Periodic Reporting for period 2 - Mesomorph (all-in-one machine for hybrid technologies enabling high value added multi-scale integrated micro.optoelectronics)
Periodo di rendicontazione: 2022-04-01 al 2024-03-31
Microelectromechanical systems, micro sensors, and microdevices are transforming industries, making high-precision microfabrication essential for European manufacturers to maintain leadership. However, conventional miniaturization techniques face physical limitations at the micro/nano scale, preventing their effective industrialization. The MESOMORPH project addressed this challenge by developing an all-in-one, fully automated manufacturing system housed in a compact, self-contained cleanroom. This system integrates three advanced technologies:
1.) Femtolaser Micro-Ablation for high-precision material removal and glass-to-glass welding.
2.) Two-Photon Polymerization (2PP) for microchannel fabrication and intricate 3D structuring.
3.) Atomic Layer 3D Nanoprinting (SADALP) for multi-material deposition, enabling complex functional components.
The MESOMORPH machine successfully demonstrated a flexible, high-throughput hybrid process chain, achieving submicron accuracy and scalability to compete with high-volume microfabrication methods for advanced optoelectronic and microelectronic components. The final project phase validated its industrial viability, proving its ability to integrate and optimize these processes in real-time, reducing lead times and enhancing automation.
Key Achievements and Objectives
- Successful Demonstration of a Scalable Production Concept: The system achieved sub-10 nm resolution fully automated.
- Breakthrough in High-Value Optoelectronics Manufacturing: Enabled the production of complex micro-optical components, integrating multiple materials for enhanced functionality.
- Industrialization of Microfabrication: Developed a next-generation manufacturing platform combining femtosecond laser processing, atomic-layer 3D nanoprinting, and intelligent micromanipulation within a single system.
- Smart Process Monitoring & Adaptive Control: Integrated real-time sensing with an advanced CAD-CAM-CNC workflow, allowing automatic adjustments to optimize precision and efficiency.
- Knowledge Integration & Future Development: Established a lifecycle-driven design and manufacturing platform, ensuring the machine’s adaptability for emerging microfabrication needs across industries such as automotive, healthcare, and semiconductor packaging.
The MESOMORPH system is now well positioned for first industrial adoption after some final industrialization requirements, offering unparalleled precision, automation, and scalability for next-generation microfabrication.
1.) Femtolaser Micro-Ablation for high-precision material removal and glass-to-glass welding.
2.) Two-Photon Polymerization (2PP) for microchannel fabrication and intricate 3D structuring.
3.) Atomic Layer 3D Nanoprinting (SADALP) for multi-material deposition, enabling complex functional components.
The MESOMORPH machine successfully demonstrated a flexible, high-throughput hybrid process chain, achieving submicron accuracy and scalability to compete with high-volume microfabrication methods for advanced optoelectronic and microelectronic components. The final project phase validated its industrial viability, proving its ability to integrate and optimize these processes in real-time, reducing lead times and enhancing automation.
Key Achievements and Objectives
- Successful Demonstration of a Scalable Production Concept: The system achieved sub-10 nm resolution fully automated.
- Breakthrough in High-Value Optoelectronics Manufacturing: Enabled the production of complex micro-optical components, integrating multiple materials for enhanced functionality.
- Industrialization of Microfabrication: Developed a next-generation manufacturing platform combining femtosecond laser processing, atomic-layer 3D nanoprinting, and intelligent micromanipulation within a single system.
- Smart Process Monitoring & Adaptive Control: Integrated real-time sensing with an advanced CAD-CAM-CNC workflow, allowing automatic adjustments to optimize precision and efficiency.
- Knowledge Integration & Future Development: Established a lifecycle-driven design and manufacturing platform, ensuring the machine’s adaptability for emerging microfabrication needs across industries such as automotive, healthcare, and semiconductor packaging.
The MESOMORPH system is now well positioned for first industrial adoption after some final industrialization requirements, offering unparalleled precision, automation, and scalability for next-generation microfabrication.
Work carried out during the second period can be summarized in the following point:
- Finalization and Integration of Modules: Completion of the femto/2PP, SADALP modules, followed by their successful integration into the MESOMORPH machine.
- Development of Machine Architecture & Mechatronics: Completion of the super-stiff structure, ensuring stability and precision in microfabrication processes.
- Implementation of Adaptive Automation & CNC: Development of a real-time monitoring system and intelligent control algorithms to optimize process accuracy.
- Refinement of the All-Around Monitoring System: Full implementation of sensor-based quality control for process and product validation.
- Demonstration and Validation: Assembly of the full-scale industrial prototype at SUPSI facilities, extensive functional testing, and small-batch production of demo applications.
- Exploitation and Dissemination: Development of a business model, industry outreach, and scientific dissemination to promote commercialization.
