B.R.A.T diet • a call to action in store coupons through Beacon technology for the adult demographic The POP was designed in collaboration with Nicole Hermann from Pacific Southwest Containers (PSC) . Pacific Southwest Container (PSC) is one of

90

the largest packaging companies on the West Coast, with multiple offices located throughout the Central Valley of California. The back panel of the POP houses the primary text element of the B.R.A.T. logo, and the front panel has scalloped edges that contain the graphic visuals from the logo.

The side panels were printed with a 100% and 50% tint and contain text that prompts consumers to download the B.R.A.T. app and read about the product through the newly developed multichannel marketing strategies.

To make this information stand out, the design used knocked out text and trapped following FIRST specifications for B-flute corrugated material over a 50 line screen tint. Cal Polyâ&#x20AC;&#x2122;s Flexo Lab does not have large format plate making technology. Sun Graphics, a division of Sun Chemical, made the plates for the POP display. Pacific Southwest Containers (PSC) printed the POP. Though Sun Chemical and PSC assisted with the production of the POP, the prepress and design was a team effort. Team members were on press for the production run at PSC to ensure colors were matched.

During the initial prototyping process for the POP display, an E-Flute corrugated board was used to get a rough estimation of the final production size. The display itself needed to have shelves for the 4-wedge packs as well as the 16oz bottles, which posed a very difficult structuring challenge. The team collaborated with Cal Polyâ&#x20AC;&#x2122;s Industrial Technology Department to develop a solution to house both of the products while maintaining the redesigned theme of the brand.

Implementing Cal Polyâ&#x20AC;&#x2122;s Learn by Doing philosophy, the team created the files for prepress output , and worked alongside Sun Graphics, a division of Sun Chemical, to make the premounts for the print run for the large format plates. With the additional assistance from a structural designer from the PSC Modesto location, a scaled-down dieline and a more structurally sound dieline were developed. The design team was able to successfully generate artwork for a full scale, B-flute corrugated structure that can hold roughly twenty bottles and of forty-eight wedges for the entire display.

The team and PSC worked together to ensure that the POP was printed based on the target L*a*b* values. The visit to PSC was a knowledgeable experience in collecting manufacturing data and cost information to be conveyed to B.R.A.T. for a potential extension of their products to a company that specializes in corrugated converting and printing.

91

Figure 16: POP prototyping conditions

In a growing technologically-dependent age, consumer expectations change according to technological trends. More often than not, tech-savvy consumers expect increased interactivity between themselves and a brand. A new trend to fulfill this growing expectation is Bluetooth Low Energy (BLE) interactivity. Bluetooth Low Energy “is an emerging low-power wireless technology developed for short-range control and monitoring applications” and can be used in conjunction with Bluetooth beacons located in products stores to communicate with consumers about the brand (Gomez, C., Oller, J., & Paradells, J., 2012).

As a startup, B.R.A.T. would greatly benefit from the investment in a BLE marketing campaign. The main purchasers of B.R.A.T. products are parents and caregivers. Since tech-savvy Millennials are starting families, implementing a technologically-interactive element to B.R.A.T.’s in-store presence would be successful. This was further supported by the fact that beacon and proximity marketing already reaches not only 15% of US Millennials, but more importantly, 38% of US Millennial moms as well (Kaplan, D., 2015). These facts, combined with the importance of customer loyalty programs described previously, would all position B.R.A.T. for success with implementing a BLE marketing campaign.

92

Below is the summary of prototyping conditions while producing the POP display.

