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The design and manufacture of 3D miniaturised integrated products
The Grand Challenge Project
3D-Mintegration
Results, opportunities and challenges
Prof. Marc Desmulliez
The design and manufacture of 3D miniaturised integrated products
What is 3D-MINTEGRATION about?
The EPSRC-funded project has for aim to develop radically new ways of thinking for the end-to-end
DesignProcessingAssemblyPackagingIntegrationand Testing
of complete 3D miniaturised/integrated “3D-MINTEGRATED” products
The design and manufacture of 3D miniaturised integrated products
Industrially focussed
23 companies providing £2.8M of support
Market driven: The work is aimed at next generation automotive, aerospace, telecommunications, medical and consumer products
Tangible deliverables: The project will push breakthrough processes into companies
The design and manufacture of 3D miniaturised integrated products
Large
8 Institutions: Greenwich, Loughborough, Nottingham, Heriot-Watt, NPL, Cambridge, Cranfield, Brunel
A £9.2M 4.5-year programme
We have 100 Man/Years of research, a new equipment spend of £1.1m, and an existing equipment asset base of £7m
Multiple span out projects at National and European levels
The design and manufacture of 3D miniaturised integrated products
Radical - but organised
The research is organised in 5 themes, spanning from raw materials (e.g. nano-particles) to products
&3D ProcessingPackaging
IntegrationMicroassembly
Design
Simulation&
Measurement
Materials
&Test
Products
The design and manufacture of 3D miniaturised integrated products
….with a framework….
Design &
Simulation
Deliverables
3D Processing
Deliverables
Microassem
bly D
eliverables
Packaging &
Integration D
eliverables
Test & M
easurement
Deliverables
Workpackage 1
Design & Simulation
Chris Bailey Greenwich
Workpackage 2
3D Processing
David Allen Cranfield
Workpackage 3
Microassembly
Svetan Ratchev Nottingham
Workpackage 4Packaging & Integration
Paul Conway Loughborough
Workpackage 5
Test & Measurement
Richard Leach NPL
HUMMS demonstrator
BCF
MiniFluidic demonstrator
Epigem
MiniEMS demonstrator
NPL
Project Management
Determine the key characteristics (most
influential design variables)
The design and manufacture of 3D miniaturised integrated products
Influence of 3D-M on the wealth of the Nation
Generate sustainable energy-efficient products and manufacturing processesReduce the UK’s vulnerability to globally-strategic supply chainsCreate agile thinking processes in a new generation of applications-orientated product and process designers and developers
The design and manufacture of 3D miniaturised integrated products
Four delivery channels
Academic outputsPersonnel developmentKnowledge transfer activitiesImmediate applications
The design and manufacture of 3D miniaturised integrated products
Academic outputs to date
JOURNAL CONFERENCE PAPER
BOOK/CHAPTER/
THESISPATENT SOFTWARE DISSEMINATION
Total Number of Publications 35 107 13 5 1 96
Number of Refereed Publications (if different from
above)
34 94 2 0 0 0
Number of Publications That
Contain An Industrial Co-Author
11 17 3 0 0 0
Number of Publications That Contain Another Member of the
Consortium
19 24 1 0 0 0
The design and manufacture of 3D miniaturised integrated products
Academic Output Highlights
15 Keynote Presentations in International Conferences2 Best paper awards (HDP-ICEPT 2008, HDP-ICEPT 2009)1 Best poster presentation award (MicroTech - IMAPS UK 2008)33 Invited talks
The design and manufacture of 3D miniaturised integrated products
Personnel Development
22 Ph.D. students, 12 Research Fellows, 6 Technicians, and 2 Industrial advisers directly engaged by the 3D-M project, plus a further 21 Man-years of resource contributed by the IMRCs.
The design and manufacture of 3D miniaturised integrated products
Community building
Events– Annual get-together of the whole community
– As-required demonstrator workshops involving all concerned
– Annual conference, streamed for external and internal audiences : the next one is TOMORROW, here !
Web site– www.3d-mintegration.com
Publications– Annual Review in the form of a house magazine
– Doubles as a brochure for dissemination
– Monthly newsletter
The design and manufacture of 3D miniaturised integrated products
Follow on projects (UK)
IMRCs and IeMRC:– Micromachining of probe. £100K (Cranfield)– Megasonic electroplating. £455K (Heriot-Watt)– Microsystems Applications. £450K (Cranfield)– Process integration for manufacturing of microtooling. £650K (Nottingham)– Prognostics. £250K (Greenwich)
EPSRC-IKC on ultraprecision structured surfaces (Cambridge,Cranfield, UCL). £7M.
