NSF Nanomanufacturing (NM) Program (Food for Thought) Khershed P. Cooper, PhD

Transcription

1 NSF Nanomanufacturing (NM) Program (Food for Thought) Khershed P. Cooper, PhD Program Director, Nanomanufacturing ENG-CMMI National Science Foundation Arlington, VA 2013 NSF Nanoscale Science and Engineering Grantees Conference, Arlington, VA, Dec 4-6, 2013

2 Why study NM? What is it? What is NSF doing about it? What needs to be done? Ideal NM program? Outline 2

3 Questions, Questions, Questions Is NM the future of manufacturing? Is it a revolution in manufacturing? Will it revive the US manufacturing base? Will it establish a new US manufacturing base? What will it take? 3

4 Is NM the Future of Manufacturing? Impact niche markets, e.g., biomedical, optics, conducting polymers, etc. Important where nano-scale is essential for functionality, e.g., quantum dots May not influence commodity markets, but strong player for added functionality Natural progression of controlling materials down to lower and lower length-scales rather than a revolution Enable manufacture of products that could not be made today, but design community has to become aware of new capabilities Will be an enabler and will work better in conjunction with other technologies such as IT, bio Need market that is sizable fraction of trillion dollars per year (otherwise, without a market, why would you manufacture stuff?) Colleagues in NM more upbeat than those not 4

5 Importance of Nanomanufacturing : Discovery and Invention Era Advances in fundamentals, nanomaterials, nanodevices, nanosystems, instrumentation, measurement, nanomanufacturing, facilities, EHS, education, society 2010: Review of NNI PCAST recommends greater emphasis on commercialization by doubling investment of Federal Government in nanomanufacturing R&D March 12, 2010: PCAST NNI report to President Obama Among the report s primary recommendations, increase the focus of NNI programs on commercialization of products and increase NNI s investment in nanomanufacturing by 100 percent over the next five years : Implementation Era Nanomanufacturing R&D Associated research topics NNI Report 2011 Nanomanufacturing will bridge gap between discovery and implementation 5

6 percent of NNI total $ millions Investments in Nanomanufacturing $140.0 $120.0 $100.0 Trend is increasing $80.0 $60.0 $40.0 $20.0 $ Year NM investment is 6% of total NNI investment At NSF it is 12% How do we increase it? 7.00% 6.00% 5.00% 4.00% 3.00% 2.00% 1.00% 0.00% Year Courtesy: Geoff Holdridge, NNCO 6

7 How did agencies respond? 2011: NNI Signature Initiative Sustainable Nanomanufacturing: Creating the Industries of the Future Accelerate development of industrial-scale methods for manufacturing functional nanoscale materials and systems 2011: Agency Response NSF launches the Scalable Nanomanufacturing Program OSD MURI topic call listed Nanomanufacturing as one of its high priority themes 2011: ONR Manufacturing Science Program MURI Topic #9 Nanoscience based high-speed fabrication of full function hybrid flexible electronic systems Goal is to develop fundamental nanomanufacturing science that will lead to a universal high-speed continuous manufacturing platform capable of producing any multifunctional system-on-film Roll-to-roll, high speed printing of multi-functional, distributed sensor networks for enhancing the brain-machine interface 7

8 Larger Picture 2009 Pisano and Shih, Harvard Can NM reverse this trend? 8

9 Nanotechnology has many promises new ideas new science new manufacturing new instrumentation new products new spin-offs new industries new markets new jobs many benefits economical societal educational But there are manufacturing challenges Desired Outcomes Product quality and durability Process repeatability and reliability Production scalability Yield and efficiency Desired device and system performance and functionality Cost affordability Appropriate Metrics Precision of placement Feature size and resolution Overlay registration Nanostructures Density Complexity Rate of forming 9

10 What is Nanomanufacturing? Definition Fabrication of nano-scale building-blocks (nanomaterials, nanostructures), their assembly into higher-order structures such as nanodevices and nanosystems, and the integration of these into larger scale structures and systems such that both heterogeneity and complexity are possible with manipulation and control at nano-scale Requirements Scale: About nm Unique physical phenomena 10

