Sirris materials day 2011 small is smart - denis vandormael - sirris

Sirris materials day
4th October, Ghent

SMALL is SMART
Denis Vandormael

le centre collectif de l’industrie technologique belge

Sirris Application Labs = gateways

© sirris 2011 | www.sirris.be | info@sirris.be | 2

Sirris Microfabrication Application Lab

SMALL at a glance

- Miniaturization in product development

© Sirris | www.sirris.be | info@sirris.be | 3


SMALL at a glance


- Machining, replication of small parts



SMALL at a glance


- Machining, replication of small parts

- Surface fonctionnalization thanks to:
- micro-texturing
- selective material deposition
- embedded micro-systems (sensors, light sources, …)
 smart products



Idea, problem

© Sirris | www.sirris.be | info@sirris.be |


Idea, problem

Solution



Idea, problem

Technological
Breakdown

Engineering

Solution



Idea, problem

External Technological
Resources Breakdown
PARTNERS
Internal
resources
Engineering
External
Resources Solution
SUB-CONTRACTORS



Internal resources
• Design, simulation (CAD, thermal, process)



Internal resources
• Micro-machining
• micro-milling
• electro-discharge machining 75µm-diam. end mill

• wire-cutting

In partnership with Technifutur



Internal resources
• Micro-replication
- UV soft embossing,
- micro-injection (polymer, PIM)

In partnership with Technofutur and Optim Test Center



Internal resources
• Selective material deposition:
- Stereolithography (75µm laser beam)
- Aerosol Jet Printing (10µm minimum feature size)



Internal resources
• Design, simulation (CAD, thermal, process)
• Micro-machining (milling, EDM, wire-cutting) Design, simulations

• Micro-replication (soft embossing, micro-injection)
• Material deposition (Aerosol Jet Printing, stereolithography)
• Metrology (SEM, confocal, interferometry, …) Micro-machining

Selective
Material deposition

Metrology

+ a large network of partners
Micro-replication


Network of partners


What is a smart product ?

Smart materials and systems
- are able to sense and respond to the environment around them,

- have the potential to improve existing technology
/ add new functionalities to products,
- are miniaturised devices which are able to describe
and diagnose a situation,
-may be energy autonomous and networked.

http://www.parliament.uk/documents/post/postpn299.pdf

http://www.smart-systems-integration.org/public/documents/publications/Eposs_flyer.pdf


Smart products at SMALL

Micro-needle patch in polymer

Injection-moulded replica
Micro-machined master

Electroformed
insert

Smarter because:
- painless



Microfluidics

Injection Moulding
machining (micrmilling)
Electrode micro-

Electro-discharge
machining

Smarter because:
- point-of-care diagnostic
- less products, more data



Surface functionalization

Smarter because:
- safer (traceability)
- integrated in the product
- optical (non-contact) reading

Replicated data-matrix structure
in polymer
 anticounterfeiting



Micro-optical waveguides
(a few µm width, a few tens nm depth)

Smarter because:
- micro-optics for sensing
- integrated in the product




Smarter because:
Micro-replication of a Lotus leaf
 hydrophobic effect - added functionality: self-cleaning effect
- no coating required (single material)



Printed Electronics (P.E.)
Based on the deposition (= « printing ») of polymer, organic,
inorganic « inks » onto any kind of substrates
P.E. = not a substitute to classical electronics
= complementary to classical electronics
Products - low cost - wearable (clothes)
- foldable - ultra-thin
- transparent - bio-compatible
- stretchable - environment-friendly
-…
 Paradigm shift !
© sirris | www.sirris.be | info@sirris.be | 25


Printed electronics by Aerosol Jet Printing
-High resolution:
10µm minimum feature size
Principle:
-Maskless process:
(1) Aerosol origination high flexibility and cost efficiency
- Ultrasonic © OPTOMEC/Sirris

- Pneumatic
- Large range of available inks
(2) Aerosol transportation

(3) Jet collimation and deposition - Conductive, dielectrics, semi-conductive
and even biologic materials

- Compatible with low Tg materials
(local laser sintering)

- Flat, flexible and even 3D substrates




Principle:

© OPTOMEC/Sirris

Interdigitated structures
Aerosol Jet printed
Smarter because: on various materials

- directly integrated in the product
- any substrate (even 3D)
- customizable wrt application
© Sirris for PRISTIMAT project


Other potential applications

Printed electronics

Full polymer transistor
OLEDs and Photodiodes
 Interactivity
 Energy harvesting
© David Kronholm and J. C. Hummelen in spie.org


Conclusions

SMALL is SMART

APPLICATIONS
Miniaturization in product development
Embedded sensors TECHNIQUES
Printed electronics Micro-machining and mastering
… Micro-injection moulding
Stereolithography
Aerosol Jet Printing


More info and examples

www.small-lab.be


Sirris materials day 2011 small is smart - denis vandormael - sirris

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