- Finalization and Integration of Modules: Completion of the femto/2PP, SADALP modules, followed by their successful integration into the MESOMORPH machine.
- Development of Machine Architecture & Mechatronics: Completion of the super-stiff structure, ensuring stability and precision in microfabrication processes.
- Implementation of Adaptive Automation & CNC: Development of a real-time monitoring system and intelligent control algorithms to optimize process accuracy.
- Refinement of the All-Around Monitoring System: Full implementation of sensor-based quality control for process and product validation.
- Demonstration and Validation: Assembly of the full-scale industrial prototype at SUPSI facilities, extensive functional testing, and small-batch production of demo applications.
- Exploitation and Dissemination: Development of a business model, industry outreach, and scientific dissemination to promote commercialization.
The MESOMORPH project serves as a key enabler for the next generation of micro-scale products, with significant potential to enhance future industries and society. From a production perspective, MESOMORPH is a fully autonomous system that automates tasks that are traditionally hazardous for workers, such as managing micro- and nano-components and reducing micro-emissions. By removing direct human intervention, the project improves workplace safety while ensuring precise, high-throughput manufacturing.
Moreover, MESOMORPH significantly contributes to the digital transformation of European manufacturing by increasing production efficiency and enhancing the functional capabilities of high-value micro-components. Unlike traditional automation, which primarily focuses on replacing manual tasks, MESOMORPH promotes a knowledge-based digital manufacturing approach. This allows companies to improve production without relying on mass automation that could lead to job displacement. Instead, MESOMORPH supports a distributed business model, enabling small and medium-sized enterprises (SMEs) to access highly profitable microfabrication technologies without the need for large-scale investments. This approach strengthens the European economy by creating new high-skilled job opportunities and boosting the competitiveness of local industries.
The MESOMORPH system already demonstrates a strong business case for customers, with a projected reduction in production costs due to improved process efficiency, automation, and material savings. Additionally, the project’s exploitation strategy includes innovative business models such as Manufacturing-as-a-Service (MaaS), reducing upfront investment barriers for potential users. This will accelerate market adoption by allowing companies to access MESOMORPH’s advanced capabilities without heavy capital investment.
MESOMORPH is fully compliant with EU safety regulations, including the 2006/42/EC Machinery Directive, ensuring a high level of worker safety.
Micro manufacturing technologies often require a lot of energy, especially in the early stages of development. However, MESOMORPH tackles this challenge by making production more efficient and reducing material waste. By combining femtolaser processing, two-photon polymerization (2PP), and atomic layer 3D nanoprinting (SADALP), the system has achieved:
- Less waste and material loss thanks to precise deposition and real-time monitoring.
- Lower energy consumption over time as the system optimizes its processes.
- A more sustainable approach to manufacturing, including a micro-disassembly process that makes recycling easier and helps reduce environmental impact.
The MESOMORPH platform ultimately demonstrates that next-generation microfabrication can be both highly efficient and environmentally responsible, opening the way for sustainable industrialization across multiple sectors.
Moreover, MESOMORPH significantly contributes to the digital transformation of European manufacturing by increasing production efficiency and enhancing the functional capabilities of high-value micro-components. Unlike traditional automation, which primarily focuses on replacing manual tasks, MESOMORPH promotes a knowledge-based digital manufacturing approach. This allows companies to improve production without relying on mass automation that could lead to job displacement. Instead, MESOMORPH supports a distributed business model, enabling small and medium-sized enterprises (SMEs) to access highly profitable microfabrication technologies without the need for large-scale investments. This approach strengthens the European economy by creating new high-skilled job opportunities and boosting the competitiveness of local industries.
The MESOMORPH system already demonstrates a strong business case for customers, with a projected reduction in production costs due to improved process efficiency, automation, and material savings. Additionally, the project’s exploitation strategy includes innovative business models such as Manufacturing-as-a-Service (MaaS), reducing upfront investment barriers for potential users. This will accelerate market adoption by allowing companies to access MESOMORPH’s advanced capabilities without heavy capital investment.
MESOMORPH is fully compliant with EU safety regulations, including the 2006/42/EC Machinery Directive, ensuring a high level of worker safety.
Micro manufacturing technologies often require a lot of energy, especially in the early stages of development. However, MESOMORPH tackles this challenge by making production more efficient and reducing material waste. By combining femtolaser processing, two-photon polymerization (2PP), and atomic layer 3D nanoprinting (SADALP), the system has achieved:
- Less waste and material loss thanks to precise deposition and real-time monitoring.
- Lower energy consumption over time as the system optimizes its processes.
- A more sustainable approach to manufacturing, including a micro-disassembly process that makes recycling easier and helps reduce environmental impact.
The MESOMORPH platform ultimately demonstrates that next-generation microfabrication can be both highly efficient and environmentally responsible, opening the way for sustainable industrialization across multiple sectors.