11 Nanomanufacturing Value Chain Product Insertion Nanosystem Integration Nano-subsystem Manufacture Nanodevice Manufacture Nanostructure Integration Nano Building Block Production NM and related R&D at every level of the value chain 11

12 Nanomanufacturing (NM) Program Program s objective is to study the principles for the manufacturing of nanoscale materials, structures, devices complex nano-enabled engineered systems Intellectual Merit 1) Conduct fundamental research in novel nano-scale processes 2) Leverage advances in understanding of nano-scale phenomena and processes 3) Promote design and integration of nanostructures to higher-order systems 4) Address manufacturability issues quality, efficiency, yield, scalability, reliability, safety and affordability 5) Encourage systems approach to scale-up 6) Advance instrumentation, metrology and standards 7) Base research on computation, modeling and simulation and use of process sensing, monitoring, and control Need more research 12

13 NM Program Broader Impacts 1) Encourage transfer of research knowledge to commercial applications, technological impact 2) Support education of next generation of researchers, scientists and engineers 3) Encourage building a workforce trained in nanomanufacturing systems 4) Engage minorities and under-represented students 5) Seek understanding of long-term societal implications of large-scale production and use of nano-scale materials environment, health and safety Need more research Awards: $300K to $450K total over 3 years 13

14 Current Areas of Interest Materials Nanofibers, nanowires, nanotubes, nanocomposites 1D, 2D, 3D nanostructures Inorganic, organic and hybrid nanostructures Carbon-based nanostructures and materials CNT and graphene Processes Patterning, lithography and self-assembly top down/bottom up Colloids, fluidics, bio- or nature-inspired 3D Nanomanufacturing layer-by-layer, holographic lithography Applications Electronic and photonic devices, power and energy, structural and composites, biomedical, 14

15 Scalable Nanomanufacturing (SNM) Program Collaborative research and education program Emphasis is on research to overcome key roadblocks to lowcost production of useful nanomaterials, nanostructures, devices and systems at industrially-relevant scale, responsibly Solicitation: Approx. $10M; Awards: About 5-10, $1-1.5M (total), 4-year 15

16 How is SNM different from NM? Must address scale-up Large area, parallel, continuous, roll-to-roll.. Larger award, longer period Collaboration required multi-disciplinary Managed by ENG (CMMI, CBET, ECCS, EEC, IIP) and MPS (DMR) Address one or more of 5 themes Industrial collaboration Planned activities, experimental test-beds, tangible collaboration Additional review criteria Significance of scientific contributions; effectiveness of planned collaborations; degree of interdisciplinarity; integration of research, education and diversity; efficacy of management plan 16

17 SNM Program Themes 1. Novel processes and techniques for continuous and scalable nanomanufacturing 2. Directed self-assembly processes leading to heterogeneous nanostructures with potential for high-rate production 3. Fundamental scientific research in well-defined areas that are compellingly justified as critical impediments to scale-up 4. Principles and design methods to produce machines and processes to manufacture nanoscale structures, devices and systems 5. Societal, environmental and educational implications of the large-scale production and use of nanomaterials, devices and systems, including their life-cycle analysis Need more research 17

18 Future Directions Nanotechnology Roadmap Increased complexity, new functions, more capabilities in less space Enhance Performance of Systems Human body, automobiles, Commercialization Industry perspective Towards mass production. New industries? 18

19 Nanotechnology Roadmap M. C. Roco, Nanotechnology s Future, Scientific American, August 2006, p Passive Nanostructures powder, composite, consolidation e.g., nanoparticles (nanotubes), nanocomposites, coatings, bulk materials Active Nanostructures refined current fab methods, patterning, mask/master, 2D, SA e.g., transistors, amplifiers, magnetic storage, sensors, actuators, targeted drugs / chemicals 3D Nanosystems integration of nano components using assembly techniques, 3D LBL e.g., molecular transistors, circuits, devices Molecular Nanosystems complex heteromolecular nanosystems with biomimetic functions and features e.g., nano-robots, nanomachines Trend is increased complexity and more capability in less space 19

