The design and manufacture of 3D miniaturised integrated products 3D-MINTEGRATION The Grand Challenge David Topham
The design and manufacture of 3D miniaturised integrated products
3D-MINTEGRATION
The Grand Challenge
David Topham
The design and manufacture of 3D miniaturised integrated products
This project has some very interesting and unforeseen problems!
Pay attention, you may be able to help!
The design and manufacture of 3D miniaturised integrated products
What is it all about?
A project 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
The silicon revolution
It has to be cut up and put back together somehow to fit in our pockets!But silicon is just so, well, flat!
The design and manufacture of 3D miniaturised integrated products
Visionary
Our vision is a momentous departure from the production of silicon-based "microsystems" whose processing derives from the flat-land of semiconductors
Our intention is to– Design in 3D– Manufacture in 3D– Test in 3D
And at the same time save materials…...and eradicate capital-intensive plant…...and break down restrictive supply chains
The design and manufacture of 3D miniaturised integrated products
Industrially focused
Market driven: The work will underpin next generation automotive, aerospace, telecommunications, medical and consumer products
Tangible deliverables: The project will push breakthrough processes into companies by delivering fundamental design and manufacturing toolsets
Practical: The toolsets will validated through industrially-relevant demonstrators that embody and probe the complex issues behind 3D-MINTEGRATION
The design and manufacture of 3D miniaturised integrated products
Large
We have 20 companies on board
We have a £9.2M 4-year programme involving 7 Research Institutes
With 100 Man/Years of research, a new equipment spend of £1.1m, and an existing equipment asset base of £7m, this is big!
The design and manufacture of 3D miniaturised integrated products
Radical
The Grand Challenge faced by the 3D-MINTEGRATION project is to develop the technologies and strategic approaches required to break the compromises of conventional manufacturing
This is a giant leap from the customary planar integration of semiconductors and silicon microsystems
It meets all of design and manufacture and test head on
It is difficult!
It is why 3D-MINTEGRATION won £4.1m funding under the EPSRC’s UK-wide Grand Challenge Competition
The design and manufacture of 3D miniaturised integrated products
Radical - but organised
The research is organised in 5 themes, spanning from raw materials to products
&3D ProcessingPackaging
IntegrationMicroassembly
Design
Simulation&
Measurement
Materials
&Test
Products
The design and manufacture of 3D miniaturised integrated products
With a direction….
Package device interactionGeneric packaging platforms‘The disappearing package’
Volume independentHighly responsive
Low cost entry
Multi-probe metrologyIn-process testing methodsTrace-ability and calibration
Manufacturingstrategy
Economy of ScaleArtificial Constraints
Test & Measurement
Thought of last, done last. Lab-based practices
Packaging & Integration Discrete Costly Approach
Miocroassembly Product Specific
High throughput 3D technologiesMulti materials
Low cost customisation3D Processing 2D Technologies
20th Century Si fabrication
MultidisciplinaryImmersive design
Risk MitigationConcurrent product & process design
Design & Simulation 19th Century Approach20th Century Tools
Tomorrow (2014)Today (2006)
The design and manufacture of 3D miniaturised integrated products
….and a framework….
Design &
Simulation
Deliverables
3D Processing
Deliverables
Microassem
blyD
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 RatchevNottingham
Workpackage 4Packaging & Integration
Paul Conway Loughborough
Workpackage 5
Test & Measurement
Richard Leach NPL
HUMMS demonstratorBCF & MBDA
Mini-Fluidic demonstrator
Syngenta & Unilever
Miniaturised Electro-Mechanical
demonstratorMBDA & Flomerics
Project Management
The design and manufacture of 3D miniaturised integrated products
….and a plan of action
Build Demonstrator 1
Build Demonstrator 2
Build Demonstrator 3
Develop and Build Testbed
Develop design methodology for capturing key product and process characteristics
Develop a front-end design environment, including needs capture, haptic sensing, visualisation and simulation
DesignDemonstrator 1
Design Demonstrator 2
Design Demonstrator 3
Conceptualise Demonstrator 1
Conceptualise Demonstrator 2
Conceptualise Demonstrator 3
Develop parts and processes
Validate Demonstrator 1
Validate Demonstrator 2
Validate Demonstrator 3
Identification and analysis of the key metrology and testing issues
The design and manufacture of 3D miniaturised integrated products
Design & Simulation
Radical change - a risky business?
