An advanced production platform for 3D layered materials
Multifunctional microsystems are currently expensive to produce, requiring long turn-around times and relying on complicated machinery. Particularly in the case of small batches, the production cost is prohibitive for many small and medium-sized enterprises (SMEs). The EU-funded project SMARTLAM (Smart production of microsystems based on laminated polymer films) combined new material properties with state-of-the-art scalable 3D manufacturing technologies such as aerosol jet printing. The result is the first-ever realisation of combined micro-milling, micro-welding, micro-cutting, micro-structuring and surface functionalisation, and micro-positioning in one machine. The 3D integrated design and manufacturing (3D-I) concept provides a knowledge-based platform to support the designer from start to finish. It integrates laminating technologies adopted from rapid prototyping with handling of discrete parts that cannot be substituted by printed or nano-structured films. It also incorporates advanced surface and patterning technologies implemented at the micro- and nanoscales. SMARTLAM combined function-related manufacturing steps with the required process chain capabilities. The framework also includes an extensive database on material properties, cost assessment and production parameters. These allow for highly specific production planning with the selection of an optimal process chain right from the start of the design process. SMEs, potential customers in the fields of lighting and bioanalytics applications, evaluated two demonstrators. The first one is a flexible light-emitting diode module with structured conductive paths, and the second is a microfluidic chip containing microchannels and electrodes for analysing liquids. SMARTLAM created a new paradigm for process integration in rapid prototyping of 3D microproducts. The project demonstrated how to produce at low cost future customised products such as functional microdevices based on stacks of polymer films. The proposed approach addresses the manufacturing of a small or medium-sized series of micro-components. This contrasts with roll-to-roll manufacturing that deals with high-throughput manufacturing of flexible printed devices for use in consumer electronics, flat panel displays or organic photovoltaics. Implementation of the 3D-I SMARTLAM platform and technologies could yield important benefits. Among these are faster product development and up-scaling for both small series and mass-produced parts, 100 % inspection and tolerance for medium-sized lots, and important energy savings. Taken together, the platform could facilitate innovation, open new markets and contribute to development of new business models.
Keywords
Smart production, microsystems, manufacturing platform, SMARTLAM, 3D manufacturing
