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Computer to Print based on Ink Jet Technologies 5.5.1 Overview of Ink Jet Technologies
In additon to electrophotography, the most common and Processes
non-impact technology used for digital printing sys-
tems is ink jet. The ink jet process is a computer to A more detailed division of ink jet processes as in figure
print technology in which ink is sprayed from nozzles, 5.1-4 is given in figure 5.5-1.
which means that no image carrier is needed (see fig. The basic variants of the process are continuous ink
5.1-5). As shown in figure 5.1-1 imaging is done directly jet and drop on demand ink jet. A schematic diagram of
onto the substrate. The data of the digital print job is the processes is given in figure 5.5-2.
transferred directly to control the imaging unit. In
this case the imaging unit is the ink jet system itself, Process Variants
which transfers the ink to the paper via nozzles, most- Whereas in the continuous ink jet process, only part of
ly directly or in same applications indirectly depend- the continuously generated flow of small ink drops is
ing on the technology used. Therefore, in the system directed onto the paper during printing in accordance
illustrated in figure 5.1-5 the functional units, imag- with the image, in drop on demand ink jet processes
ing system, image carrier, and inking unit are com- drops of ink are only generated if the information to be
bined into a single module and they transfer the ink printed requires them.
directly onto the paper. (However, there are also ink Continuous ink jet can be subdivided into the process
jet systems in which printing is done via an interme- variants of binary deflection and multi-deflection. The
diate carrier.) binary deflection variant, in which the drop has one of
Because of its importance, explanations of ink jet two charge states (namely uncharged for conveyance to
technology have already been given in preceding the paper and charged for deflection in an electrical field)
chapters and sections of the book, together with ex-
amples for conversion and application as a printing
system in sections 1.3.3.2, 4.1, and 4.5.2. In section
4.4.2.1 it was explained how the ink jet process can al- Ink Jet Technologies
so be used as an option for setting up computer to
press/direct imaging systems. In section 4.3.2.2 the
Continuous Ink Jet Drop on Demand Ink Jet
platemaking process based on ink jet technology in a
computer to plate system for offset printing was de-
scribed. Binary Multi- Electro-
deflection deflection Thermal Piezo static
This means that in the ink jet process the infor-
mation to be printed can be transferred to the
paper by the shortest route, with a minimum of
functional elements (and in the case of page-wide Liquid ink Hot-melt ink
nozzle arrays even without moving parts), and it is
this fact that is the driving force behind further
enhancements and new developments in ink jet sys- Paper/Substrate
tems and processes.
Fig. 5.5-1 Ink jet technologies: overview of processes
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712 5 Printing Technologies without a Printing Plate (NIP Technologies)
Ink
Heat source
(Heating resistor) Imaging signal
Nozzle b Paper
Gutter
Paper
Pump Paper Imaging signal
Piezoelectric
ceramics
a Ink
Ink
Ink
Paper
d Imaging signal Meniscus
has been described in preceding sections (fig. 5.5-2a). In In piezo ink jet systems, the drop is generated as a re-
the multi-deflection process the drops receive different sult of a change of volume within the ink chamber due
charges,so that as they pass through the electric field they to piezoelectric effects, which leads to the drop of ink
are deflected in different directions and are transferred being ejected from the nozzle system (fig. 5.5-2c).
to different positions on the substrate (see fig. 5.5-9). Electrostatic ink jet is the third variant of the drop on
Drop on demand ink jet processes can be classified ac- demand ink jet process referred to in figures 5.5-1 and
cording to the way that the individual ink drop is gen- 5.5-2d. There are different process variants, but com-
erated. In the thermal ink jet process this is done by heat- mon to all of them is the fact that an electrical field ex-
ing the liquid ink until it vaporizes, whereupon a cer- ists between the ink jet system and the surface to be
tain quantity of ink is ejected from the nozzle as a result printed, and that by means of image-dependent alter-
of the pressure exerted by the vapor bubble, hence the ations in the ink jet nozzle system, either the forces can
name “bubble jet” (fig. 5.5-2b). be balanced or the surface tension ratios between ink
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5.5 Ink Jet 713
and outlet nozzle can be changed, so that a drop of ink However, larger drops for creating gray values can be
is released as a result of the field forces. Withdrawal of generated whereby shortly before striking the substrate
ink from the nozzles is prepared via the electrical field, several individual drops combine in flight or strike the
and a control pulse (e.g., electric signal or the supply substrate in rapid succession, before the information
of heat) then enables the release of a drop. for the next pixel is generated for printing.