&3D ProcessingPackaging
IntegrationMicroassembly
Design
Simulation&
Measurement
Materials
&Test
Products
The design and manufacture of 3D miniaturised integrated products
Design & Simulation
Innovative thinking:Rapid real-time feedback to integrate and optimise product, tool and process design - Cost implications; Risk factors; and multi-physics simulation of combined materials in unfamiliar environments
Understanding riskIdentify key process and
product characteristics Mitigate risk early in the
design
Fast modellingAnalyse the design space and characterise uncertainty in real timeMulti-physics reduced order models to optimise designs in terms of product and process
The design and manufacture of 3D miniaturised integrated products
Design & Simulation
Innovative thinking:The project is exploring the use of a virtual reality design environment - immersing designers into their own 3D micro-world.
Through 3D-visualisation and hapticfeedback, designers will actually feel
the different emphases of forces, intense heat gradients, stiction, electrostatics and magnetics…...in a totally alien world made
real
The design and manufacture of 3D miniaturised integrated products
3D Processing
Fuelling the step change that is needed
&3D ProcessingPackaging
IntegrationMicroassembly
Design
Simulation&
Measurement
Materials
&Test
Products
The design and manufacture of 3D miniaturised integrated products
3D Processing
Innovative thinking:
Micro manufacturing currently uses complex and high cost processes to realise low cost microchips through economies of scale.
The very high cost of entry at present limits the spread of micro manufacturing activities, restricting the market to large industrial enterprises.
3D-MINTEGRATION is developing micro manufacturing technologies that will not only extend the range of materials used, but will increase the take-up of micro manufacturing by establishing processes with a much lower cost of entry
The design and manufacture of 3D miniaturised integrated products
3D Processing
Tool, mould & stencil production
Focused Ion Beam, laser machining, precision
milling, turning, electroforming
Embossing, injection moulding and machining
Design & Simulation
Test & Measurement
… with a focus on costs and industry needs
The design and manufacture of 3D miniaturised integrated products
Microassembly
A paradigm shift in miniature
&3D ProcessingPackaging
IntegrationMicroassembly
Design
Simulation&
Measurement
Materials
&Test
Products
The design and manufacture of 3D miniaturised integrated products
Microassembly
Innovative thinking:
The 3D-MINTEGRATION project is concerned with a paradigm shift into the unknown. There may indeed be no "best" microassembly techniques that can be applied across the whole range of products.
The answers sought are those compatible with whole product integration, where 3D Processing, Microassemblyand Packaging are eventually rolled into one seamless process - the ultimate destiny for 3D-Mintegrated products
The design and manufacture of 3D miniaturised integrated products
Microassembly
Today’s ImagingTraditional manufacturing/assembly cell
Desktop factoryCapsule endoscope
The design and manufacture of 3D miniaturised integrated products
Packaging & Integration
Gateways and smart boundaries
&3D ProcessingPackaging
IntegrationMicroassembly
Design
Simulation&
Measurement
Materials
&Test
Products
The design and manufacture of 3D miniaturised integrated products
Packaging & Integration
Innovative thinking:
Packaging can be developed to be a smart boundary layer between a product's internal components and also a gateway to the outside world with which the complete product must interact:Polymer packaging, embedding and surface engineering. to create multi-functional integrated systemsReducing the levels of packaging by integration and design whilst preserving the functions and performance of complete 3D systems and sub-systemsSelective polymer microwave and laser processing to create new bonding or sealing technologies that are localized and material selective
The design and manufacture of 3D miniaturised integrated products
Packaging & Integration
Bucking the trends
ComplexityAssembly & joining steps
Materials InterfacesPackagingDesign tools
Func
tions
Sens
ing
Con
trol
Opt
ical
Act
uatio
nFl
uidi
csC
omm
s
Current
trends
Integrat
ed m
ateria
ls
Embedded
inter
connec
t
Smart ch
assis
Substrate
less as
sembly
Integrat
ed pro
cess
es
DfX to
ols
3D-M Goals
3D In
terco
nnect
The design and manufacture of 3D miniaturised integrated products
Test & Measurement
Permeating all activities
&3D ProcessingPackaging
IntegrationMicroassembly
Design
Simulation&
Measurement
Materials
&Test
Products
The design and manufacture of 3D miniaturised integrated products
Test & Measurement
Innovative thinking:
The advanced capability of the test laboratory has not yet made it to the production environment, but it will be needed there. Smart, adaptive Test & Measurement must be integrated into every phase of design and manufacture
3D-Mintegrated products, with their buried structures and composite materials, pose tough questions in testing and measurement. These questions spread further, to encompass the validation of tooling and the calibration and control of processes.
