ADDITIVE MANUFACTURING

REPORT ON:
Experiment A: Printing a humidity sensor
Experiment B: Calibration of humidity sensor

SUBMITTED BY: ARAVINTH SUBRAMANIAN

Matrikel-Nr.671156
Group 13

1
CONTENTS

1.0 INTRODUCTION……………………………………………………………….….3
2.0 EXERCISE A- PRINTING A HUMIDITY SENSOR………………………….…4
2.1 AIM…………………………………………………………………….……4
2.2 PROCEDURE………………………………………………….………….4
2.3 OBSERVATIONS…………………………………………………………5
2.4 DISCUSSIONS…………………………………………………………..10
3.0 EXERCISE B- CALIBERATION OF HUMIDITY SENSOR…………………..11
3.1 AIM……………………………………………………………………......11
3.2 PROCEDURE…………………………………………………………....11
3.3 OBSERVATIONS………………………………………………………..12
3.4 DISCUSSIONS…………………………………………………………..15

2
1.0 INTRODUCTION

Water exists in the atmosphere in the form of liquid and gas. When water is in
gaseous state it is known as water vapor. So, the amount of water vapor that are present in
the air is known as humidity. Therefore, humidity sensor is a device which can detect and
measures water vapor present in the air. Hygrometer is a device which is used to measure
the amount of water vapour or the humidity in the air. There are various types of humidity
sensos like Resistive humidity sensor, Thermal humidity sensor and Capacitive Humidity
sensor. For our exercise, we are using an electronic absorption hygrometer along with
Capacitive humidity sensor. This humidity sensors measure the humidity through electrical
capacitance.

1.1 ABSOLUTE HUMIDITY

The measure of actual amount of water vapor or moisture present in the air, without
considering air temperature is known as Absolute humidity. Therefore, higher the
amount of moisture, higher the absolute humidity. Absolute humidity is expressed as
grams of water vapor present per cubic meter volume of air. Absolute humidity is
independent of the air’s temperature.
1.2 RELATIVE HUMIDITY
It is the measure of water vapor or moisture present in the air, with regards to air’s
temperature. It is also be expressed as percentage (%), that means, the percentage of
the amount of moisture the air could hold. Also, relative humidity can be defined as, at a
current temperature, the measure of actual amount of water vapor present in the air in
comparison to the total amount of water vapor which can be present in the air. Relative
humidity is dependent on temperature, as if temperature reduces then relative humidity
increases and vice-versa
1.3 DEW POINT
It is defined as the temperature where the air has to be cooled down to, in order to
achieve or reach complete saturation. In simple words, to reach 100% Relative humidity.
1.4 CAPACITANCE
Capacitance is defined as the ability of electrical component or conductor to store
energy in the form of electric charge, if a potential difference exits between the
conductors. Capacitance is the effect of the capacitor. It can also be defined as the
ratio change in electric charge to the corresponding change in electric potential. The
unit of capacitance is “Farad”.

3
2.0 EXERCISE A- PRINTING A HUMIDITY SENSOR

2.1 AIM

To print the humidity sensors in the laboratory using screen printer and to analyse
the printed sensor by means of electrical characterization.

MATERIALS USED

1. Screen printing machine EKRA X1-SL

2. Screen printing form
3. Silver filled screen printing inks
4. Paper substrates
5. Multimeter
2.2 PROCEDURE

1. The humidity sensor is printed on Coated-Glossy (CG) paper in the Screen-printing

machine EKRA X1-SL.
2. The machine has to be initialised and the printing parameter has to be set every
time before the start of the printing process.
3. Suitable screen-printing form with the layout of required humidity sensor is selected
and placed in the machine.
4. Silver (Ag)-5028 ink is applied on the printing form after the squeegee is fixed to the
machine
5. Coated-Glossy (CG) paper is placed on the vacuum table and it is properly placed
by turning off and turning on the vacuum.
6. After the paper is set, then it moves right below the printing form and the ink is
spread all over the form and the ink transfers to the paper through the mesh gaps.
7. The printed sensor has to be moved to the oven which is around 125 °C for curing
for a time period of 6min.
8. Once curing is done, the printed substrate is taken out and with the help of
multimeter the resistance values are checked at any two points of defined length by
placing the positive and negative terminal of the multimeter and the values are noted
down as shown in Table 1
9. Also, for other substrates and ink, the resistances values are measured and
tabulated.