Figure 5.5-3a shows in simplified form how several
Inks drops, which combine after release from the nozzle to
The states (liquid or solid) in which the ink for ink jet form a single drop volume, can be generated in rapid
processes is used are summarized in figure 5.5-1. It is usu- succession by means of special controlling of the heat-
ally liquid inks that are used although some drop on de- ing elements for the bubble jet process. The sequence of
mand ink jet systems are equipped to use hot-melt inks. photographs taken of drops (fig. 5.5-3b) shows how a
An overview of the inks for ink jet processes is given larger drop forms from three separate pulses of a piezo
in figure 5.1-16, which also contains information on the ink jet system.
composition of the inks and the drying processes asso-
ciated with them. An explanation is also given as to
what ink film thicknesses occur in single-color printing
with ink jet systems according to the type of ink used.
Particularly noteworthy here is the fact that if liquid
inks are used, very thin ink films (low drop volumes)
can be applied, which is the basis for very high quality
prints especially in the case of color images.
Multicolor prints of extremely high quality can be
created by using specially coated papers that help to pre- 1st 2nd 3rd level-3
level-1 level-2
vent the ink from feathering, to control the spreading nucleation drop nucl. drop nucl. drop
and penetration into the substrate), and also offer good a
setting characteristics and good drying results.
Further improvement in quality can primarily be
achieved using ink jet systems with which several gray
values per pixel (printed dot) can be created.
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714 5 Printing Technologies without a Printing Plate (NIP Technologies)
Figure 5.5-3c shows in simplified form how individ- Figure 5.5-6 shows how drop formation is calculated
ual drops can be selectively collected on the pixel posi- with a mathematical model and captured by means of
tions of the substrate for density modulation as a result a high-speed exposure. Drop size and interval
of the very high frequency during generation of the basically depend on the nozzle diameter, and the vis-
drops in the continuous ink jet process. This process can cosity and surface tension of the liquid, as well as the
produce up to around thirty gray values. frequency of the excitation.
The individual drops are electrically charged by an
Drying Process electrode in accordance with the image just before sep-
Figure 5.5-4 shows examples of how ink drops may re- aration from the jet (fig. 5.5-5). The charged drops are
act with the paper in the ink jet printing process. The deflected in a subsequent electrical field (plate capaci-
surface properties of the paper determine the spread- tor, deflector) and fed to a collecting device. The un-
ing and penetration into the substrate. The illustration charged drops reach the paper.
shown refers to water-based or solvent-based standard As shown in figure 5.5-6b, so-called satellite drops are
inks with which the colorants (pigments or dyes) and produced during the drop formation process, which
binders produce a very thin layer of less than 1 µm ink should then merge with the main drop. The quality of
application after vaporization and absorption of the the print depends on the quality and continuity of the
base liquid. drop stream generated.
More data on the drying of ink jet inks is to be found Typical data (Hertz technology) on frequencies
in figure 5.1-16. (around 1 MHz) and drop sizes (approximately 4 pl)
Pump
Drop Drop Drop Volatile Paper
strikes spreads penetrates substances Specifications (example):
the paper the paper evaporate
Drop frequency: approx. 1 MHz
Paper Drop volume: approx. 4 pl
Ink Drop diameter: approx. 20 1m
Drop speed: approx. 40 m/s
Drop diameter Dot size
approx. 30 1m approx. 60 1m Note:
6 · V 1/3 1/3
Layer thickness d= π ≈ 1.24· V
less than 1 1m d [1m] ≈ 12.4 · ( V[pI] )1/3
d = Drop diameter
V = Drop volume
Fig. 5.5-4
Dot formation resulting from the reaction of ink drop with substrate
in the ink jet process Fig. 5.5-5 Continuous ink jet: process specifications
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5.5 Ink Jet 715
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716 5 Printing Technologies without a Printing Plate (NIP Technologies)
Fig. 5.5-7
High-speed ink jet system for web-fed
printing.