The design and manufacture of 3D miniaturised integrated products
Test & Measurement
Early in the project, the Test & Measurement workpackageteamed up with the 3D Processing workpackage to co-develop small scale Co-ordinate Measuring Machine (CMM) stylus manufacture using Ultra-Fast Laser machining.
The design and manufacture of 3D miniaturised integrated products
Three demonstrators
Design &
Simulation
Deliverables
3D Processing
Deliverables
Microassem
blyD
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 RatchevNottingham
Workpackage 4Packaging & Integration
Paul Conway Loughborough
Workpackage 5
Test & Measurement
Richard Leach NPL
HUMMS demonstratorBCF & MBDA
Mini-Fluidic demonstrator
Syngenta & Unilever
Miniaturised Electro-Mechanical
demonstratorMBDA & Flomerics
Project Management
The design and manufacture of 3D miniaturised integrated products
Three demonstrators
Mini-Fluidic systems – The project is concerned with miniaturisation and integration, not
pioneering MEMS fluidics.– There is a particular interest in interfacing, cost/life balance, and graceful
failure modes
Health and Usage Monitoring MicroSystems (HUMMS)– Not inventing new sensor technology but manufacturing and integrating
existing sensor technology. – A “bandage” of sensors and transducers might launch and detect signals
in a cableform, or other kinds of structures including biological structures
Miniaturised Electromechanical systems– Precision engineering at the micro-scale– The demonstrator emphasises the design and simulation problems
entailed by such systems, and the fabrication and testing of critical parts that will enable radical approaches to established applications
The design and manufacture of 3D miniaturised integrated products
Three demonstrators
Creating product ideas to demonstrate and validate the research behind the 3D-MINTEGRATION project presented an unexpected difficulty......thinking of things that have never been done before, because the enabling techniques and processes have not yet been developed, is far more demanding than dreaming up applications for existing expertiseThe project deliverables will push breakthrough processes into companies by introducing fundamental design and manufacturing toolsetsThe demonstrators are intended to validate these toolsets, rather than being deliverables in their own right
The design and manufacture of 3D miniaturised integrated products
Me too?
Zune (and similar) integrate the 3D complexities, mechanics, coatings, magnetics and fluidics of a miniature hard drive, the electrochemistry of both a display and a rechargeable battery, silicon and software, wireless technology and an outer skin and user interface
What does 3D-MINTEGRATION offer in the face of this?
The design and manufacture of 3D miniaturised integrated products
Me too?
These products are the direct result of many years of focused incremental development
But what will these products be?
3D-MINTEGRATION aims to bring similar integration capabilities to a much wider range of products…… through a swift one-time non-incremental product development process
The design and manufacture of 3D miniaturised integrated products
Project partners
Five Innovative Manufacturing Research Centres are providing extensive resources and £2.3m of cash support to the project:– Cambridge Institute for Manufacturing (IFM) – Cranfield Innovative Manufacturing Research Centre (CIMRC) – Loughborough Innovative Manufacturing and Construction Research
Centre (LIMCRC) – Nottingham Innovative Manufacturing Research Centre (NIMRC) – Scottish Manufacturing Institute (SMI)
The consortium is complemented by two leading institutions in Design and Metrology:– University of Greenwich– National Physical Laboratory
£4.1m funding has been received from the UK’s Engineering and Physical Sciences Research Council (EPSRC)Furthermore the project partnership extends to 20 companies, committing some £2.8m of support
The design and manufacture of 3D miniaturised integrated products
Contact info:
www.3d-mintegration.com
Co-ordinator: David [email protected]