Applications. Applications

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Barnaby Norris
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1 Applications Marc Madou UC Irvine Dept. of Mechanical and Aerospace Engineering April 22, 2005 Chapter 6 Non-Lithography Applications Fraunhofer Gesellschaft Institute for Production Systems and Design Technology (IPK) 5-Axis-HP-Milling Center Gamma High Performance 303 by WISSNER GmbH, Göttingen Intro Foreign Highlights US State-of-the-Art Competitive Assessment-Report Card/Suggested Recommendation Q/A

AIST-DTF precursor Intro Handheld EDM at

assembly at Olympus Intro Desk Top Factory is

But Korea and Europe are starting large new

Over the last 20 years the US has emphasized

2 AIST-DTF precursor Intro Handheld EDM at Panasonic Sankyo Seiki-Commercial DTF DTF lens assembly at Olympus Intro Desk Top Factory is now commercially available in Japan (Sankyo Seiki). Impact remains to be seen. Many skeptics both in Asia and Europe. But Korea and Europe are starting large new programs in it. Over the last 20 years the US has emphasized MEMS, while Japan and Germany also continued funding incremental improvements in more traditional manufacturing processes.

3 Intro Problems encountered in manufacture of next generation products has led to new manufacturing processes in Asia. Examples: RT deposition of piezo-electrics (AIST) Stitching of fibers on substrates (Hitachi) Pressure sensitive/anisotropic contacts (Hitachi) Institutes in Europe specialize very narrowly and have become leaders in their field. Laser machining (LZH), packaging (Fraunhofer IZM), stainless steel micro chemical reactors (IMM), etc LZH IZM IMM IZM Intro MEMS and traditional machining foundries are moving (have moved) to Asia and Europe: Olympus MEMS foundry services in Japan MiPLaza the Microsystems Plaza of Philips Research in Holland IMM in Germany IMEC in Belgium Center for Microsystem Technology in Berlin-Adlershof Institutes/companies that used to do both MEMS and traditional machining are now shifting away from MEMS in favor of traditional machining. Center for Microsystem Technology, Berlin

Intro Incremental improvements we saw at many

Examples: Tool design at IPK Wave printing soft

time to work out the details of manufacturing

abandoned in the US because they did not make it

inspired) All the Europeans Institutes we visited

4 Intro Incremental improvements we saw at many places could not get funded in the US. Examples: Tool design at IPK Wave printing soft lithography at Philips Engineers seem to have the time to work out the details of manufacturing processes Processes that are sometimes already abandoned in the US because they did not make it in a start-up mode are still researched in Asia and Europe (e.g., tilting micro-mirrors at Philips-No Si, TI inspired) All the Europeans Institutes we visited are extremely well equipped and work very close with Industry Philips IPK Philips Foreign Highlights-Applications Philips IMM

Applications of DTF Sankyo Seiki -the industrial leader in DTF- describes the DTF as an effort to prevent hollowing out of manufacturing in Japan!

5 Applications of DTF Sankyo Seiki -the industrial leader in DTF- describes the DTF as an effort to prevent hollowing out of manufacturing in Japan! First commercial equipment is for cleaning of micro-parts Next product will be for assembly Assembly (e.g., camera lenses at Olympus). Mounting and applying glue to camera lenses (200 µm diameter). Applications All types of micromotors (while we were making Si surface micromachined MEMS motors!!!)-samsung. Micro-speakers-Samsung. Cameras with more and more features- Olympus. Mobile telephones with more and more features-panasonic. Large scale optics (at Philips): Diamond turning is used to make linear and circular structures on large surfaces using the Lifrel (Linear Fresnel Lathe) and Cifrel (Circular Fresnel Lathe) machines. These structures are used as moulds to produce e.g. frontlights, backlights, Fresnel lenses, lenticulars for 3D-TV,etc. Mould dimensions can be up to 1.5 m by 1.2 m on the Lifrel and 2 m diameter on the Cifrel. Philips Samsung Panasonic

Applications Mass consumer applications instead of military

, smart toilet Toto) Optical components for laser printers

diodes (OLEDs) at LG Chemical for displays Toto Samsung

6 Applications Mass consumer applications instead of military or homeland security (e.g., smart toilet Toto) Optical components for laser printers instead of optics for Mars at Samsung Organic light emitting diodes (OLEDs) at LG Chemical for displays Toto Samsung Samsung-LG Chemical US State-of of-the-art QuickTime and a GIF decompressor are needed to see this picture.