a System with four print heads (240 dpi,
head width of about 108 mm (4.25"), web
speed of up to about 2 m/s);
b Ink jet heads with nozzle system
(System 3600, Scitex Digital Printing)
Proof
b Imaging head
Fig. 5.5-8 Digital proof system with continuous ink jet NIP technology.
a System example (300 dpi, 15 gray values per pixel);
b Mounting the paper on the drum and ink jet head with 4 systems for the process colors cyan, magenta, yellow, and black moved in axial
direction (Digital Cromalin, DuPont/Stork Digital Imaging)
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5.5 Ink Jet 717
Paper
Substrate
movement
Deflector
Nozzle
Gutter
Ink pump
Charging
system
Fig. 5.5-9
Multi-deflection continuous ink jet system (e.g., seven drops with-
in the height of a line)
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718 5 Printing Technologies without a Printing Plate (NIP Technologies)
Heat source
(Heating resistor) The bubble presses
Imaging signal the ink drop
out of the nozzle.
Paper
Specifications (example):
Drop frequency: approx. 5–8 kHz The temperature drops
Drop volume: approx. 23 pl and the bubble collapses.
a Drop diameter: approx. 35 1m
Nozzle
Specifications (example): (orifice)
Drop frequency: approx. 10–20 kHz
Drop volume: approx. 14 pl
b Drop diameter: approx. 30 1m
Rapid heating Drop Bubble Orifice meniscus
100 4C/1s formation collapse settles to
Fig. 5.5-11 Drop on demand ink jet: system specifications. produces vapor begins refill complete refill
a Thermal ink jet (bubble jet); explosion in ink
b Piezo ink jet
Fig. 5.5-12 Drop generation with thermal ink jet.
a Principle of bubble formation and of the drop outlet (Canon);
8 kHz, and with three hundred nozzles per printing b Time sequence for drop formation (HP)
head. The nozzles are arranged in several rows and
staggered to ensure the desired resolution and the space
required for installation of the individually addressable Piezo-ceramic materials are ideally suited for small,
nozzles (see also figs. 5.5-20 and 5.5-21). electrically addressable systems. As illustrated in figure
5.5-13a materials of this type change shape or volume
Piezo Ink Jet in the electrical field. The so-called “shear mode,” with
With piezo ink jet, unlike thermal ink jet, ejection of an the appropriate electrical controller, is usually used in
ink drop is generated by mechanical displacement in the piezo ink jet systems. In shear mode operation the ma-
ink channel, and not by heating and vaporization with- terial’s volume remains unchanged and the geometry
in the ink jet system (fig. 5.5-11b). is deformed (fig. 5.5-13a).
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5.5 Ink Jet 719
Imaging signal
Piezoelectric Electrodes
Piezo- ceramics (PZT) Electrodes
Polarized electric
material P
ceramics
Orifice
Extension
mode
Electrical E (bend
Meniscus
field (E) mode)
Shear
mode
E
a b Drop c
Fig. 5.5-13 Structure of drop on demand ink jet systems using piezoelectric ceramics.
