LMP s Contributions in Manufacturing Process Research. September 28, 2007

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1 LMP s Contributions in Manufacturing Process Research September 28, 2007

2 Outline Introduction Selective Examples Summary

3 Introduction Founded as an interdepartmental laboratory within the School of Engineering in Mission: Establishing manufacturing science base & innovation More than 700 alumni, 1000 publications and 100 patents

4 Selective Manufacturing Process Research Activities at LMP Design (Axiomatic Design). Polymer processing (MIT-Industry Polymer Processing Program, MIT-Industry Microcellular Plastics Consortium, Polymer MicroFabrication Program). Metal processing (Mixalloy process, Discrete Die Sheet Metal Forming, Droplet-Based Manufacturing Program, CastScan Consortium). Ceramics processing (3D Printing Program). Semiconductor processing (CMP, Photoresist Coating). Control (Precision Engineering, Robotics, Welding).

5 Microcelluar Plastics (Courtesy of Trexel, Inc.)

6 What is a Microcellular Plastic? Microcellular Plastics (MCP) is defined as the plastic that has a large number of small bubbles, typically less than 30 microns. MuCell Technology: Simultaneous nucleation of an extremely large number of cells.

7 Design of a Continuous Process/Equipment for Microcellular Plastics (1) Rapid dissolution of gas into molten, flowing polymer to form a solution, (2) Nucleation of a large number of cells, (3) Control of the cell size, and (4) Control of the geometry of the final product.

8 Design of a Continuous Process Hopper with Pellets Vent Port Heaters Metered Gas Supply P b Breaker Plate/ Flow Stabilizer Static Mixer Single-Phase Polymer/Gas Solution P n Foaming /Shaping Die Motor & Gear Drive Barrel Two-Stage Screw Polymer Processing System Gas/Polymer Solution Formation System T n Nucleation Nozzle Schematic of the Microcellular extrusion system used for the shaping and cell growth control experiments (From Baldwin, Park and Suh, 1997)

9 Injection Molded Printer Chassis (Courtesy of Trexel, Inc.)

10 Unanticipated Advantage of MuCell Technology Decrease in viscosity. Lowering of melting point and glass transition temperature. Elimination of shrinkage.

11 Discrete Die Sheet Metal Forming

12 Conventional Tooling Tool Pallet Parking Lot

13 60 Ton Matched Discrete Die Press (Robinson et al, 1987) Tool Setup Actuators Press Motion Programmable Tool Passive Tool

14 The Shape Control Concept desired shape + - shape error SHAPE CONTROLLER DISCRETE DIE SURFACE WORKPIECE finished part SHAPE MEASUREMENT Die Shape Change DISCRETE DIE FORMING PRESS New Part Shape TRACING CMM CONTROLLER Part Error

15 Cylindrical Part Error Reduction MAXIMAL SHAPE ERROR [x0.001 in.] MAX 40 RMS SYSTEM ERROR THRESHOLD 0 P1 P2 P3 P RMS Error [x0.001 in.] PART CYCLE

16 Large Scale Tool 6 feet

17 Stretch Forming with Reconfigurable Northrop Grumman

18 Droplet-Based Manufacturing

19 Uniform-Droplet Spray (UDS) Process Thermocouple Piezoelectric Actuator Crucible Inert Gas Supply Shaft & Disk Vibration transmitter Heater Liquid Metal Orifice - + Charging Ring Uniform Droplets

20 Ball-Grid Array (BGA) Packaging and Chip-Scale Package (CSP) SIGNAL/ GROUND VIA WIRE BOND CHIP DIE DIE PAD PLATED COPPER CONDUCTOR PROTECTIVE CAP CHIP DIE SOLDER MASK EPOXY PCB THERMAL/GROUND VIA SOLDER BUMPS SOLDER BUMPS BGA Packaging Chip-Scale Package

21 On-Line Size Measurement 1 mm Orifice 3 d = 2 d D 2 O 1/ 3 Actual CCD Camera Image

22 Control Scheme TTL Frequency Signal Frequency Divider Vibration Frequency Voltage Amplifier F / 10 Frame Grabber Function Generator Stroboscope CCD Camera Computer Motherboard UDS Generator Computer

23 UDS Apparatuses Spray Forming Chamber Automated UDS Generator

24 Three Dimensional Printing (3D Printing, 3DP) Emanuel Sachs Fred Fort Flowers and Daniel Fort Flowers Professor of Mechanical Engineering

25 3D Printing

26 Office Modeler Z Corp., Burlington, MA Market Leader in Office Modeling (fastest growing sector). 500 machines in field (over 40 at universities). Office environment (water binder, starch powder or plaster based) High reliability. FAST

27 Other Commercial Applications Medical: drug delivery, scaffolds for tissue eng., tools for endoscopic surgery Ceramic molds for metal casting Direct printing of metal tooling Cutting tools Electronic ceramic parts Ceramic filters

28 Current Research Programs Center for Polymer Microfabrication (SMA) Chemical Mechanical Polishing Portable Fuel Cells MEMS Fabrication Processes Ink Jet Printing

29 LMP s Educational and Research Programs Educational Initiative - Mfg-related subjects Processes and equipment - Micro- & nano-scale processes - Precision equipment Systems - Factory - Supply chain - Information Systems-level design Sustainability - Environmentallybenign mfg - photvoltaics

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