1. Low Energy Printing Project P10505 David Hatch

2. Outline Introduction Competitive Technologies Objectives and Markets Project Requirements Future Vision

3. Introduction The goal of P10505 is to reduce the energy used in fusing toner onto printing material. After the ink has been printed onto the paper it undergoes a fusing process to bind it to the paper’s fibers. Current technology uses high energy thermal or light processes to affix the toner to the paper. P10505 intends to accomplish toner bonding without using thermal or radiant energy to fuse the ink.

4. Project Introduction Project Name and Number o Low Energy Printing Project, P10505 Project Family o Printing Systems Track o Aerospace and Energy Systems Guide and Consultant o Bill Nowak, Xerox Corporation, Principal Engineer - Motion Quality Systems Primary Customer o John Knapp, Xerox Corporation, Research Fellow P10505 is a continuation of P09505. Due to this, a lot of groundwork has been laid for the current iteration of the project.

5. Fuser Descriptions Flash fusing uses high intensity strobes to fix toner to paper. Images: Xerox.com Hot-roll fusing uses heated rollers and pressure (100-200 lbs) to melt the toner and force it into the paper.

6. Cold Pressure Fusing High pressure (4000-5000 lbs) application without thermal or radiant heat. Current toner formulas cannot work with cold pressure fusing. Design is being focused on what toner is expected to do in the near future. Disadvantages are paper wear and loss of quality from smearing and uneven distribution. Image: Waseda University

7. Stakeholders Xerox corporation o Wants a developed technology to implement in printer designs. o New innovative approaches and employee opportunities MSD team o Want a challenging and educational learning experience. o Opportunity for future growth. Engineering Department o Wants a rewarding student experience and a satisfied sponsor.

8. Proprietary Constraints Since MSD is in the public domain, Xerox does not want to divulge information to team members beyond the scope of the project. The engineers at Xerox want to see how successful the current project is before moving forward. Because of this, information on next year’s project will be limited until the conclusion of the quarter or possibly until next year.

9. Objectives Primarily – make money o Decrease energy use to make the printer more marketable. o Open third world markets unavailable to high energy printers. Augment company image. o Establish customer loyalty Reduce energy footprint.

10. Industrial use o High volume, continuous production  Books, magazines, printing labels etc. Office use o Medium volume, intermittent use  Reports, presentations etc. Personal use o Low volume, sporadic use Markets Image: xerox.com

11. Low Energy Use Easily Manufactured Readily available materials Low cost Integrable into Current Printers Reasonable size Low weight High rate capable Long Term Considerations Low maintenance Customer Safety Efficient Print Time Low warm-up period High feed rate Print Quality High image quality No paper damage Durable image Reliable print Affinity Diagram Information drawn from P09505

12. Low Energy Printing Low Energy Fuser Satisfy User Requirements Easily Manufactured Efficient PrintingQuality Printing Readily Available Materials Reasonable size Low weight Low cost High image quality No paper damage Reliable print Durable image Usable for high rate printing High speed printing Low warm up time Customer safety Low maintenance No thermal or radiant energy Long Term Considerations Objective Tree Information drawn from P09505 Integrable

13. Needs Statements I.The fuser uses less energy than current fusers. II.The fuser creates a high quality, long lasting print image. III.The fuser can function at rates equal to or better than the rest of the printer. IV.The fuser can be implemented in current printer designs. V.The fuser can be manufactured easily and at low cost.

14. Low Energy Fuser High Quality Print Constant Pressure Uniform Contact Surface Adjustable Pressure Safety Finite Element Analysis Factor of Safety Manufacturability / Integrability Simple Design Function Tree

15. Resources Xerox prefers to manufacture in-house for billing purposes and quality control. Potentially all manufacturing needs will be accomplished in this manner. CNC work may be completed in the Brinkman lab. Technical TA’s who are closely associated with Xerox. Project guide is a Xerox engineer.

16. Future Plan This Quarter Follow P90505 closely through the remainder of the quarter. Meet directly with John Knapp. Next Year Re-interview Xerox for any design changes. Evaluate final success of P09505.

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18. References "Flash Fusing Technology." Fuji Xerox. 2009. Fuji Xerox Corporation. 13 Apr. 2009. Jones, Joshua, et al. "P09505: Low Energy Printing (Xerox)." Edge. 4 Apr. 2009. Rochester Inst. of Technology. 14 Apr. 2009. Xerox Corporation, David Thompson, and Dinesh Tyagi Eastman Kodak Company. "Tutorial T14: Fusing Technologies and Toner Materials Relationships." NIP 24: 24th International Conf. on Digital Printing Technologies. Edge. 15 Apr. 2009.

19. P09505 Cold Pressure Fuser Design

20. Deflection in P09505 Roller Design