How inkjet printing of phase change materials is revolutionising jewellery production

The jewellery manufacturing sector demands precision, cost efficiency and agility. Often driven by trends or limited-edition exclusivity, production needs to allow for a variety of batch sizes as well as regularly changing designs. Historically, this has required a high-level of labour, or lengthy timeframes as new jewellery moulds are created for each new design.

The advent of digital printing has offered manufacturers much greater flexibility in terms of design and customisation, as well as faster production.

Now, inkjet technology, once associated with surface decoration in jewellery, has become an integral part of the manufacturing process itself. Its role has evolved from embellishment to enabling the precise creation of moulds and components, driving innovation in how jewellery is produced.

So, when it comes to quality of product output, it is the growing adoption of inkjet printing of wax which is currently making waves in the industry.

The Challenge

In recent years, as manufacturers have tried to find cost effective and time efficient new ways to produce jewellery, 3D printers have grown in popularity.

In jewellery production, resin 3D printers were initially most popular, as these have typically been more accessible and affordable. However, over time, significant issues with resin use in mould making have become apparent.

From a quality perspective, resin moulds often leave behind ash or carbon, which can impact the finish of the jewellery, and the rigid support structures typically required by this material can result in visible marks and extensive post-processing. Resin printers also struggle with ultra detailed designs, with most models unable to reliably print beneath 0.3mm.

What’s more, from a process standpoint, resin models can’t be cast together with traditional wax models, necessitating an additional casting schedule with customised temperature settings that complicates production.

When used at scale, the drawbacks of resin only grow, with different formulas and discrepancies in exposure settings between machines resulting in inconsistent outputs.

The Inkjet Printing Solution

In answer to these issues, inkjet printing of phase change materials is rapidly being adopted by jewellery manufacturers.

When harnessed by the right technology, wax is the perfect solution for jewellery manufacturers, seamlessly integrating with traditional lost-wax casting workflows and providing greater quality and precision than resin alternatives.

In the past, the challenge of using wax as part of a mould printing solution has been its melting point and viscosity level. But, with the use of advanced printing technology, such as our own Xaar 2002 printhead, wax printers are becoming increasingly popular.

Our Xaar 2002 printheads are ideal for phase change applications, as their structure and our unique technologies provide the ability to jet fluids of up to 100 centipoises (cP) at jetting temperature (approximately 1000 cP at ambient temperature). They also offer dual channel capability, which in the context of jewellery production, allows for the printing of two different materials, creating the build and support components simultaneously. Furthermore, our unrivalled TF Technology is the ideal facilitator for phase change printing, circulating the wax or phase change fluid within the printhead and keeping it at the temperature necessary for the required viscosity. This delivers increased print reliability and superior part quality as the risk of nozzles dropping out during a print is minimised avoiding downtime and costly waste.

In terms of quality, our printheads provide superior drop placement, delivering greater printing accuracy. The drop size of our Xaar 2002 printheads allows for a smoother mould surface, in turn delivering a cleaner finish for the product. This translates to less time spent re-processing and a reduction in error-driven waste.

From an efficiency and sustainability perspective, our OEM customers are now seeing demand for and delivering three printhead machines, allowing for printing across the printing plate in a single pass. Our printheads are also known for reliability, with current wax printing customers seeing much longer product life cycles than previously experienced with competitor products.

The exciting adoption of digital inkjet wax printing by the jewellery industry is just one example of how inkjet technology, and the use of phase change materials within this, can be revolutionary. As manufacturers seek ever more time and cost-efficient solutions, which don’t compromise on quality, we look forward to continuing to unleash the power of inkjet, working with our OEM partners to deliver the innovative and disruptive advanced manufacturing solutions of the future.