The screen-printing method consists of a thick film metal paste that is composed of metal powder, glass fritt, solvent and non-volatile polymers that are blended together in a three roll mill. A squeegee applies a downward force on the paste moving it across the screen that has a deposition pattern within. This action creates a reduction in viscosity of the paste so it can penetrate into the screen holes. This way, the metal paste is deposited in select patterns onto the substrate. The factors that affect the screen-printing process include snap off distance, squeegee pressure and squeegee speed.
The snap off distance is the distance between the screen and the wafer. During the printing process, when the paste is printed onto the screen, a downward force is applied to the screen. The screen, being elastic, restores its shape and this upward movement aids in the deposition of the paste. If the snap off distance was too high, then pressure will have to be applied to force the paste onto the wafer. If it is too low, the paste might not get released from the screen. The pressure applied also plays an important role in the deposition of the paste. When too much pressure is applied, excessive paste from the screen could be deposited which can break the wafer. On the contrary, when too little pressure is applied, the paste might not get released from the screen at all. The speed of the squeegee movement also determines the print quality. If the speed is too high, the paste can miss many holes and lead to a non-uniform deposition.
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