TSB:– Technologies for health call. MEMSpatch. £1.3M. 2 industrial partners (Nottingham)
KTP:– HUMMS. £380K. With industrial partners Ultra-Electronics BCF. (Heriot-Watt)
Others:– NMS 2005-2008 Microprobe project. £450K (NPL). – NMS 2008-2011 Microprobe project. £780K.(NPL)– Feasibility study Renishaw. £28K. (Heriot-Watt)– Centre of Excellence in Customised Assembly CECA, funded by £5M HEIF Grant jointly with
Sheffield and Loughborough Universities
The design and manufacture of 3D miniaturised integrated products
Step 1: Preconditioning
Step 2: Vias and cavity formation
Step 3: Printing
Step 4: Stacking
Step 5: LaminationStep 6: Firing
Step 7: Post processing
Step 8: Singulation
Facilities – Example of LTCC
The design and manufacture of 3D miniaturised integrated products
Knowledge Transfer Activities
The design and manufacture of 3D miniaturised integrated products
Patents
Microprobe design (PCT stage)Microwave curing (GB stage) – originally an IeMRC feasiblity study projectSelf assembly of metal/polymer nanostructures onto substrates (GB stage)Laser welding technology for microfluidics (GB stage)Microforging (GB stage)
The design and manufacture of 3D miniaturised integrated products
International engagement
FP7 INTEG-MICRO to use precision machining techniques to machine 3D components in a reduced footprint machine. 12MEuros. 20 partners out of which 14 are industrial. FP6 co-ordinated Action MicroSapient. 1 MEuros. 12 partners of which 6 are industrial.FP7 FAMOBS to microwave cure components. Working with SME associations. 2.5 MEuros. 14 partners out of which 5 are industrial.FP7 co-ordinated Action CEPoSS Technology Platform on Smart System Integration. 1 MEuros. 20 partners of which 18 are industrial.High level involvement in global working groups/consortia
The design and manufacture of 3D miniaturised integrated products
Industry predictions for 3D-MINTEGRATION processes
2025+2007 2015+2009 20132011 2014 2020+2008 2010 2012
Not used at all
Widely used
Ramp up
Sampling
Seven individual predictions of usage in each category, ranked by timescales
Growth patterningfar from market
Micro imprintingfar from market
Multifunctional Interconnection a little closer to market
Micro-machiningslightly earlier uptake
Design & Simulationslow start, but fast ramp to 2013
Integration & Encapsulationearly adoption, medium ramp
Microassemblyimminent adoption, slower ramp
Micro injection mouldingalready deployed, but much to do
The design and manufacture of 3D miniaturised integrated products
Industrial take up
Microprobe demonstrator by NPL for commercialisation– Metrology, instrumentation market
Optical metrology techniques by Taylor Hobson Ltd– Instrumentation
Microfluidic designs for blood separation by EPIGEM– Biomedical, life sciences
HUMMS demonstrator by Ultra Electronic (ex-BCF)– Aerospace, transport
The design and manufacture of 3D miniaturised integrated products
Instrumentation
NPL acquired Zeiss micro-CMM equipment as part of CEMMNTNMS funding to shrink probe size required radical new 3D design conceptsA 3D vibrating, high aspect ratio micro-CMM probe3DM team – Greenwich (modelling, simulation and optimisation), Cranfield (manufacture of flexures and piezo films), Cambridge (cost effective manufacturing strategies), Nottingham (assembly)Patent applied for and potential commercialisation routes investigatedPotentially large market for micro-probes in milli/micro-manufacture, automotive, microfluidics, etc,Also, novel uses of flexure concept, adhesion/fundamental force probe, bio-manipulator, others
The design and manufacture of 3D miniaturised integrated products
Software – 3D-Mintevision
Design and Simulation – 3D-Fabrication
• Imprint Forming, FIB• Micro-Injection Moulding• Electro-deposition
– Micro-Assembly • Micro-feeder
– Packaging • Microwave Curing, Laser Joining
– Test and Measurement • Micro-probe
– Demonstrators• Mini-Fluidic; Micro-Probe
3D-Mintevision– Design assistant– Reduced order models– Risk evaluation and risk mitigation– Optimisation
The design and manufacture of 3D miniaturised integrated products
Microfluidic systems
Cell separation system machined by fiber laser
Blood flow through T channels
3D cell separation system
Plasma
Cells
The design and manufacture of 3D miniaturised integrated products
Success story – the next generation
Each year, the whole team of consortium members and 40+ researchers meets for a “Community Event”As a community, we have evolved to think radically, and to think in our own “3D-MINTEGRATION” space
...Ready for the next challenge
The design and manufacture of 3D miniaturised integrated products
Conceptual application: the i-ball
The design and manufacture of 3D miniaturised integrated products
i-ball
i-ball is a biologically-inspired washball, tossed in with the laundry to sample the wash water– to monitor and adjust detergent levels and wash cycle energy, and
to minimize the use of rinse water– To analyze for health-indicating trace materials from soiled clothing
A complex biomimetic system
The design and manufacture of 3D miniaturised integrated products
i-ball
Sealed microchannels with a width of
50um and a height of about 72um.
The design and manufacture of 3D miniaturised integrated products
The way ahead
Develop applications, machines, services,
New ways of thinking
Grow3D-MINTEGRATION
Downstream collaboration
Commercial exploitation
The design and manufacture of 3D miniaturised integrated products
More information
David Topham (Email:[email protected])
Marc Desmulliez (Email:[email protected])
4th Annual 3D-Mintegration conference: tomorrow- Henry Ford College.
