Micro-manufacturing : research, technology outcomes and development issues

Besides continuing effort in developing MEMS-based manufacturing techniques, latest effort in Micro-manufacturing is also in Non-MEMS-based manufacturing. Research and technological development (RTD) in this field is encouraged by the increased demand on micro-components as well as promised development in the scaling down of the traditional macro-manufacturing processes for micro-length-scale manufacturing. This paper highlights some EU funded research activities in micro/nano-manufacturing, and gives examples of the latest development in micro-manufacturing methods/techniques, process chains, hybrid-processes, manufacturing equipment and supporting technologies/device, etc., which is followed by a summary of the achievements of the EU MASMICRO project. Finally, concluding remarks are given, which raise several issues concerning further development in micro-manufacturing

An integrated framework for developing generic modular reconfigurable platforms for micro manufacturing and its implementation

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.The continuing trends of miniaturisation, mass customisation, globalisation and wide use of the Internet have great impacts upon manufacturing in the 21st century. Micro manufacturing will play an increasingly important role in bridging the gap between the traditional precision manufacturing and the emerging technologies like MEMS/NEMS. The key requirements for micro manufacturing in this context are hybrid manufacturing capability, modularity, reconfigurability, adaptability and energy/resource efficiency. The existing design approaches tend to have narrow scope and are largely limited to individual manufacturing processes and applications. The above requirements demand a fundamentally new approach to the future applications of micro manufacturing so as to obtain producibility, predictability and productivity covering the full process chains and value chains. A novel generic modular reconfigurable platform (GMRP) is proposed in such a context. The proposed GMRP is able to offer hybrid manufacturing capabilities, modularity, reconfigurablity and adaptivity as both an individual machine tool and a micro manufacturing system, and provides a cost effective solution to high value micro manufacturing in an agile, responsive and mass customisation manner. An integrated framework has been developed to assist the design of GMRPs due to their complexity. The framework incorporates theoretical GMRP model, design support system and extension interfaces. The GMRP model covers various relevant micro manufacturing processes and machine tool elements. The design support system includes a user-friendly interface, a design engine for design process and design evaluation, together with scalable design knowledge base and database. The functionalities of the framework can also be extended through the design support system interface, the GMRP interface and the application interface, i.e. linking to external hardware and/or software modules. The design support system provides a number of tools for the analysis and evaluation of the design solutions. The kinematic simulation of machine tools can be performed using the Virtual Reality toolbox in Matlab. A module has also been developed for the multiscale modelling, simulation and results analysis in Matlab. A number of different cutting parameters can be studied and the machining performance can be subsequently evaluated using this module. The mathematical models for a non-traditional micro manufacturing process, micro EDM, have been developed with the simulation performed using FEA. Various design theories and methodologies have been studied, and the axiomatic design theory has been selected because of its great power and simplicity. It has been applied in the conceptual design of GMRP and its design support system. The implementation of the design support system is carried out using Matlab, Java and XML technologies. The proposed GMRP and framework have been evaluated through case studies and experimental results

Design and construction of a novel reconfigurable micro manufacturing cell

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Demands for producing small components are increasing. Such components are usually produced using large-size conventional machining tools. This results in the inadequate usage of resources, including energy, space and time. In the 1990s, the concept of a microfactory was introduced in order to achieve better usage of these resources by scaling down the size of the machine tool itself. Several industries can benefit from implementing such a concept, such as the medical, automotive and electronics industries. A novel architecture for a reconfigurable micro-manufacturing cell (RMC) is presented in this research, aiming at delivering certain manufacturing strategies such as point of use (POU) and cellular manufacturing (CM) as well as several capabilities, including modularity, reconfigurability, mobility and upgradability. Unlike conventional machine tools, the proposed design is capable of providing several machining processes within a small footprint (500 mm2), yet processing parts within a volume up to 100 mm3. In addition, it delivers a rapid structure and process reconfiguration while achieving a micromachining level of accuracy. The approach followed in developing the system is highly iterative with several feedback loops. It was deemed necessary to adopt such an approach to ensure that not only was the design relevant, but also that it progresses the state-of-the-art and takes into account the many considerations in machine design. Following this approach, several design iterations have been developed before reaching a final design that is capable of delivering the required manufacturing qualities and operational performance. A prototype has been built based on the specifications of the selected design iteration, followed by providing a detailed material and components selection process and assembly method before running a performance assessment analysis of the prototype. At this stage, a correlation between the Finite Element Analysis (FEA) model and prototype has been considered, aiming at studying the level of performance of the RMC when optimising the design in the future. Then, based on the data collected during each stage of the design process, an optimisation process was suggested to improve the overall performance of the system, using computer aided design and modelling (CAD/CAM) tools to generate, analyse and optimise the design

