Nikitin D. Models and methods of controlling the technological process of manufacturing printed circuit boards using photopolymer 3D printing technology

Nikitin D.O. Models and methods of controlling the technological process of manufacturing printed circuit boards using photopolymer 3D printing technology - Qualification scientific work on the rights of a manuscript. Thesis for the degree of Doctor of Philosophy in speciality 151 "Automation and computer-integrated technologies" – Kharkiv National University of Radio Electronics, Ministry of Education and Science of Ukraine, 2024. The dissertation is devoted to an urgent scientific and practical problem, that is development of cyber-physical production systems for the manufacture of single- and double-sided printed circuit boards using an automated technological process based on additive 3D printing technologies, which allows solving the following tasks: minimisation of consumables; minimisation of operations in the structure of the technological process; printed circuit boards topology manufacturing accuracy increasing. The thesis is a continuation of the research conducted at the Department of Computer-Integrated Technologies, Automation and Robotics (CITAR) of the Kharkiv National University of Radio Electronics under the supervision of the Head of the CITAR Department, Doctor of Technical Sciences, Professor, Honoured Worker of Science and Technology of Ukraine, Laureate of the State Prize in Science and Technology of Ukraine; Laureate of the State Prize of Ukraine in Education; Member of the Academic Council, Nevliudov Ihor Shakyrovych. The purpose of the thesis the purpose of the thesis is to improve the accuracy of single-sided and double-sided printed circuit boards manufacturing and to reduce production costs by using models and methods of process control based on photopolymer 3D printing. The object of research is the technological process of exposing topological images of printed circuit boards obtained by photopolymer printing. Subject of research – methods and models for controlling the technological process of exposing and applying the topology of printed circuit boards using photopolymer production technologies based on SLA, DLP and LCD. Research methods. The following methods are used in the work: factor analysis – to determine the influence of the parameters of PCB topology exposure on the preservation of the geometric dimensions of conductors and contact pads; image filtering methods - to prepare the required topological drawing of printed circuit boards using SLA, DLP and LCD exposure and to compare the specified topology with the one obtained using a vision system and to develop a graphical user interface for finding deviations in the geometric dimensions of the resulting photopolymer masses methods of automated control of the temperature of photopolymer resin during LCD exposure were used. The scientific novelty of the dissertation is as follows: 1. For the first time, a method of exposing single- and double-sided printed circuit boards using additive 3D printing technologies is developed with the use of photopolymer masks, which, unlike existing methods of applying photoresist, allows to reduce the cost of materials by 37% (compared to the use of film photoresist) and the lab our intensity of PCB production. 2. The technological process of creating photopolymer masks of the topology has been improved, taking into account the influence of temperature conditions of the photopolymer resin, which makes it possible to increase the accuracy of manufacturing the topology of the PCB mask by an average of 0,03 mm (depending on the exposure modes). 3. For the first time, a mathematical model of the influence of SLA- and DLP-exposure parameters on the geometric dimensions of the PCB topology during the exposure of photopolymer masks has been developed, which makes it possible to reduce the deviation of geometric dimensions by 15%. 4. The method of adaptive binarisation of image processing was further developed by using the size of the scanning matrix when scanning an image according to the Otsu threshold, which reduces noise in binarised processing.