US State-of of-the-art http://www.almaden.ibm.com/vis/stm/atomo.

protein arrays and associated fluidics MEMS emphasis on RF-MEMS and BIOMEMS Assembly

micro-factory work Proximal probe work Huge amount of nanotube work and more and more

decompressor are needed to see this picture.

Artificial cell attempts Still in the run for ultraprecision machining (see Nanotech

7 US State-of of-the-art Very heavy emphasis on nanotechnology Dip-pen nanolithography writing DNA and protein arrays and associated fluidics MEMS emphasis on RF-MEMS and BIOMEMS Assembly and self-assembly Hybrid bottom-up and top-down Some limited Micro-EDM work and micro-factory work Proximal probe work Huge amount of nanotube work and more and more nanowires Bimometic bottom-up approaches Eigler QuickTime and a Photo - JPEG decompressor are needed to see this picture. Montemagno US State-of of-the-art Drug delivery CD based fluidics Building with DNA Artificial cell attempts Still in the run for ultraprecision machining (see Nanotech Machine at IPK) Madou QuickTime and a GIF decompressor are needed to see this picture. Seeman 5-Axis-UP-Machining Center Nanotech 350 FG by Moore Nanotechnology Systems Ltd. (USA)

8 US State-of of-the-art E-ink User sees White User sees Black + - Negative Charge - + Comparative Assessment- Report Card

9 Report Card Countries Japan Taiwan Korea Europe U.S. Activities DTF/ Traditional Manufacturing ***** ***** NA *** ** **** * **** NA ** Equipment Base * * * * * *** *** ***** *** Nanotechnology * * * * * * * * * * ***** Suggested Recommendations Four Asian strategies to retain manufacturing Base Increase funding of new manufacturing technology (4-8 %/Y) Build IP portfolio R&D in India, Eastern Europe and Russia Only let manufacturing for a given product go (say computers) if something of equal value is in the pipeline Desk top factory (DTF)

10 Suggested Recommendations US Possible Strategies Start new courses in fundamentals of manufacturing Set up very specialized labs in new manufacturing technology Fund incremental improvements not only blue sky Help transition military technology to the commercial world Encourage industrial collaborations for Universities and Institutes Work towards mass consumption products not only high addon-value Exchange programs for US students with Japan, Korea, Germany and Switzerland Suggested Recommendations More US Possible Strategies Do fund the desk top factory concept as a demonstrator program Avoid funding only nanotechnology Implement longer term strategies to avoid further manufacturing loss Stricter government oversight before manufacturing jobs are sent abroad Urge mechanical engineering departments to get back into manufacturing Do not give up on new concepts as quickly as we have in the past Sweat out the details Compensate people that create new manufacturing jobs, not stock manipulators Find a funding balance between steady progress and true innovation

Q/A Are we too negative ( The grass is always

What are the bright spots in the US in terms

Can a country be secure without manufacturing

11 Q/A Are we too negative ( The grass is always greener on the other side)? What are the bright spots in the US in terms of micromanufacturing? Will nanotechnology save the US? Do we need manufacturing in the US? Can a country be secure without manufacturing (by % of the IC Industry might be located in China)? Can the US even control what type of manufacturing we export? Can we still teach manufacturing processes if we are not a player? Thank You!

Industrialization of Micro-Electro-Mechanical Systems. Werner Weber Infineon Technologies

Industrialization of Micro-Electro-Mechanical Systems Werner Weber Infineon Technologies Semiconductor-based MEMS market MEMS Market 2004 (total 22.7 BUS$) Others mostly Digital Light Projection IR Sensors