4
2.3 OBSERVATION

PAPER 1
Short name- CG
Paper Type-Coated – Glossy
Manufacturer-DuPont
Material name-5028
Conductive filler-Silver (Ag)
Nom. Sheet Resistance* Rs-12 mΩ/sq./mil

w
R s= R
l

Rs – Sheet Resistance
w- width = 1cm=0.01m
l – Length in meter
R- Resistance in Ω

w.t
ρ= l
R

ρ- Resistivity in Ωm
t - layer thickness in µm = 32.4 µm

TABLE 1: Resistance values of Silver (Ag)-5028

Sl. No. Length Resistance, R in Sheet Resistance, Resistivity, ρ

Ω RS in Ω in Ωm
l (m)

1 0.03 0.235 0.078 -6

2.54.10
2 0.05 0.325 0.065 2.11.10
-6

3 0.07 0.407 0.058 -6

1.88.10
4 0.08 0.453 0.056 1.83.10
-6

5 0.09 0.475 0.052 -6

1.71.10
Mean 0.379 0.062
Standard Deviation 0.099 0.010

5
 Resistance R vs length Sheet Resistance RS vs length

Sheet Resistance RS
Resistance, R in Ω
0.5 9.000
0.45 8.000
0.4 7.000
0.35 6.000
0.3 5.000
0.25 4.000
0.2
0.15 3.000
0.1 2.000
0.05 1.000
0 0.000
0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1

length (m) length (m)

Figure 1: Resistance R vs length in m Figure 2: Sheet Resistance RS vs length

Sheet Resistance Rs in Ω

Corelation of Resistance R Corelation of Sheet Resistance Rs

0.400 0.070
0.350 0.060
0.300
Resistance R in Ω

0.050
0.250
0.040
0.200
0.030
0.150
0.100 0.020
0.050 0.010
0.000 0.000
Average Standard Deviation Average Standard Deviation

Figure 3: Correlation of Resistance Figure 4: Correlation of Sheet Resistance

(Average and Standard deviation) (Average and Standard deviation)

PAPER 2
Short name- CG

6
Paper Type-Coated – Glossy
Manufacturer-Acheston
Material name- 965SS (electrodag)
Conductive filler- Carbon (C)
Nom. Sheet Resistance* Rs- 60 Ω/sq./mil

w
R s= R
l

Rs – Sheet Resistance
w- width = 1cm=0.01m
l – Length in meter
R- Resistance in Ω

TABLE 2: Resistance values of Carbon-- 965SS (electrodag)

Sl. No. Length l Resistance, R in Ω Sheet Resistance, RS

(m) in Ω
1 0.04 591 147.75
2 0.05 678 135.60
3 0.06 778 129.66
4 0.08 973 121.62
5 0.09 1063 118.11
Mean 816.6 130.55
Standard Deviation 197.97 11.79

7
 Resistance, R vs length l Sheet Resistance, Rs vs length l
1200 160.000
1000 140.000

Sheet Resistance, Rs
Resistance, R in Ω

120.000
800 100.000
600 80.000
400 60.000
40.000
200
20.000
0 0.000
0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1 0.03 0.04 0.05 0.06 0.07 0.08 0.09 0.1
length (m) length (m)

Figure 5: Resistance R vs length in m Figure 6: Sheet Resistance Rs vs length in m

Corelation of Resistance R
Corelation of Sheet Resistance Rs
900.000
140.000
800.000
700.000 120.000
Sheet Resistance Rs
Resistance R in Ω

600.000 100.000
500.000 80.000
400.000
60.000
300.000
200.000 40.000
100.000 20.000
0.000 0.000
Average Standard Deviation Average Standard Deviation

