Hans N. Hansen, (DTU) (Denmark)
||The European large-scale integrating project COTECH
Humbert Noll (FHWN) (Austria)
The continuous development of ever-smaller products in almost every industrial sector not only leads to an emerging industrial demand for suitable micro replication processes but also leads to a demand for efficient process chains for the development and production of micro-mechanical components and systems.
In the frame of the COTECH
The COTECH project is aimed at converging technologies and at developing hybrid solutions by following the vision of desktop or micro factories for the production of polymer-based micro-mechanical components and systems. The project started in October 2008, the consortium is composed of 25 European organisations (SMEs, industrial leaders, research centres, universities and service organisations), has a duration of 4 years and is supported by the European Commission under the Seventh Framework Programme.
project 8 different industrial
demonstrators will show the
relevance of the outcome of
the project. The demonstrators
have been chosen from different
application areas in the field
of mechanical Microsystems.
A short résumé of the presenter.
PhD in Physics from the Karl-Franzens-University of Graz/Austria, Head of Department Micro & Nanosystems at the University of Applied Sciences in Wiener Neustadt, Member of the Board of the Austrian Society for Microsystems Technology, Member of the Board of the Erwin Schroedinger Society for Nano Sciences, Head of Unit "Advanced CMOS Devices" of the German Society for Microelectronics and Microsystems Technology, Coordinator of the European large-scale integrating project COTECH.
25 organisations from 10 European countries form the COTECH consortium. Nine of them are SMEs coming from various industrial sectors, five of them are industrial leaders, nine of them are research organisations or universities and two of them are service organisations.
Part 1 - General know-how of micro replication
- Micro replication processing technologies:
||Micro injection moulding and Multi component micro injection moulding
Klaus Plewa (KIT) (Germany)
The near-net-shape production of small or micro parts is of high relevance for industries such as automotive, medical technology, clock and watch industry, modelling and pharmacy. Additionally the micro technology provides the opportunity to reach a higher functionality, improved precision of parts and an enhanced integration density in the same volume. To use micro parts in a broad range of environments, materials like plastics, ceramics and metals are available for micro injection moulding. This offers the possibility to substitute e.g. cutting processes for the production of small parts by micro injection moulding.
The one-component injection moulding process is currently the main production route for micro parts, but multi-component injection moulding will become more and more useful for the fabrication of micro parts. Typical combinations such as hard / smooth, electrically conducting / insulating and movable or fixed connections will be realized by utilization of plastics, ceramics and metals.
Another interesting process to produce micro parts made of ceramics is inmould labelling which provides the possibility to use several ceramic powders in one part. For example the microstructure can be build by using a ceramic foil filled with very fine ceramic powder particles sizes like nano particles and the residual volume will be filled with a feedstock made of micro ceramic powder. During the injection moulding cycle the back pressure effects to replicate the micro structure of the mould insert into the ceramic foil.
Education: Degree of plastics engineering from the University of Applied Science, Darmstadt
He is working at the Institute for Applied Materials (IAM-WPT) at the Karlsruhe Institute of Technology (KIT) for more than ten years. Since 2007 he is responsible for CAD, injection moulding simulation and the experimental plant at the IAM-WPT.
- Machinery and tooling for micro replication processing technologies:
||Machinery for high accuracy micro injection moulding
Martin Ganz, Senior Product Manager MicroPower, Wittmann Battenfeld Ges.m.b.H. (Austria)
The gears are for pumps
With the MicroPower machine series, WITTMANN BATTENFELD demonstrates its more than 20 years of expertise in the production of all-electric injection molding machines. The MicroPower is not only setting benchmarks. It also offers the advantages of extreme cost-efficiency, precision, flexibility and userfriendliness.
made in PEEK material,
mould temperature 210°C.
The MicroPower represents an other successful and substantial increase of customer benefit ininjection-molding of small, high-precisionand micro parts. Cost savings between 30 and 50 % can be achieved compared to standard machines.
