WTEC Study on Micromanufacturing

Final report

The final report on Micromanufacturing is now available in PDF format.
Individual chapters are also available.

Micromanufacturing Report (~13 MB)
Executive Summary (Richard E. DeVor and Kornel F. Ehmann)
Ch. 1 - Introduction (Kornel F. Ehmann and Richard E. DeVor)
Ch. 2 - Design (Martin L. Culpepper and Thomas R. Kurfess)
Ch. 3 - Materials (David Bourell and Kamlakar Rajurkar)
Ch. 4 - Processes (Kamlakar Rajurkar and Marc Madou) ( ~ 2 MB )
Ch. 5 - Metrology, Sensors and Control (Thomas R. Kurfess and Thom J. Hodgson)
Ch. 6 - Non-lithography Applications (Marc Madou)
Ch. 7 - Business, Education, the Environment and Others (Thom J. Hodgson)
Appendices ( ~ 8 MB )

A. Biographies
B. Site Reports-Europe
C. Site Reports-Japan
D. Glossary

Final Workshop

The proceedings are available from the final workshop, which was held on April 22, 2005 at the Hilton Arlington and Towers conference room in Arlington, VA.
Our WTEC U.S. Review Workshop on Micromanufacturing was held at the National Science Foundation in Arlington, VA on August 12, 2004.

Scope of the Work

This international technology assessment study will focus on the emerging global trend toward the miniaturization of manufacturing equipment and systems for micro-scale components and products, i.e., “Small Equipment for Small Parts.” This trend, with increasing frequency referred to as the “Microfactory Manufacturing Paradigm,” encompasses the creation of miniaturized unit or hybrid processes integrated with metrology, material handling and assembly to create “microfactories” capable of producing micro-precision products in a fully-automated manner at low cost. The study will investigate both the state-of-the-art and as well as emerging technologies from the scientific, technological, and commercialization perspectives across key industrial sectors including medical, electronics, aerospace, and consumer products. This study will NOT include the lithographic based processes.

Issues to be Explored:

The principal questions, broadly classified into three categories, that relate to miniaturization and for which answers will be sought are:

Scientific:
- Impact of scaling laws on manufacturing processes/equipment
- State-of-the-science; gaps, deficiencies and needs in fundamental process knowledge
- Understanding of multi-disciplinary science-based requirements
Technological:
- Driving forces for miniaturization needs
- State-of-the-art; gaps, deficiencies and needs for miniaturization of manufacturing
- Bridging between scales; nano to micro to macro
- Results from proof-of-concept testbeds
Commercialization:
- Understanding principal current and future applications
- Economics of micro-scale manufacturing
- Societal benefits and broad-based impact of miniaturization
- Possibility of creating a disruptive manufacturing technology
- Results from proof-of-concept testbeds

Panelists

Kornel F. Ehmann (panel chair)

James N. and Nancy J. Farley Professor in Manufacturing and Entrepreneurship, Department of Mechanical Engineering, Northwestern University – Dr. Ehmann’s research focuses on Machine Tool Dynamics and Control; Metal Cutting Processes; Automation and Robotics; Precision and Micro-manufacturing
Northwestern University
Department of Mechanical Engineering
2145 Sheridan Road
Evanston, Illinois 60208

David Bourell

Temple Foundation Endowed Faculty Professor No. 2 Professor of Mechanical Engineering, University of Texas at Austin - Dr. Bourell's areas of research include materials selection, mechanical behavior of materials and particulate processing.
1 University Station C2200
Mechanical Engineering Dept.
The University of Texas at Austin
Austin, TX 78712-0292

Martin L. Culpepper

Rockwell International Assistant Professor of Mechanical Engineering. Dr. Culpepper's research focuses on Nanopositioning, Micro/Nano-scale machine design, Multi-scale Design and Precision Machine Design.
Room 3-449B
Department of Mechanical Engineering
77 Massachusetts Avenue
Cambridge, MA 02139-4307

Thom J. Hodgson

NAE member, James T. Ryan Professor & Director of Integrated Manufacturing Systems Engineering Institute, NCSU - Dr. Hodgson's research focuses on scheduling, logistics, production and inventory control; manufacturing systems; and applied and military operations research.
North Carolina State University
Department of Industrial Engineering
Office: 113 Park Shops

Thomas R. Kurfess

Dr. Kurfess’ research focuses on the control of precision grinding systems that involve the development and implementation of adaptive controllers for precision grinding operations, including bore grinding, through fee centerless grinding and surface grinding. Ultrarigid machines tools with open architecture controls are employed. The results of this work are used in a number of industrial environments.
Professor and BMW Chair of Manufacturing
Department of Mechanical Engineering
Director, Carroll A. Campbell Jr. Graduate Engineering Center
International Center for Automotive Research
Clemson University