INKS

PLATES •

• •

DuPont corrugated solvent processed plates, mounted to a 10 point mylar backing and 10 point foam underpacking 0.125" thickness, ~0.075" relief 4,000 dpi RIP

ANILOX

• •

• •

PMS 121 (Yellow) : 23 seconds with #3 Zahn, pH 9.3 PMS 7459 (Blue) : 25 seconds with #3 Zahn, pH 9.1

SUBSTRATES

Station 1: PMS 121, Apex 480 lpi, Vol = 8.0, Angle = 60 Station 2: PMS 7459, Apex 480 lpi, Vol = 8.0, Angle - 60

Figure 17: POP prototyping conditions

In dealing with the larger scale production of B.R.A.T.’s startup, the team has been looking into environmental initiatives that B.R.A.T. could include in their marketing initiative. For the Point of Purchase display, the current initiative for printers and packaging converters is to follow a “cradle to cradle” mentality for the life cycle of a corrugated product (Corrugated Packaging Life Cycle, 2014).

The POP display designed for this project was made with corrugated B-flute which is 100% recyclable and compostable. The water-based inks are sustainable and easily recyclable, and the corrugated structure is also compostable for supermarkets and convenience stores that have their own methods for composting.

93

The finalized POP display stand provided: • • • •

Sturdy B-flute interior Easy-assemble for wide variety of supermarkets Consistent branding between Wedge and Shrink Sleeve Implementation of Internet of Things technology - Beacon BLE

Chapter 5: Financial Impact The team evaluated the financial probability of the redesigned packaging forums for B.R.A.T. Below shows the return on investment of four packaging forms: • • • •

4,800 Tetra Wedges: $1857.60 USD ($0.39/unit) 1,200 Carrier Trays: $1644.00 USD ($1.37/unit) 2,100 Shrink Sleeve Bottles: $2310 USD ($1.10/unit) 100 POP Displays: $2357.69 USD ($23.58/unit)

A complete financial spreadsheet was created including start up costs, cost per unit, print specification pricing for commercial runs, overall return on investment, and a sample job ticket highlighting the complete cost of rebranding and product implementation. This process was calculated for several different run sizes to accommodate B.R.A.T.’s start-up budget.

Figure 18: Finalized redesigned POP

94

Chapter 6: Distribution Feasibility B.R.A.T.â&#x20AC;&#x2122;s current contract with Tetra Pak allowed for a smooth transition from the Tetra Brik Slim to the Tetra Wedge Aseptic. Athough the new wedge differs in size and shape, the manufacturing and distribution workflow should remain approximately the same. B.R.A.T.â&#x20AC;&#x2122;s Tetra Pak contractor in Denton, Texas prints the Tetra Wedge Aseptic packages, then ships to a co-packer, where the wedges are formed, products are filled, and sealed. After packing, the products are either shipped to stores directly, or the customer picks up the product from the co-packer. As far as product integrity throughout shipment, the wedges have a laminate on the surface of the package that will prevent excessive scuffing or damage associated with package-to-package contact in transit. As well, the wedges will be shrink wrapped in groups of four that will provide an extra layer of scuff prevention.

For the shrink sleeve, there are a handful of companies along the central coast that offer printing and shrink all under one roof. However, it will be more difficult to find a company that will print, shrink, fill, and seal all in one location. B.R.A.T. may need to investigate for the most cost-effective approach. In the shipment process, the square structure of the bottle will produce a highly space-efficient (and cost-efficient) formation within boxes and ultimately pallets. The bottles will be packed in a compact manner to prevent excessive movement and rubbing. Since the labels are reverse-printed, the inks are not prone to scuffing.

The POP Display would need to be shipped flat to stores in order to prevent severe damage to the structure and save on truck space and shipping costs.

The press company would create a die that is large enough to produce the POP in a few pieces to allow for quick assembly in stores, as well as ease of packing in transit.

95

References B.R.A.T. Diet Drink Marketing Plan [PDF]. (2012, March 17). San Luis Obispo, CA BRAT diet: Recovering from an upset stomach. (2011, February). Retrieved from http://familydoctor.org/familydoctor/en/prevention-wellness/food nutrition/weight-loss/brat-diet-recovering-from-an-upset-stomach.html Connor, D. (2004, March 5). The Harmful Effects of UV Light Exposure. Retrieved

from http://www.packaging-gateway.com/features/feature16/ Corrugated Packaging Life Cycle Assessment Summary Report [PDF]. (2014).