a Deformation of the piezo-ceramics in the electrical field;
b Drop generation with piezo ink jet (shear mode) by deformation of the rear wall of the channel (Spectra);
c Piezo ink jet with drop formation by deformation (shear mode) of the channel walls (MicroJet, XAAR)
There are various options for different geometrical trated in figure 5.5-14. Four-color printing is generated
configurations to set up nozzles and nozzle systems via an ink jet head with 96 nozzles at a resolution of
based on these materials. An example of how a drop is 300 dpi. (In spite of the considerably larger nozzle spac-
generated for an individual ink channel via the rear wall ing of 500 µm, the low pixel spacing of 84 µm is
of the chamber, similar to the way a diaphragm pump achieved by inclining the nozzle row by about 10° when
functions, is shown in figure 5.5-13b. the line row is arranged vertically to the direction of pa-
In the version illustrated in figure 5.5-13c the channel per transport. See fig. 5.5-14b and fig. 5.5-20c, but in this
walls are deformed, which produces a pumping/suc- figure for a stationary writing head.) The solid hot-
tion action in one channel and an ejection action in the melt ink is heated and liquefied by heat transfer before
adjacent channel. This means that in this configuration being fed into the ink jet array. After transfer of the ink
there is always an effect on the adjacent channels (so- to the paper in accordance with the image, it cools
called cross talking). In the example shown, compensa- down again and solidifies.
tion is made for this effect by the fact that only every Figure 5.5-15 shows a more recent application of
third nozzle chamber can be addressed simultaneous- piezo ink jet technology, an imprinting unit which can
ly. Adjacent chambers cannot be used at the same time. be used to imprint additional information on preprint-
Consequently there is alternate pumping and ejection ed web material. The preprint may have been produced
and “cross talking” is put to positive effect. with a system such as the digital high-speed single-col-
Unlike thermal ink jet systems (normally, water- or printing system illustrated in figure 4.5-9. Imprint-
based inks are used), electro-mechanically based piezo ing can, however, also take place in-line, as shown in
ink jet systems can be addressed at higher frequencies figure 5.5-15c. In the configuration shown in figure
and a broader variety of ink formulations can be used to 5.5-15a and b, eight ink jet heads are arranged behind
great advantage. one another in the direction of travel of the web. The
The first applications using piezo ink jet technology axial position of each one can be changed independ-
with nozzle arrays came onto the market around 1990. ently of the others and each ink jet system can print an
Hot melt inks are used in the multicolor printer illus- additional, different color, which means that informa-
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720 5 Printing Technologies without a Printing Plate (NIP Technologies)
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5.5 Ink Jet 721
Imprinting system
a b c
a b
nozzle outlet and the superimposing of voltage sig- shape. The nozzle diameters are about 400 µm and
nals. The drop’s volume is determined by the duration nozzle spacing of less than 1 mm is realistic. By arrang-
of the control pulses (see fig. 5.5-17a). Hot-melt inks ing the nozzles in several rows behind one another
are used in the design shown in figure 5.5-17c. where the nozzles are staggered within a row, arrays can
There are concepts relating to the above process for be created which are able to attain resolutions of
designing nozzle arrays on the basis of special micro- 600 dpi and higher, also for larger imaging widths (see
mechanical methods with optimal design of the nozzle fig. 5.5-20b).
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722 5 Printing Technologies without a Printing Plate (NIP Technologies)
Paper
Heating
element
b
Electrical Ink
field (slight Nozzle plate
Hot melt ink overpressure)
a
Heating
elements
Paper
b Nozzle array Heating Ink (slight
Nozzle array element overpressure)
c
Fig. 5.5-18
Fig. 5.5-17 Electrostatic ink jet based on the “Taylor effect.” Electrostatic drop on demand ink jet with control via heating ele-
a Underlying principle of drop generation; ments.
b Drop formation in electrostatic field (sequence); a Section of a nozzle array with integrated heating elements and
c Concept with specially shaped nozzle array and hot-melt inks electric circuit;
(ESIJET, iTi: Imaging Technology International; [5.5-3]) b Drop generation via electric field after reduction of the interfacial
tension by heating the nozzle rim (LIFT technology, Silverbrook
Research, [5.5-4])
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5.5 Ink Jet 723
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724 5 Printing Technologies without a Printing Plate (NIP Technologies)
Ink jet print heads can either be designed as page- shows an array for magnetography that is designed to
wide stationary arrays or assembled in imaging systems provide a resolution of 480 dpi from six lines (see fig.