Figure 7: Correlation of Resistance Figure 8: Correlation of Sheet Resistance

(Average and Standard deviation) (Average and Standard deviation)

PAPER 3
Short name- UM
Paper Type-Uncoated – Machine finish
Manufacturer-Acheston
Material name- 965SS (electrodag)
Conductive filler- Carbon (C)
Nom. Sheet Resistance* Rs- 60 Ω/sq./mil

w
R s= R
l

Rs – Sheet Resistance
w- width = 1cm=0.01m

8
l – Length in meter
R- Resistance in Ω

TABLE 3: : Resistance values of Carbon-965SS (electrodag) in Uncoated Machine

finish

Sl. No. Length l Resistance, R in Ω Sheet Resistance, RS

(m) in Ω
1 0.03 672 224
2 0.04 844 211
3 0.06 1114 185.66
4 0.07 1298 185.42
5 0.085 1492 175.52
Mean 1084 196.32
Standard Deviation 331.85 20.28

Resistance, R vs length l
1600 Sheet Resistance, Rs vs length l
1400 250.00
Resistance, R in Ω

1200
Sheet Resistance, Rs

1000 200.00
800
150.00
600
400 100.00
200
50.00
0
0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
0.00
length (m) 0.02 0.03 0.04 0.05 0.06 0.07 0.08 0.09
length (m)

Figure 9: Resistance R vs length in m Figure 10: Sheet Resistance Rs vs length in m

9
 Corelation of Resistance R Corelation of Sheet Resistance Rs
1200.00 250.00

1000.00
200.00

Sheet Resistance Rs
Resistance R in Ω

800.00
150.00
600.00
100.00
400.00
50.00
200.00
0.00
0.00 Average Standard Deviation
Average Standard Deviation

Figure 11: Correlation of Resistance Figure 12: Correlation of Sheet Resistance

(Average and Standard deviation) (Average and Standard deviation)

2.4 DISCUSSION
1. If printed on the Coated-Glossy substrate with Silver (Ag)-5028 it will have lowest
resistance values

2. It is clear from the above graph of Resistance vs length, that if length increases, then
resistance also increases. It clearly shows, resistance is in direct proportion to length.

3. Higher the thread diameter of the mesh, higher the layer thickness can be achieved

4.Resistance of Silver (Ag)-5028 is comparatively less compared to Carbon (C) inks

5. Hence, silver is more conductive when compared to carbon.

3.0 EXERCISE B-CALIBERATION OF HUMIDITY SENSOR

10
3.1 AIM

The aim of this exercise is to calibrate the humidity sensor printed in the Exercise A
with the assistance of Arduino software.

MATERIALS USED

1. Screen Printed Humidity Sensor

2. Hygrometer
3. Arduino
4. USB 2.0 cable
5. Snap connectors (push buttons type)
6. Riveting Tool

3.2 PROCEDURE

1. Now the humidity sensor that was printed during the Exercise A is cut out from the
substrate paper.
2. Since the printed sensor is a passive type sensor, it cannot be directly connected to
an instrument to obtain the required output data.
3. Hence, we use Arduino hardware to convert the parameter variations of the printed
sensor into voltage/current signal variations which can then become a readable
format.
4. Now, the printed sensor is connected to Arduino by means of snap connectors (push
button type) which is attached to the sensor by riveting tool.
5. The above setup is now connected to a laptop by means of a USB cable.
6. Now calibration is done by measuring the capacitance in the ambient air through
Arduino in laptop and humidity by means of commercial hygrometer. These values
are recorded as a reference.
7. The entire setup of hygrometer, Arduino and the printed sensor is now transferred to
a box, which contains a water container.
8. The water in the container will evaporate and thus will increase the humidity within
the box and, now the capacitance and the relative humidity are measured and noted
down with a defined time interval.
9. The entire setup of printed sensor along with Arduino is now taken to room and then
the capacitance is measured for a specific duration with time interval of 30 minutes
and it is shown in the table 5.