The connector is made by insert
From simple manufacturing of small parts to the production of injection-molded high-precision and micro parts, the consequently improved all-electric.
moulding, the guiding pins have
a diameter of 0.6mm
MicroPower offers optimal solutions thanks to its intelligent machine concept. This concept makes it possible to extend a basic machine model – starting from a simple "general purpose machine" for small parts – to a multi-functional production cell for highly complex micro parts, just by connecting modules.
The machines of the MicroPower series feature maximum precision, availability and reproducibility. Moreover, cost-efficiency is ensured by their fast cycles. Other benefits are low noise level and cleanness. This enables the MicroPower to meet the most stringent demands in numerous applications. The MicroPower is ideally suited for medical technology, industrial and high-precision components, automotive parts,
lifestyle products and more.
Biography of Martin Ganz
Education; Degree of mechanical and electrical engineer.
24 years dedicated to improve micro moulding technology.
Since 14 years employee of Wittmann Battenfeld in Austria. In the beginning as deputy head of research and development department then head of Microsystem department. Current job: project management, support sale and responsible for MicroPower technology.
- Tooling for micro replication processing technologies:
|Machinery for high accuracy tooling and micro inserts
Angelo Quadroni (Sarix SA) (Switzerland)
Micro tooling and micro inserts present a great challenge to the manufacturers. This presentation will highlight the factors that are crucial for the process chain and the solutions adopted by SARIX, manufacturer of micro-EDM machines.
A particular attention will be given to the achievable accuracy with the actual processes and new capability available.
The successful production of micro tools must consider not only the machine performances but also external factors like CAM performances, training and environmental factors. These factors will be presented from a machine manufacturer point of view. The presentation will help the audience to judge how to use micro-EDM in current product development. Results from the ongoing COTECH project, related to tooling and micro inserts, will be mentioned to give an indication of trends and new possibilities.
Angelo Quadroni, is General Manager of SARIX SA, Losone, Switzerland. SARIX SA is a machine manufacturing company. SARIX has specialized since 1993 in the application of EDM to the micro manufacturing process in all industry fields including automotive, medical,and aerospace industry.
||Rapid tooling for micro-injection moulding using micro additive manufacturing
Franck Lacan (MEC) (United Kingdom)
Layer-based manufacture of three-dimensional functional models and concept prototypes play a crucial role for the early assessment and verification of product designs. Any change of design, which is frequently needed during product development, causes the development costs to rise significantly. However, there is a limited set of materials available for layer-based manufacturing, especially for producing polymer micro-components. Therefore, for fabricating small batches of microcomponents in the required material it is necessary to develop rapid tooling process chains, e.g. for low-pressure injection moulding. This presentation relates the moulding performance of micro-stereolithography inserts as a function of tool geometry in combination with effects of process factors. Condition monitoring techniques applied to the micro-injection moulding process have been carried out to provide information that can be used to optimising the process. It was found that small batches of parts with fine details and relatively high aspect ratio structures can be produced, and that reduced pressure loads and in particular the decrease of the micro-stereolithography inserts layer thickness can extended the tool life.
insert details (20 μm layer thickness).
Franck Lacan is a senior research fellow at Cardiff University (UK) where he obtained a PhD in Rapid Tooling. With an extensive experience in Rapid Prototyping and Rapid Manufacturing, he is currently involved in product design, product development and manufacturing for a wide range of industries (electronic, automotive, medical). He is also involved in two European research projects on micro injection moulding: COTECH and IMPRESS.