Del, M. (2014, February 28). Why Effective POP is More Important than Ever.

Retrieved January 30, 2016, from http://www.kdmpop.com/2014/02 Why-Effective-POP-is-More-Important-than-Ever.cfm Gomez, C., Oller, J., & Paradells, J. (2012). Overview and evaluation of bluetooth low

energy: An emerging low-power wireless technology. (Basel,

Switzerland), 12(9), 11734–11753. http://doi.org/10.3390/s120911734 Kaplan, D. (2015, November 24). Beacons, proximity marketing to drive $7.5 billion

in Millennials’ holiday shopping. Retrieved from http://www geomarketing.com/beacons-proximity-marketing-to-drive-7-5-billion-in millennials-holiday-shopping Kelleher, C. , & Helkkula, A. (2010). Virtually speaking-customer to customer

communication in blogs. Journal of Applied Management and

Entrepreneurship, 15(3), 4.

Krey, M. (n.d.). 2014 Mass merchant shopper engagement study: In-store decision

rate (POPAI research insights) | POPAI: The Global Association for

Marketing at Retail. Retrieved February 27, 2016, from http://www.popai com/industry-news-blog/2014-mass-merchant-shopper-engagement study-in-store-decision-rate-popai-research-insights Ryynänen, T. , Joutsela, M. , & Heinonen, V. (2016). My grandfather kept one of

these tins on top of the bookshelf: Consumers’ recalled experiences

involving packaging. Qualitative Market Research, 19(1), 4-26. http://find lib.calpoly.edu/articles/record?id=FETCH-LOGICAL-c1230-6c57690ae9dc 78831f4adfe050729a785f5b9b69a30d81d29015986091173360 Stitzel, S. (2010). Shrinking the Challenges of Shrink Sleeve Package Design [PDF].

FLEXO Magazine.

96

The Cal Poly Phoenix Team From left to right: Professor Colleen Twomey, LeeAnne Morris, Aislinn Bryan, Natalie Jones, Lindsay Mitchell, Isabella Baldwin, Hannah Giorgi, Reina Stephenson, Nick Azevedo

97

98

Meet the Team

Not pictured

Minna Friedlander, Amber Huang, Jorge CarreĂąo, Megan Le, Kalea Louie

executives

Mayra Mejía

Jacqui Luis

Chapter President

Vice-President & Treasurer

Mayra Mejía is a fourth year student studying Graphic Communication and concentrating in Web & Digital Media. Over the last four years, she has worked as a Learning Assistant and Mentor for Cal Poly’s Summer Institute program and currently works for Cal Poly’s Dean of Students Marketing Team as a Web & Print Designer. She originates from a small town called Lodi and is very family-oriented.

During her free time, she enjoys being active outdoors, dancing, listening to Latin music, and trying new ethnic foods.

Jacqui Luis is a fourth year student studying Graphic Communication and concentrating in Web & Digital Media with a minor in Media Arts and Technologies.

She is expected to graduate the winter of 2017. She is involved with start-up companies at the Cal Poly Center for Innovation and Entrepreneurship and is the Event and Experience Coordinator for Cal Poly’s annual hackathon. She expresses her deep passion for print as the vice president of TAGA and as a graphic designer for the on-campus newspaper Mustang News.

99

executives

Amanda Ornelas

100

Jasper Lim

Production Coordinator

Design Coordinator

Amanda Ornelas is a fourth year Graphic Communication student with a concentration in Graphics for Packaging. She will be graduating in June, 2017. Amanda grew up in Torrance, California, and resides there during the summers away from Cal Poly. Amanda aspires to use her degree to work in the print and packaging industry.

She is currently a Resident Advisor for college freshmen living in the Liberal Arts residence hall and is a leader and mentor to freshmen and other Graphic Communication majors like herself.

