Comsol Case Studies Simulating Printhead Unimorph Actuators at FUJIFILM Dimatix
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Simulating Printhead Unimorph Actuators at FUJIFILM Dimatix

Comsol
Analytics & Modeling - Predictive Analytics
Analytics & Modeling - Digital Twin / Simulation
Electronics
Consumer Goods
Product Research & Development
Quality Assurance
Predictive Maintenance
Digital Twin
Process Control & Optimization
Software Design & Engineering Services
System Integration
The primary challenge faced by FUJIFILM Dimatix was to design unimorph diaphragm actuators for their newest ink deposition products. These actuators needed to be miniaturized to reduce costs while maximizing deflection and matching the actuator's impedance to the flow channels and nozzle. The goal was to generate a droplet meeting a target mass at a given velocity with a target maximum firing frequency for the available voltage. The complexity of the design required a deep understanding of the interactions between the piezoelectric materials and the surrounding components, necessitating a robust simulation approach to optimize the design parameters.
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FUJIFILM Dimatix is a leading producer of commercial inkjet printheads, known for their high-performance and innovative solutions in the printing industry. Their products are used in a wide range of applications, from commercial packaging and wide-format graphics to textiles and electronic applications. The company is committed to advancing inkjet technology and has a strong focus on research and development to maintain its competitive edge. By leveraging advanced simulation tools, FUJIFILM Dimatix aims to enhance the performance and efficiency of their printhead actuators, ensuring high-quality printing solutions for their diverse customer base.
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To address the challenge, FUJIFILM Dimatix employed a two-stage modeling approach using COMSOL Multiphysics software. In the first stage, various actuator geometries were modeled to determine their functional parameters. These parameters were then used in a complete jet model to understand the system's response. The simulation included different layers for the silicon, metals, insulators, and PZT, as well as sections of the ink-filled pumping chamber and neighboring flow channels. By simulating the actuator's deflection under pressure and voltage loads, the team could extract valuable compliance and output data. This information was crucial for optimizing the design to meet the tight specifications and smaller geometries required for the new printheads.
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The multiphysics simulation provided critical insights into the actuator and jet design, allowing the engineering team to better understand the interactions and optimize the system.
The updated design met the target specifications for droplet mass, velocity, and firing frequency, ensuring high-quality ink deposition.
The simulation approach significantly reduced design time, enabling faster product development and release.
The simulation approach reduced design time by approximately 30%.
The optimized actuator design achieved a 20% increase in deflection efficiency.
The new printhead design is expected to reduce production costs by 15%.
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