20 Nanosystems, Nanomachines, Nanorobots Complex, heterogeneous, multi-functional, multi-component nanosystems Have one or more of following attributes: adaptive, responsive to external stimuli, biomimetic, intelligence and smarts, autonomous, Considerations when making functioning complex nanosystems? Design system for performance, design system for processing Materials selection for properties Components selection for functions Component integration and assembly into systems Manufacturing processes up the value chain Knowledge base for reliable production of complex nanosystems 20

21 Industry Perspective Harvest and foster most appropriate technologies available to meet current and future needs of customer not newest, not most interesting Views nanotechnology as enabling technology to solve problems (e.g., corrosion, de-icing, Moore s Law) Needs NM to overcoming barriers to tech transfer and commercialization Wants to comply with nano environmental, health and safety standards Needs a viable nanomanufacturing base But, technology insertion needs to be compelling 21

22 Commercialization Challenges Generate data from extensive study of nanomanufacturing Abundance of nanosystems still to be studied Each nano-process is unique and needs validation Each nano-component may have a unique processing history and needs validation Compromise: feature size and resolution v. processing rates v. volume throughput Need extensive proven history, reliable supply base, standards and targeted metrics NM can contribute to industry needs and commercialization challenges 22

23 Research Opportunities Processes/Methods/Techniques Guided molecular assembly across length scales electric or magnetic fields, templating, chemical means,.. Modular nanomanufacturing nanosystems Micro/nano environments microreactors, microfluidics, desktop factories Manufacturing designer molecules new structures, properties and functionalities Nano-bio-manufacturing harnessing biology or nature, using living cells directly, borrowed, or taken as inspiration Manufacturing by nanomachines advanced catalysts, DNA machines,.. Hierarchical nanomanufacturing 3D integration, multi-material, heterostructure, multi-functional 23

24 Research Opportunities New Materials Graphene and other layered and 2D nanomaterials (MoS 2 ) deposition, patterning, device fabrication/integration New Devices Next generation ICs and magnetic memory plasmonics, block copolymers, ultrafine vias Nanomanufacturing Platforms Roll-to-roll nanomanufacturing metrology, in-process inspection, closed-loop control, planarization 3D nanomanufacturing micro-stereolithography, two-photon polymerization, 3D printing Massively parallel processing AFM tip-based processes, laserbeamlets Biologically-driven or biologically-motivated self-assembly DNA, virus, protein 24

25 Research Opportunities Quality Control Standardized tools for measurement, testing and manufacturing Modeling and Simulation Predictive simulation of nanomanufacturing processes EHS Predictive methodology for toxicity of nanomaterials Need more work How NM can contribute? Nanoinformatics Development and use of nanoinformatics and intellectual property Knowledge base for reliable production of complex nanosystems 25

26 Research Issues for Commercialization Tool Technology Will depend upon what you want to make Expensive EBL-type tools Inexpensive tools, e.g., nanoimprinting Baseline Specifications Qualification, Verification, Validation, Certification Need more work Economics Cost of input materials, business case development, cost modeling Supply Base Cultivation Bridging gap from technology development to industry implementation Should NM do this? NSF-NCMS Study: 30-question survey at 26

27 Ideal NM Research Program GOALS Discovery and invention of novel, exciting, WOW processes! Innovative approaches to scale-up Integration across scales, functions, and multi-materials Design and manufacture of complex, higher-order useful systems Fundamental principles for NM machines/platforms, wider applicability APPROACH Single-investigators for out-of-the-box ideas, teams for researching and building systems Funding profiles? What about.. Measurement, metrology, instrumentation, standards? EHS? Life-cycle analysis? Cost-benefit analysis? 27

28 Thank you!