MM. MM Magazine is overtly interested in manufacturing from the micron up. From your experience, what have been the key technological advances and cultural changes in manufacturing that make micro manufacturing a real possibility?

DB. Key technological advances that make micro manufacturing feasible across industry include incorporating micro machining techniques previously generated for other industries — such as silicone wafer technology for the semiconductor industry. High volume micron level manufacturing requires a combination of a high level of accuracy and high volume automated assembly at the microscopic level. The cultural changes I’ve seen include a more collaborative effort with multiple technologies. There’s no one answer for micro manufacturing, it takes many technologies (micro milling, micro EDM, lithography), and an understanding of several exotic and new materials to successfully provide solutions to manufacturers from across industry.

MM.Of the various technological solutions that exist for micro manufacturing (i.e. micro injection moulding, micro machining etc...), which technologies are best suited to which applications?

DB. As I just implied, no one answer can cover this, but generally speaking high volume applications demand micro moulding. Micro machining can be used for prototyping in some cases, and is needed to create the micro moulds for micro moulding. I see more use of micro EDM and micro milling used primarily to create micron-sized structures for micro moulded components. Also, a combination of micro moulding, micro stamping, and micro lead frame manufacturing are used together to create a high volume solution. Any time you can assemble micro components in the mould and not have to set them up at a later date (errors increasing at each setup), creates a higher quality and lower cost assembly in the long run.

MM. In the early stages of micro product development, numerous factors input at the design stage due to contingencies such as handling, validation, etc... What specific issues need to be considered at the design stage?

DB. Product validation is something that needs to be discussed at the beginning of a project not at the end. The reason for this is that micron level tolerances require vision systems of high accuracy fixturing to ensure 6 Sigma validation. In many cases, the Gage R&R will result in the error of measurement taking up the majority of the tolerance. Even with tolerances of +/-0.0002” (0.0008 mm) this can result in Gage R&R failures, so micron level tolerances accentuate this unless proper fixturing/vision systems are used.

MM. Materials are also being developed that are specifically suited to micro product development. What are the most important material developments, and what potential is unlocked by new material options?

DB. Nanocomposites and speciality materials have been developed and thrive in the micro manufacturing arena due to the very lean principles used in micro manufacturing. Many materials such as resorbable polymers can cost thousands of dollars per pound, and using a very minimal amount is critical for their economic success. Speciality steels impregnated with nanocomposites have improved their density and micro porosity allowing the development of many micro devices. Having microscopic features requires high speed machining (sometimes as high as 100,000 rpm) with pins the size of human hairs. Porosity is critical in these cases because of the size and robustness of the processes the steels undergo to create micro machined components and micro moulds used to make micro moulded components.

MM. If a company is considering embracing a micro-sized product development programme, what obstacles exist and how are they overcome?

DB. In the early days of embracing a micro manufacturing regime, companies will often outsource. If a company is looking for an outsource, its common for them to use existing suppliers that may not be knowledgeable in micro manufacturing but can provide precision macro components. In a majority of cases, this is a science experiment that can cost time and money — two things that can kill a development programme and provide an open door for the competition to get ahead. Its extremely important to partner with a supplier that has experience in micro manufacturing and has access to a variety of micro technologies. If a micro moulder does not have tooling in-house they need to rely on outside sources for the key component and enabler of the process. If a company only offers micro moulding and not micro machining or micro stamping, you may only have a low volume source, which is good for development efforts but can’t be ramped quickly if the programme takes off. Suppliers with multiple product offerings in micro manufacturing and multiple materials is a good place to start.

MM. What general advice do you have for a company that is about to embark on a micro-sized product development programme?

DB. If the programme is in the early stage or prototype stage, hiring a specialist/consultant in micro manufacturing can be a good start. This will allow a smooth transition to get a plan in place for prototypes, micro engineering analysis, a validation plan, and the experience of having gone through several hundred micro components. Otherwise, partnering with a good micro supplier as I just explained will also get you a good jump start.

MM. In manufacturing, every now and again, technological advances are heralded as the dawn of a new industrial revolution. Is it overstepping the mark to say that micro manufacturing is the new Industrial Revoloution?

DB. I wouldn’t say it’s an industrial revolution just yet, but certainly with a market size of just over $56 billion, it’s a manufacturing trend that will continue. New advances in medicine, biometrics, homeland security, sensors, micro electronics, and industrial pumping mechanisms will continue to push the industry to new heights. Its an exciting time for those who have waited for the industry to grow. Its finally here with great opportunities for those who had the insight to invest in the research and development of micro manufacturing.

Donna Bibber is a well-known micro manufacturing expert and the CEO of Micro Engineering Solutions (MES), Charlton City, MA, USA. MES is a manufacturing engineering firm experienced in critical tolerance-based applications. It specialises in miniature to micro sized features and components in a variety of materials. Many times the components are the size of dust specks and designing around handling, longevity, and validation are top priorities from the start of a micro programme. The company employs many different micro manufacturing processes that enable extremely small features and components. MES takes miniature to micro-sized and critical specification products from prototype concept through to high volume production.