Project description
Sustainable manufacturing of eco-friendly optoelectronics
While miniaturised, integrated photonic devices drive an increasing number of applications, the technology of manufacturing optoelectronic devices remains obsolete, inefficient, and environmentally harmful. The EU-funded FLOIM project proposes a groundbreaking solution offering automated, flexible manufacturing technology in optoelectronic components and the assembly of optical systems. Over injection of optical thermoplastic polymers directly onto the active optoelectronic components into a proper cavity will allow the incorporation of geometrical micro/nano-features. As part of this project, data-based quality awareness computing and process abstraction will be applied for predictive quality assurance and process adjustment based on cognitive control. The goal is to test the robustness, efficiency and productivity of the FLOIM solution. The demonstrations and dissemination of findings will follow.
Objective
FLOIM will develop an automated process for optical assembly of optoelectronic devices, based on optical quality injection overmoulding. Freeform and microstructured optical surfaces are generated directly on the components through thermoplastic microreplication, using microstructured inserts. The technology aims to simplify the assembly routes for heterogeneously integrated optoelectronics, with drastic cost reduction, high productivity and improved device performance. Such advantages are demonstrated by three case studies (Datacom transceiver, Optical encoder and OLCD display), showing the flexibility of the processing route and the superior quality of the produced parts. Two control strategies will be tested for improving the yield: process monitoring/actuation, and functional quality assessment of the produced optoelectronic assembly. The mould cavity will be instrumented to verify the quality of the injected material and monitor the components alignment with respect to the optical features of the mould. On the other hand, the manufacturing path will incorporate an in-line optical and functional quality inspection system, with complete traceability of each produced part. The project will incorporate data-based quality awareness computing, supported by process abstraction, for predictive quality assurance and process adjustment based on cognitive control. A pilot optical assembly line will incorporate all the advances in the project. Extended pilot test runs will allow to evaluate the robustness, quality and differential advantages of process and products, and quantify the productivity and effectiveness of the control strategies. Economic and eco-efficiency indicators will be evaluated, in terms of operational costs, recycling, material and energy efficiency, and use of critical materials. The capability of the consortium partners and the relevance of the selected demonstrators ensure a high impact of the project results and its market uptake.
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Funding Scheme
RIA - Research and Innovation actionCoordinator
36410 Porrino
Spain