Jasper Lim is a second year student majoring in Graphic Communication, double-concentrating in Web & Digital Media and Digital Reproduction Technology. With an interest in the intersection of technology and design, he looks for opportunities to apply his programming and design skills. Jasper holds a mindset of philanthropy and hopes to test and build his skills while improving the lives of others through aesthetic innovation.

Molly McCarthy

Alan Nguyen

Molly McCarthy is a second year Graphic Communication student concentrating in Web & Digital Media. She grew up in a small town in Vermont. She decided to come out to California to attend Cal Poly and experience life on the west coast. Molly enjoys a wide variety of activities including hiking, line dancing, and going to the beach. She intends to deepen her understanding of the print industry during her time at Cal Poly and is interested in the new technologies developing in the field.

Alan Nguyen is a second year Liberal and Engineering Studies student concentrating in Computer Science and minoring in Graphic Communication. He is originally from Denver, Colorado, but currently lives in Garden Grove, California. In his spare time, he enjoys drinking tea and reading books.

He also has a passion for technology and loves learning new material, from software to coding. He believes that new innovations in technology are the key to a progressing future.

Marketing Coordinator

Digital Coordinator

101

marketing

Left to right

Taryn Veldusea, Grace Khieu, Michelle Kramer, Ovie Clum

digital

From left to right

Danica Liang, Ross van der Wal, Jessica Rose

design

From left to right

Julia Graupensberger, Natalie De Golia, Diane Hahn, Steven Nguyen, Kristen Nagamatsu, Rose Chang, Hanna Trejo

From left to right

Seena Salehian, Kayla Kim, Joy Wang, Jessica Wei, Ryan Hutson, Jocelyn Tam, Ashley Chen

106 Colophon

This journal was produced entirely by the TAGA student chapter within the Graphic Communication (GrC) Department at California Polytechnic State University, San Luis Obispo. All design, print production, binding, and finishing work was completed in on-campus facilities.

Design This journal was designed using Adobe InDesign, Illustrator, and Photoshop CC. The typefaces used were Adobe Garamond Pro, Kollektif, and Montserrat.

Production All work was done under the guidance of Graphic Communication professors Brian Lawler, Colleen Twomey, Lorraine Donegan, Peter Schlosser and Dr. Xiaoying Rong. Files were printed using EFI’s Fiery Command Workstation.

The cover was printed digitally and done in-house using the GrC Department’s Xerox c800 press. Students worked on the press with help from University Graphic Systems General Manager, Meg Fukamaki. The cover stock used was Verso 100 lb. Sterling Premium Matte.

The journal’s text was produced on the Graphic Communication Department’s Konica Minolta bizhub C1100. The text stock used was Verso 80 lb.

Futura Matte.

Finishing The journal was bound using a Mueller Martini Amigo 1580 perfect binder with help from the Graphic Communication Department’s Electro-Mechanical Technician Robyn Burns. Sheets were cut to size on the Polar 92X Cutter.

The foil emboss on the case slips was completed using the Heidelberg Windmill press.

Electronic Publication The Cal Poly TAGA website (calpoly-taga.com) was coded using Adobe Dreamweaver CC.

107

108 Thank You

Acknowledgments The 2016–2017 Cal Poly TAGA Student Chapter would like to thank the following people for their help and generous contributions:

Cal Poly Graphic Communication Department, specifically: Professor Brian Lawler, Co-Chapter Advisor Professor Peter Schlosser, Co-Chapter Advisor Dr. Ken Macro, Department Chair Dr. Xiaoying Rong Professor Lorraine Donegan Professor Colleen Twomey Eric Johnson Robyn Burns

University Graphic Systems, specifically: Meg Fukamaki, General Manager

Sponsors & Supporters Brian Lawler Dr. Frank Romano Graphic Communication Alumni Chapter Jim Kersten — Diversify Labeling Solutions Jim Niemiec — Verso Corporation Paul Cousineau — Dow Jones

109

110

111