Micro-manufacturing research : drivers and latest developments (Keynote Paper)

Increased demands on micro-products and miniaturised systems/devices may have been a main driver to the rapid growth of the interest in research in micro- and nano-manufacturing. It seems, however, not to be the only reason why so much funding has been made available for researchers to be able to conduct research in this emerging field. A review was conducted recently with a view to gaining a clearer view of demands on the applications and on trends in developments in micro-manufacturing, by looking at the market, research topics, projects, interactions with industry, outcomes and applications. It was found that there have been significant changes/advances in micro-manufacturing research, compared to what had been undertaken and achieved in 5 ~ 10 years ago, being reflected especially by: (i). micro-manufacturing research bridging “nano-manufacturing” and “macro-manufacturing” and hence, bringing nano-technology into real-life and affordable products; (ii). addressing multi-length scale manufacturing problems and hence, linking it to macro-sized product manufacturing, which adds its relevance to general manufacturing and wide-sector applications; (iii). micro-manufacturing research being shifted from “process focus” to “market/product” driven research and technological development addressing production capability, product quality, pilot production line demonstration and delivery; and (iv). micro-manufacturing research playing roles in helping to transform traditional industry and products. These new developments may justify past and current significant investment in research and technological development in micro- and nano-manufacturing, and suggest more significant impacts to come in near future

Programmable photonics : an opportunity for an accessible large-volume PIC ecosystem

We look at the opportunities presented by the new concepts of generic programmable photonic integrated circuits (PIC) to deploy photonics on a larger scale. Programmable PICs consist of waveguide meshes of tunable couplers and phase shifters that can be reconfigured in software to define diverse functions and arbitrary connectivity between the input and output ports. Off-the-shelf programmable PICs can dramatically shorten the development time and deployment costs of new photonic products, as they bypass the design-fabrication cycle of a custom PIC. These chips, which actually consist of an entire technology stack of photonics, electronics packaging and software, can potentially be manufactured cheaper and in larger volumes than application-specific PICs. We look into the technology requirements of these generic programmable PICs and discuss the economy of scale. Finally, we make a qualitative analysis of the possible application spaces where generic programmable PICs can play an enabling role, especially to companies who do not have an in-depth background in PIC technology

Flight Avionics Hardware Roadmap

As part of NASA's Avionics Steering Committee's stated goal to advance the avionics discipline ahead of program and project needs, the committee initiated a multi-Center technology roadmapping activity to create a comprehensive avionics roadmap. The roadmap is intended to strategically guide avionics technology development to effectively meet future NASA missions needs. The scope of the roadmap aligns with the twelve avionics elements defined in the ASC charter, but is subdivided into the following five areas: Foundational Technology (including devices and components), Command and Data Handling, Spaceflight Instrumentation, Communication and Tracking, and Human Interfaces

Recent research on flexible fixtures for manufacturing processes

Fixtures, are used to fixate, position and support workpieces, and form a crucial tool in manufacturing. Their performance influences the manufacturing (and assembly) process of a product. Furthermore, fixturing can form a significant portion of the needed investment and total process planning time for the manufacturing system. Many fixturing concepts, as contribution to increase the flexibility of the manufacturing system, are reported in the literature. The flexible fixturing designs can be classified into the following seven categories: modular fixtures, flexible pallet systems, sensor-based fixture design, phase-change based concepts, chuck-based concepts, pin-type array fixtures and automatically reconfigurable fixtures. It is observed that the more intelligent and automated fixturing systems are designed with the demands for automation in certain industries in mind. Furthermore, different fixturing solutions suit the engineering demands for different manufacturing areas, this means that for the foreseeable future all technologies will remain current. From the self-reconfigurable fixturing techniques a new fixturing capability is emerging: in process reconfigurability for the optimal placement of clamps and supports during the whole process time. These several concepts together with some recent patents are studied here. The paper concludes with some prospective research directions in the field of flexible fixturing

2009 Exhibitors

Listings and Descriptions of 2009 Small Satellite Conference Exhibitor