in which the print head moves at right angles to the di- 5.5-20b). The magnet spacing in an individual line cor-
rection of travel of the substrate (imaging/writing di- responds to a resolution of 80 dpi. The structure of an
rection). ion source array is explained in section 5.3. A resolu-
Figure 5.5-14b shows an example of how ninety-six tion of 300 dpi from 16 ion source lines at right angles
channels can be assembled in one line. To produce a to the direction of print was achieved (consequently
resolution of 300 dpi at a distance from nozzle to noz- the spacing of the ion sources in an individual line cor-
zle of 500 µm, the line was inclined by about 9.6° (the responds to 18.75 dpi).
nozzle row is slightly inclined to the perpendicular, rel- It can be seen from figure 5.5-20 that the spacing of
ative to the cyclic/intermittent paper feed direction; the successive lines can be selected relatively freely and fo-
writing head crosses the page width). cus can be placed on manufacturing and installation
Figure 5.5-7 illustrates a system with a stationary ink aspects. However, it must be taken into account that in
jet head in page-wide configuration. The system com- imaging array installations with several lines for in-
prises several adjacent rows of nozzles, and here the rows creased resolution, in contrast to single lines, the pixel
are arranged parallel to the web travel and slightly in- size must also be adapted, that is, smaller pixels for in-
clined in order to achieve a higher resolution. creased resolution. Taking the example of ink jet tech-
Lines of nozzles, similarly slightly inclined to pro- nology, this means that the nozzles and orifices in the
duce a high resolution, are shown in figure 5.5-15. The individual line has to be designed for a drop size in ac-
lines are also oriented in direction of the paper travel. cordance with the desired high resolution.
Figures 5.5-20 and 5.5-21 illustrate how, in principle, The distances from nozzle to nozzle are determined
lines of nozzles can be suitably arranged with a greater by the nozzle design and the mechanical/electrical sys-
spacing than the desired resolution. Options for assem- tem. Moreover, the line length and the extension of an
bling page-wide arrays are also shown. array are restricted for manufacturing reasons and by
Figure 5.5-20a shows how the resolution can be dou- the requirements on the electrical circuits, ink feed,
bled quite simply by offsetting the nozzle outlet in one material properties, cost, the reliability requirements,
line of a two-line assembly. Arrays having the desired and production engineering. This results in page-wide
resolutions can be obtained by extending this alterna- arrays usually being built up from individual modules.
tive, that is, the desired resolutions can be achieved Figure 5.5-21 shows an example of the possible struc-
with each successive line having nozzles staggered in re- ture of an imaging system (made up of thirty modules)
lation to the preceding line. for 600 dpi and a printing width of 325 mm in which
An example with 6 lines is shown in figure 5.5-20b. the nozzle arrays of the individual modules are 65 mm
This results in a resolution of 600 dpi, with an individ- wide. This configuration requires both extremely ac-
ual line resolution of 100 dpi. (The corresponding curate mechanical alignment and the correct synchro-
arithmetic correlations are also given in the illustra- nization for controlling the individual channels. In
tion.) particular errors in aligning the modules at right an-
Figure 5.5-20c depicts how the resolution can be in- gles to the direction of printing for perfect positioning
creased by a single row, if the line is arranged in the di- of the imaging line can lead to clearly visible defects in
rection of printing. This necessitates a very long array the quality of the printed image.
for larger writing widths or synchronized axial move- The ink jet system illustrated in figure 5.5-16 can be
ment of the individual head, as in the system shown in assembled as a page-wide ink jet imaging head (simi-
figure 5.5-8. (Figure 5.5-15 shows a system that can be lar to fig. 5.5-21). At the DRUPA 2000 exhibition, an im-
firmly positioned in the axial direction for a writing printing system based on the configuration shown in
width of about 27 mm.) Arranging several rows along- figure 5.5.-21 was presented within a hybrid printing
side each other in this way for larger writing widths re- system similar to the concept as explained in chapter 6
sults in a structure such as the one in figure 5.5-20b. (see fig. 6.3-9).
