As industries push the boundaries of technological innovation, the demand for precision in manufacturing has never been greater. At the forefront of this revolution is High Precision Capillary Printing (HPCaP), a groundbreaking technology developed by Hummink.
What Is Micron Scale Manufacturing?
Micron-scale manufacturing refers to the process of building structures, circuits, and components at dimensions measured in microns. To put the size of a micron in perspective, a human hair is roughly 70 microns wide. At this tiny dimension, conventional production methods reach their limits.
Key Challenges in Micron-Scale Production
Working at the micro level introduces a unique set of engineering challenges:
- Traditional processes like inkjet or screen printing struggle to maintain resolution below 20 microns. Nozzle clogging, satellite drops, and material incompatibility reduce reliability and drive up production costs.
- Many conventional laser-based and electron beam methods demand controlled environments, complex multi-step fabrication sequences, and expensive infrastructure. The result is often a trade-off: higher precision means higher cost, longer lead time, and greater material waste.
How HPCaP Works: Capillary-Driven Precision
High Precision Capillary Printing, or HPCaP, is an additive technology developed by Hummink. It operates on a principle that is deceptively simple: capillary forces. Instead of relying on external pressure, laser energy, or drop-on-demand systems, HPCaP technology uses a glass micropen. It’s a precisely engineered capillary, driven by a piezo-actuated macro-resonator oscillating at approximately 1 kHz. When the micropen approaches the substrate, a stable meniscus of ink forms naturally through capillary action. This direct deposition process allows the controlled printing of functional materials in a single step, with no satellite drops and virtually zero waste.
A closed-loop electronic feedback system continuously adjusts the Z-axis in real time, adapting to the substrate topography. Combined with high-resolution live video monitoring, the process enables users to control every aspect of the operation with remarkable precision.
Resolution and Positioning Accuracy
What truly sets HPCaP apart is its resolution. The system achieves printing from 50 microns down to a few hundred nanometers, with positioning precision of 100 nanometers. Whether the task involves laying down a conductive metal trace or depositing a polymer layer for an optical biosensor, HPCaP delivers consistent, repeatable results.
Substrate Versatility
HPCaP is compatible with both flexible and rigid surfaces, including PET foils, Kapton film, silicon wafers, glass, metal, and even paper. It also handles inks ranging from low-viscosity solutions to materials reaching 100,000 cP. This makes it one of the most versatile micro-printing tools on the market for both microscale and nanoscale fabrication.
HPCaP vs. Traditional Micron-Scale Manufacturing Methods
Compared with conventional approaches, HPCaP eliminates several bottlenecks. Methods such as laser micromachining, drop casting, or electron beam lithography often require multiple fabrication steps, controlled atmospheres, or specialized equipment that limits design freedom. HPCaP condenses the process to a single direct-write step, reducing processing time from hours to minutes. The approach is also more cost-effective: less infrastructure, less energy, and no chemical etching.
For companies seeking a practical solution for microscale and nanoscale fabrication, HPCaP is a fundamental shift. Furthermore, Hummink is planning the upcoming release of a modular printing head designed to integrate into existing production lines.
Applications of Micron-Scale Manufacturing with HPCaP
Semiconductor Defect Repair
In the semiconductor industry, even a single micro-defect can destroy an entire batch of chips. HPCaP enables real-time monitoring and repair of these defects by depositing conductive or functional materials at submicron dimensions directly on the production line. This capability drives semiconductor yield improvement and significantly reduces waste.
Biosensors and Biomedical Devices
In the biomedical field, HPCaP has proven its ability to produce high-sensitivity biosensors with submicron electrode gaps. Researchers at Université Paris Cité and Duke University have used the NAZCA prototyping machine to fabricate label-free detection devices based on printed organic transistors. These applications in biosensors and healthcare include:
- Point-of-care diagnostics
- Environmental monitoring
- Real-time miniaturized sensing
Flexible Electronics
HPCaP prints directly onto flexible materials without damaging the substrate, enabling durable electronic components for:
- Wearable devices
- Aerospace systems
- Consumer electronics.
Its compatibility with conductive polymers, metal inks, and functional coatings makes it a powerful tool for printed electronics.
Display Repair (TFT)
Up to 30 percent of OLED screens are discarded each year due to micro-defects, representing billions in losses. HPCaP addresses this challenge by enabling precise TFT display repair at the micron level.
Why HPCaP Is the Future of Micron Scale Manufacturing
The demand for smaller, more reliable, and sustainable electronic devices is accelerating across every sector. HPCaP meets this demand with a technology that combines precision, material versatility, and process simplicity. Backed by a recent €15 million funding round and partnerships with research institutions like CEA-Leti and IMS Bordeaux, Hummink is moving its technology from lab to fab.
FAQ
What is the smallest feature size HPCaP can print?
HPCaP achieves resolutions from 50 microns down to approximately 100 nanometers, depending on the material and substrate.
What types of materials can be deposited?
The system handles conductive metal inks, polymers, quantum dots, and functional coatings, with viscosities up to 100,000 cP.
Is HPCaP compatible with existing production lines?
Yes. Hummink is developing a modular printing head for direct integration into semiconductor and display fabs.
How does HPCaP compare to inkjet or laser-based printing?
Unlike inkjet, HPCaP avoids nozzle clogging and works at much finer resolutions. Unlike laser methods, it requires no masking or etching. It’s a single-step, additive deposition approach.
What industries benefit most from this technology?
Semiconductor fabrication, display repair, biomedical device development, flexible electronics, and sensor engineering all benefit from HPCaP’s capabilities.