Marc Madou

Chancellor’s Professor, Department of Mechanical and Aerospace Engineering, Department of Biomedical Engineering, Department of Integrated Nanosystems Research Facility, University of California at Irvine – Dr. Madou’s research focuses on DNA Arrays, CD Fluidics - Sample Preparation, Polymer Actuators, C-MEMS, and Novel Lithography Techniques.
University of California at Irvine
Department of Mechanical and Aerospace Engineering
S3231 Engineering Gateway
Irvine, California, 92697

Kamlakar Rajurkar

Distinguished Professor of Engineering, Director of Center for Nontraditional Manufacturing Research and Interim Associate Dean, College of Engineering and Technology at the University of Nebraska-Lincoln - Dr. Rajurkar's research focuses on Modeling and Analysis and Control of Traditional and Nontraditional Manufacturing Processes.
University of Nebraska at Lincoln
Department of Industrial and Management Systems Engineering
176 Nebraska Hall
Lincoln, Nebraska 68588
Center for Non Traditional Manufacturing Research

Advisor

Richard DeVor

College of Engineering Distinguished Professor of Manufacturing, Research Professor, University of Illinois at Urbana-Champaign.
Dr. DeVor’s research focuses on Engineering Statistics and Quality Control; Environmental Engineering; Manufacturing Systems; Nano-, Micro-, and Meso-Technology.
Department of Mechanical and Industrial Engineering
University of Illinois at Urbana-Champaign
158 Mechanical Engineering Building, MC-244
1206 West Green Street
Urbana, IL 61801

Kornel F. Ehmann (panel chair)	James N. and Nancy J. Farley Professor in Manufacturing and Entrepreneurship, Department of Mechanical Engineering, Northwestern University – Dr. Ehmann’s research focuses on Machine Tool Dynamics and Control; Metal Cutting Processes; Automation and Robotics; Precision and Micro-manufacturing Northwestern University Department of Mechanical Engineering 2145 Sheridan Road Evanston, Illinois 60208
David Bourell	Temple Foundation Endowed Faculty Professor No. 2 Professor of Mechanical Engineering, University of Texas at Austin - Dr. Bourell's areas of research include materials selection, mechanical behavior of materials and particulate processing. 1 University Station C2200 Mechanical Engineering Dept. The University of Texas at Austin Austin, TX 78712-0292
Martin L. Culpepper	Rockwell International Assistant Professor of Mechanical Engineering. Dr. Culpepper's research focuses on Nanopositioning, Micro/Nano-scale machine design, Multi-scale Design and Precision Machine Design. Room 3-449B Department of Mechanical Engineering 77 Massachusetts Avenue Cambridge, MA 02139-4307
Thom J. Hodgson	NAE member, James T. Ryan Professor & Director of Integrated Manufacturing Systems Engineering Institute, NCSU - Dr. Hodgson's research focuses on scheduling, logistics, production and inventory control; manufacturing systems; and applied and military operations research. North Carolina State University Department of Industrial Engineering Office: 113 Park Shops
Thomas R. Kurfess	Dr. Kurfess’ research focuses on the control of precision grinding systems that involve the development and implementation of adaptive controllers for precision grinding operations, including bore grinding, through fee centerless grinding and surface grinding. Ultrarigid machines tools with open architecture controls are employed. The results of this work are used in a number of industrial environments. Professor and BMW Chair of Manufacturing Department of Mechanical Engineering Director, Carroll A. Campbell Jr. Graduate Engineering Center International Center for Automotive Research Clemson University
Marc Madou	Chancellor’s Professor, Department of Mechanical and Aerospace Engineering, Department of Biomedical Engineering, Department of Integrated Nanosystems Research Facility, University of California at Irvine – Dr. Madou’s research focuses on DNA Arrays, CD Fluidics - Sample Preparation, Polymer Actuators, C-MEMS, and Novel Lithography Techniques. University of California at Irvine Department of Mechanical and Aerospace Engineering S3231 Engineering Gateway Irvine, California, 92697
Kamlakar Rajurkar	Distinguished Professor of Engineering, Director of Center for Nontraditional Manufacturing Research and Interim Associate Dean, College of Engineering and Technology at the University of Nebraska-Lincoln - Dr. Rajurkar's research focuses on Modeling and Analysis and Control of Traditional and Nontraditional Manufacturing Processes. University of Nebraska at Lincoln Department of Industrial and Management Systems Engineering 176 Nebraska Hall Lincoln, Nebraska 68588 Center for Non Traditional Manufacturing Research