- Micro product development tools
||Experimental validation and optimization of micro injection moulding simulations
Guido Tosello (DTU) (Denmark), Franco Costa (Autodesk Moldflow) (Australia/US)
Micro injection moulded part and mesh
Micro injection moulding (µIM) is the key replication technology for high precision manufacturing of polymer micro products. The use of simulation for injection moulding design is a powerful tool which can be used up-front to avoid costly tooling modifications and reduce the number of mould trials. Experimental validation studies are an important tool for establishing best practice methodologies for use during analysis set up and the development of new products. Data analysis and simulations on micro-moulding experiments have been conducted during the present validation study. Detailed information about the µIM process was gathered and used to establish a reliable simulation methodology suitable for µIM parts. Various simulation set-up parameters have been considered in order to improve the simulation accuracy: injection speed profile, melt and mould temperatures, 3D mesh, material rheology and pvT data, inertia effect and shrinkage prediction. Quality factors investigated for the quantitative comparisons were: short shots length, injection pressure profile, moulding mass and flow pattern. Step-by-step simulation implementation and validation will be shown during the presentation applied on a micro injection moulding study case part. The work was carried out in close collaboration with Dr. Franco Costa (Autodesk Inc) at the Autodesk Moldflow R&D Center (Melbourne, Australia).
details prepared for the micro injection
moulding process simulation (three-
dimensional element size = 100µm,
no. layers across the thickness
> 10, number of elements = 1000000).
Guido Tosello is assistant professor on polymer micro/nano processing at the Department of Mechanical Engineering of the Technical University of Denmark, where he received his PhD title "Precision Moulding of Polymer Micro Components" in 2008. Guido holds a MSc in Mechanical Engineering from the University of Padova (Italy) and he has 7 years of experience of research on precision engineering, micro technology, polymer micro processing, micro/nano metrology. He is member of the Polymer Processing Division of Multi-Material Micro Manufacturing Network of Excellence, member of the NanoMicro Moulding Special Interest Group of SPE (Society of Plastic Engineers), member of Euspen (European Society for Precision Engineering and Nanotechnology) and member of the Polymer Group of ATV-Semapp. He is author and co-author of more than 50 peer-reviewed international including journal articles, conference papers, and book chapters. He is currently project leader within the EU FP7 project COTECH for Work Package 4 "Material optimisation, simulation, quality control and reliability".
Part 2 - New micro-manufacturing processes based on converging technologies (COTECH processes)
||Micro injection moulding converged with hot embossing
Dr. Andreas Schoth (IMTEK) (Germany)
Micro injection moulding has recently emerged as a competitive manufacturing method for polymer, metal and ceramic 3D components (< 1g) with micro scaled features and surface textures. Hot Embossing has recently emerged as a common manufacturing method for low and medium batch size production of high aspect ratio microstructures on thin planar substrates with low shear rate induced stress and a cycle time in the range of a couple of minutes. Nowadays there are fewer investigations on pvt controlled micro injection compression moulding processes showing the real process capabilities of this new converging process. This is mainly due to the request of very precise, compression gap movement control. The measurement of optical transmission and internal stress has to highlight the pvt optimum in HE as well as to specify an injection compression moulding process with optimized pvt related process capability as input for converging. An advanced Cotech process towards improved pvt control will be discussed and the route of realization with a complete new machinery presented.
Overview on transmission
|Normalized transmission rate of
New process application, advanced smart intra ocular lense (near and far view)
Dr. Andreas Schoth, University of Freiburg-IMTEK, Assistant Professor-Academic High Council in MEMS, Precision Engineering, Micro Mould Making and Micro Injection Moulding, Cotech SP3 Leader, Member of the Organizing Committee 4M Conference, 4M (Head of Division Polymer Processing), Project leader in different national and EC projects, e.g. NemosLAb (Polymer Packaging of Silicon Biosensors, Disposable for Point of Care, μTBC, German Innovation award, more than 10 patents and more than 20 publications in the field of MEMS. Senior Lecturer, International PhD auditor, peer reviewer of different international journals. Member in different societies, e.g. DPG, APS and SPE. From 1988 to 1993, he joined the Institute of precision mechanics and biomedical technology of the University of Berlin as a research associate in MEMS, where he did his doctorate as well, on the subject of "Force Feedback Silicon Accelerometer with differential tunnelling probe". He then worked at the IMM Mainz as assistant of the Managing director from 19995 to 1997 in the field of micro tooling and micro moulding. The focus of his current research- and development activities are: advancement of processing in electro chemical micro fabrication, micro tool making, and micro injection moulding for life science and consumer applications.