These design principles for imaging arrays produc- The configurations for array systems discussed above
ing high resolutions can, of course, be applied to other refer to systems for one color. For multicolor printing,
imaging systems, in spite of the large installation space assignment within an array can be done according to
required by the individual components. Figure 5.4-6 colors (e.g., as shown in the system given in fig. 5.5-14).
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5.5 Ink Jet 725
For multicolor printing with a page-wide ink jet array jet NIP technology for various, wide-spread applica-
configuration (singlepass system), four separate arrays tions, are explained below.
are needed. In principle, distinction can be made between high-
speed printing systems, which print predominantly with
5.5.5 Printing Systems based on Ink Jet one color or with an additional spot color, and systems
for the high-quality printing that is required for proof
Technology for Multicolor Printing purposes. Small-format (A4,A3) multicolor ink jet print-
(Selection) ers are most widely used in office applications, desk-top
As a supplement to the preceding examples and the ex- publishing, and for private use. Ink jet systems for large-
amples dealt with in other chapters, systems using ink format printing, such as posters and billboards, are
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726 5 Printing Technologies without a Printing Plate (NIP Technologies)
100 dpi
254 1m line art). This system is designed for the production of
7680 nozzles
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5.5 Ink Jet 727
Fig. 5.5-22
Ink jet system (piezo drop on demand tech- Calibration and
nology) for digital proofing; 600 dpi resolu- customer-specific
setting of hue Eight multi-density inks
tion, eight colors (2¥ cyan, 2¥ magenta,
(color management)
3¥ black, 1¥ yellow, different ink density),
A3 format
(DryJet, Polaroid Graphic Imaging)
320 ink jet nozzles
Frequency-modulated
screening
Printing cylinder
and imaging system
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728 5 Printing Technologies without a Printing Plate (NIP Technologies)
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5.5 Ink Jet 729
Fig. 5.5-26
Ink jet printing systems for the multicolor
printing of large formats.
a Model Blueboard 2; resolution 70 dpi,
printing speed 60 m2/h, max. printing
width 5 m, continuous ink jet (NUR
Macroprinters/Salsa);
b Model UltraVu 5000; resolution 300 dpi
(also addressable for 37.5 and 18.75 dpi),
printing speed 110 m2/h with low resolu-
tion of 18.75 dpi, max. printing width 5 m,
piezo drop on demand ink jet (VUTEk)
Fig. 5.5-27
System configuration for a multicolor continuous ink jet printing
system (Scitex Digital Printing; diagram based on sundry company
information, status: 1996, not confirmed; see also fig. 4.5-14)
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730 5 Printing Technologies without a Printing Plate (NIP Technologies)
References in 5.5
[5.5-1] Nilsson, J.: Application of Micro Drops. Report
6/1993, Department of Electrical Measurements, Lund
Institute of Technology, Lund, Schweden 1993.
[5.5-2] Taylor, G. I.: Electrically driven jets. Proceedings
Royal Society, Vol. A313. London 1969, pp. 453–475.
[5.5-3] Mills, R.: ESIJet Printing Technology. Proceedings
NIP12: International Conference on Digital Printing
Technologies (revised). The Society for Imaging Science
(IS&T), Springfield (VA) 1996, pp. 262–266.
[5.5-4] Silverbrook, K.: Company Information Brochures.
Silverbrook Research, Leichhart (NSW), Australia 1995.
[5.5-5] Fukumoto, H.: Printing with ink mist ejected by
ultrasonic waves. Proceedings NIP 15: International
a Conference on Digital Printing Technologies. The Society
for Imaging Science (IS&T), Springfield (VA) 1999, pp.
310–314.
Fig. 5.5-29
Ink jet printing system for high quality multicolor printing/digital
proof; resolution 720 dpi (1440 dpi possible in direction of printing),
six colors (2¥ cyan, 2¥ magenta, black, yellow), piezo ink jet tech-
nology, A3+ format, around 5 min. printing time per A3 page
(Stylus Pro 5000, Epson)
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731
5.6 Thermography
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