FUJIFILM Dimatix SG1024 Starfire Grayscale Printhead and System Solution

FUJIFILM Dimatix SG1024 Starfire Printhead Specifications

The FUJIFILM Dimatix STARFIRE SG1024 is designed for today’s demanding high-speed scanning and single-pass industrial systems. It is a high-performance piezoelectric drop-on-demand (DOD) inkjet printhead, suitable for single-channel or dual-channel configurations, with resolutions of up to 400 dpi.

The printhead utilizes field-proven components and REDIJET® continuous ink recirculation, delivering consistent output over an extended service life. The printhead is fully serviceable and features a replaceable metal nozzle plate assembly.

Technical Specifications – SG1024 Series

 

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What Is Grayscale Printing?

From the perspective of droplet generation, there are three primary printing modes:

1. Binary Printing (Native Mode)

• Also known as native binary printing
  
  

• 1 bit per pixel (1 bpp)
  
  

• Each pixel is either 0 or 1 droplet
  
  

• All nozzles fire droplets of the same fixed size
  
  

2. Variable Binary Printing (Binary Multi-Pulse)

• Also known as binary multi-pulse
  
  

• 1 bit per pixel (1 bpp)
  
  

• Multiple droplets are fired and merged into a single droplet of user-selected size
  
  

• Enables ink volume adjustment in single-pass printers without changing printhead type
  
  

• Requires a multi-pulse amplifier
  
  

3. Grayscale Printing (Multi-Bit Printing)

• Also known as multi-bit printing
  
  

• 2 bpp or 3 bpp per pixel
  
  

• Each nozzle fires a controlled number of droplets that merge into small, medium, or large droplets
  
  

• Each firing cycle can generate different droplet sizes
  
  

Unlike binary printing, which produces only “ink” or “no ink” pixels, grayscale printing offers:

• Sharper text
  
  

• Cleaner edges
  
  

• Improved color matching with less ink
  
  

• High image quality without sacrificing throughput, which is critical for single-pass printing systems
  
  

 

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VersaDrop™ Grayscale Technology and the SG1024 Starfire Printhead

FUJIFILM Dimatix’s grayscale technology is known as VersaDrop™.

With VersaDrop:

• A fixed amount of fluid is injected into a droplet before nozzle separation
  
  

• Droplets merge close to the nozzle, improving drop placement accuracy compared to merging near the substrate
  
  

The SG1024 Starfire supports all three printing modes:

• Binary
  
  

• Variable binary
  
  

• Grayscale
  
  

It is a 2 bpp printhead, supporting up to 4 grayscale levels (0, 1, 2, or 3).

Droplets are generated by non-resonant piezo excitation, using precisely timed waveforms with variable amplitudes.

Printing Modes Explained

Binary Mode

• Uses a single optimized trapezoidal pulse
  
  

• Produces the base droplet size for which the printhead is designed
  
  

Variable Binary Mode

• Uses multiple trapezoidal pulses with increasing amplitudes
  
  

• Produces droplets 1.5× to 3× the base droplet size
  
  

• No per-pixel droplet size selection within the same image
  
  

• Requires a multi-pulse amplifier
  
  

Grayscale Mode

• Each firing cycle can produce small, medium, or large droplets
  
  

• Droplet size is selected based on image data
  
  

• Requires:
  
  

• Multi-pulse amplification
  
  

• Multi-bit data encoding/decoding
  
  

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Printhead Driver Electronics

Designing a driver board for grayscale printing is a highly complex task requiring significant expertise.

To support the SG1024 Starfire’s grayscale capability, Dimatix specifies critical requirements for:

• Pulse generation circuitry
  
  

• Data path architecture
  
  

The driver system must:

• Generate high-voltage trapezoidal waveforms across a range of jetting loads
  
  

• Support multiple trapezoidal pulses of different amplitudes within a single waveform
  
  

• Provide fully programmable waveforms optimized for different inks and applications
  
  

• Update switch states immediately before each pulse event
  
  

Precise waveform control is essential to ensure correct droplet size and velocity, considering factors such as:

• Early pulses cause droplets to emerge sooner
  
  

• Smaller droplets have longer flight times than larger droplets
  
  

• Droplet velocities vary due to pulse amplitude differences
  
  

• Droplet collisions and coalescence during flight
  
  

• Variations in nozzle-to-substrate distance
  
  

• Ink-dependent waveform requirements
  
  

Ideally, the driver board provides one power amplifier per nozzle row, allowing compensation for row-to-row variation.

Low-cost driver boards typically switch only between two voltage levels, which limits control. For optimal grayscale performance:

• Each sub-droplet pulse should have a unique waveform shape
  
  

• The first pulse requires more energy than subsequent pulses because the piezo element is already oscillating
  
  

Independent timing and waveform control for each pulse enables far superior droplet control beyond basic multi-pulse operation.

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SG1024 Starfire Grayscale System Requirements

To utilize the grayscale functionality of the SG1024 Starfire printhead, the system must support:

• Image files in TIFF format
  
  

• 2 bpp grayscale depth
  
  

• Driver electronics and software capable of:
  
  

• Processing 2 bpp grayscale data
  
  

• Decoding pixel values
  
  

• Sending multiple synchronized data blocks to the printhead
  
  

• Generation of digitally defined, multi-pulse complex waveforms
  
  

• Precise droplet placement on moving substrates
  
  

 

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Meteor System Solution for SG1024 Starfire

Meteor Inkjet provides production-grade electronics and software that fully support grayscale printing with the FUJIFILM Dimatix SG1024 Starfire printhead.

Meteor’s SG1024 Starfire solution offers:

1. Support for all three printing modes (binary, variable binary, grayscale)
   
   

2. Generation of digitally defined multi-pulse complex waveforms with selectable pulses for variable droplet sizes
   
   

3. Integrated multi-pulse amplifiers and multi-bit data encoding/decoding
   
   

4. High-voltage trapezoidal pulse generation across a wide jetting load range
   
   

5. Precise switch-state updates before every waveform pulse
   
   

6. Fully programmable waveform optimization for different inks and applications
   
   

7. Dedicated power amplifiers per nozzle row, not simple two-level switching
   
   

8. Support for unique analog pulse shapes for each sub-droplet
   
   

9. An intuitive hardware/software integration model with global customer support
   
   

 

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★ Tips: About Meteor Inkjet

Meteor was founded by TTP Group, a leading independent technology and product development company based in Cambridge, UK, and is a wholly owned subsidiary of Hybrid Software Group PLC (Euronext: HYSG).

Meteor is a world-leading independent supplier of industrial inkjet electronics, software, tools, and services. Renowned for technical expertise and innovation, Meteor is trusted by printhead manufacturers and printer OEMs worldwide.

With decades of deep understanding of the science and engineering behind digital printing, Meteor delivers robust, cost-effective, and future-ready solutions.

Meteor’s global customer base spans industries including:

• Ceramic tiles
  
  

• Pharmaceuticals
  
  

• Direct shaping
  
  

• Textiles
  
  

• Packaging
  
  

• 3D/additive manufacturing
  
  

• Functional and security printing
  
  

• Electronics
  
  

• Labels
  
  

• Signage and display
  
  

• Decorative printing
  
  

• Commercial printing
  
  

• Book printing
  
  

• Glass printing