|| COFFEE BREAK
||Hot embossing converged with thermoforming
Dr.Matthias Worgull, Markus Heilig, (Karlsruhe Institute of Technology) (Germany)
Fluidic channel with submicron
Hot embossing or nanoimprinting are today state of the art in micro- and nanoreplication. With these processes and their technology a large diversity of structures can be replicated on thin polymer films. These films can be uses as starting material for a second process step – so called microthermoforming. By this second step of thermoforming these prestructured polymer films can be formed into a three dimensional shape. Because of the different process windows the structures on the film still remains.
structures at the bottom and
at the sidewalls fabricated by
process combination of hot
embossing and thermoforming
This combination allows the fabrication of new applications for example in microfluidics. For example microfluidic channels can be coated by structures in the submicron range by an additional thermoforming and bonding step.
Thermoformed polymer film,
prestructured by hot embossing
PD Dr. Matthias Worgull currently works at the Institute for Microstructure Technology at the Karlsruhe Institute of Technology (KIT), Germany. His degree from the University of Karlsruhe is in Mechanical Engineering. He has been the leader of the Nanoreplication Group at the Institute since 2005. He is author of the book "Hot Embossing: Theory and Technology of Microreplication", published in 2009 by Elsevier Science.
Part 3 - Case study
|Micro socket for signal carriage of a hearing instrument
Dr. Aminul Islam (Sonion) (Denmark)
Evolution of hearing aid RIC
RIC (Receiver-in-canal) hearing aid refers to a BTE hearing aid system where the receiver (loudspeaker) is placed outside the hearing aid body. A thin-wire that is insulated in a thin-tube connects the receiver with the rest of the hearing aid body. The mechanism that connects the hearing aid body with the hearing aid receiver is called RIC connector usually comprises with the combination of a Plug and a Socket. Today BTE hearing aid is more stylish, more esthetically appealing and functionally versatile. RIC connector is the enabling technology behind the recent boost in BTE hearing aid.
2k moulded 4 Pin Socket house
The next generation of RIC connector is discussed in this presentation where the main focus is placed on the RIC Socket. The main problem associated with the RIC connector today is the inadequate sealing between the Plug and Socket which allows sweat, moisture, dirt and other foreign particles to get inside the Socket house to make corrosion with the inner metallic components of the RIC system. Subsequently the connection between Plug-Socket is hindered and hearing aid cannot work anymore. To overcome this problem a new design of RIC socket is introduced with an integrated sealing ring to protect the inner metallic components of the RIC connector. A demonstrator hearing aid RIC Socket is presented here to reveal full process chain of RIC socket production based on two component micro injection moulding. Furthermore the presentation focuses on some other aspects of the next generation RIC socket like the increasing number of connection pins to facilitate simultaneous programming while getting feedback from the user, adding more than one receiver in the same ear canal for superior sound quality and also to incorporate more hearing aid components - like microphone or on-off switch or volume control with the same Socket base.
(left picture) and rapid prototype
Socket house (right picture).
Dr. Aminul Islam has been working as a Project Leader for Sonion A/S, Denmark since January 2009. Sonion is a global leader in design of advanced miniature components and solutions for hearing instruments and advanced acoustics.
Dr. Islam graduated with a BSc (Mech.Eng) from the Bangladesh University of Engineering and Technology, Dhaka, Bangladesh in 2002. During the period 2003-2004, he studied at Dalarna University in Sweden, where he obtained an MSc (Mech.Eng). Afterwards he worked for Swedish LCD Center for a short period before he started his PhD at DTU in the year 2005, obtaining his PhD degree in July 2008. His PhD-thesis was on "Two component micro injection moulding for moulded interconnect devices", which was carried out under the supervision of Professor H.N. Hansen at the Department of Mechanical Engineering, DTU. Dr. Islam’s research interest comprised of micro injection moulding, two component micro injection moulding, selective metallization of polymers, hearing aid components and technology, micro product design & development etc.