10. The relative humidity is the noted from the calibration table 4 itself.
11. Also, graph is drawn between relative humidity and the corresponding time of the day

11
3.3 OBSERVATIONS

TABLE 4: CALIBRATION TABLE

TIME CAPACITANCE RELATIVE HUMIDITY

(Picofarad) (%)
(T1) 10 44
(T2) 10.5 57
(T3) 11.6 66
(T4) 12.8 70
(T5) 15.4 74
(T6) 20 77
(T7) 24 78
(T8) 29-45.2 80
(T9) 46-58 81
(T10) 59-70 82

Calibration graph
90
80
70
RELATIVE HUMIDITY (%)

60
50
40
30
20
10
0
10 10.5 11.6 12.8 15.4 20 24 29-45.2 46-58 59-70

CAPACITANCE (Pico Farad)

TABLE 5: Relative humidity and Time measurement at room

TIME CAPACITANCE RELATIVE HUMIDITY

12
 (Pico Farad) (%)
7:30 pm (T1) 11.7 66
8:00 pm (T2) 11.25 60
8:30 pm (T3) 12.08 70
9:00 pm (T4) 12.06 70
9:30 pm (T5) 12.06 70
10:00 pm (T6) 14.88 72
10:30 pm (T7) 15.41 74
11:00 pm (T8) 15.31 74
11:30 pm (T9) 15.46 74
12:00 pm(T10) 15.45 74
12:30 pm (T11) 15.48 74
13:00 pm (T12) 15.38 74

Relative humidity vs Time at room

80

70

60
RELATIVE HUMIDITY (%)

50

40

30

20

10

0
(T1) (T2) (T3) (T4) (T5) (T6) (T7) (T8) (T9) (T10) (T11) (T12)
TIME

TABLE 6: RELATIVE HUMIDITY OF CHEMNITZ FROM WUNDERGROUND.COM

RELATIVE TEMPERATURE DIFFERENCE IN

13
 TIME HUMIDITY from from Website (°C) HUMIDITY (%)
Website (%) (Room and and
website values)
7:20 PM 64 18.8 2
7:50 PM 68 17.7 8
8:20 PM 68 17.7 2
8:50 PM 72 17.2 2
9:20 PM 72 17.2 2
9:50 PM 77 17.2 5
10:20 PM 77 17.2 3
10:50 PM 77 17.2 3
11:20 PM 77 17.2 3
11:50 PM 77 17.2 3
12:20 AM 77 17.2 3
12:50 AM 82 16.1 3
1:20 AM 77 17.2 2

Date: 18/08/2021
Assumed Room Temperature: 17 °C

Relative Humidy of Chemnitz

RELATIVE HUMIDITY from Website (%)

90
80
70
60
50
40
30
20
10
0
7:20 PM

7:50 PM

8:20 PM

8:50 PM

10:50 PM

11:20 PM

12:20 AM

12:50 AM
9:20 PM

9:50 PM

10:20 PM

11:50 PM

1:20 AM

Time

Calculation of absolute humidity from the relative humidity:

14
 ( T17.67T
+243.5 )
Absolute humidity = 6.112∗ⅇ ∗RH∗2.1674
( 273 ⋅15+T )

RH – Relative humidity
T- Temperature in °C
Let’s take T- Temperature in °C = 19 °C
Relative Humidity at 10.20 PM = 77%
Absolute Humidity = 11.3 g/m3

3.4 DISCUSSIONS

1. From the above graph, it is clearly evident that capacitance and Relative humidity are
directly proportional.

2. With the help of Arduino chipset and software, the capacitance is measured using the
printed humidity sensor. The recorded capacitance is then used to find the corresponding
Relative Humidity by referring to the calibration table.

3.Also, Relative humidity is dependent on the temperature, whereas absolute humidity is

independent of temperature

4.Gradual increase in capacitance and relative humidity was observed when the setup was
placed in the box containing a container of water, whereas in room condition it is almost
constant

15