Dr. Islam is active in the European project named “COTECH” which is a collaboration project between 25 European partners and deals with the convergence of micro manufacturing processes for cost effective production of future micro products. He is author of around 30 publications in international journals and conference proceedings.
Systems for micromoulding process monitoring and control
Ben Whiteside (Bradford University) (United Kingdom)
Micro and nano moulding processes typically encounter environments which are far removed from those found in conventional injection moulding. Injection velocities, shear and temperature gradients can be orders of magnitude higher and ancillary technologies such as mould evacuation and temperature cycling are often required to achieve an acceptable product. These factors all contribute to a particularly narrow processing window, which when combined with external factors such as material variability, can result in loss of adequate process repeatability and substandard mouldings. It is therefore vitally important to monitor the process using a network of sensors capable of measuring the performance of the moulding hardware, plus the environment within the mould itself in order to assess the performance of the manufacturing system as a whole and correlate the specific input parameters which may contribute to a deficient product. Such systems can be used as tools for traceability of processes and for intelligent process control.
Dr Ben Whiteside completed a PhD in 2001 studying ‘Simulation and validation of glass fibre orientation in automotive injection mouldings’. Since then he has actively researched the field of micro-injection moulding (micromoulding) including specific areas such as including material rheology, process characterisation and product property assessment. He is now the Director of the Centre for Polymer Micro and Nano Technology, based at the University of Bradford in the UK which combines pure research activities with Industrially funded R&D.
|Exchange and discussion / Review of specific points
Hans N. Hansen (Chairman)
The program will be of interest for
- Engineers active on micro production development and micro product design
- Researchers on micro/nano technology active in micro/nano injection moulding R&D projects
- Micro and precision tooling companies
- Medical and micro/mechanical companies
- Companies developing and producing high precision plastic products
- Universities and research centers with focus on micro/nano technologies
ATV•SEMAPP/the Polymer- og MicroNanogroup in cooperation with Dansk Maskinteknisk Selskab (DMS), IDA and COTECH.
Guido Tosello, assistant professor, Ph.D. and Hans Nørgaard Hansen, professor, DTU Mechanical Engineering in collaboration with the Polymer Technology and the MicroNano managing committees.
Hans Nørgaard Hansen, DTU Mechanical Engineering.
The Technical University of Denmark/Danmarks Tekniske Universitet (DTU), Anker Engelunds Vej, Meeting Room 1, Building 101, DK-2800 Kgs. Lyngby.
Members of ATV-SEMAPP and IDA/DMS: DKK: 2150,- Others: DKK: 2775,-
For Ph.D. -student members: DKK 700, none members DKK 900.
If registering is made before the 14th of April 2011 the above prices are lowered with DKK 200.
For B.Sc. og M.Sc.-student members: DKK 300.
The prices are excl. VAT (MOMS).
The price covers the fee, the catering and the released material.
Fill in the registration form (a confirmation is sent to the registration-PC and to the registration E-mail address immediately after sending the registration form) or send an E-mail with registration information to semapp @ atv-semapp.dk.
You can also sign up to Anette Kaltoft, 09:00-12:30 on tel +45 4525 4717 or to Erling D. Mortensen, tel +45 4525 4630.
If possible please register before 14th of April and get the 200 DKK reduction in the fee.
For IDA-members: To get the membership reduction in the fee please register with a note that you are an IDA/DMS-member.
Link to a web-page for download of seminar documents HERE (no longer available). Logon information will be published to seminar attendees on the seminar day. The link will be open for 14 days after the seminar and then removed.