High-Tech Sub-Micron Manufacturing and Design: Mechanical Engineering for the 21st Century by J. Michael McCarthy, Melissa Orme and Ken Mease

Contents: Goals and Objectives Challenges The Future of Mechanical Engineering Proposed Position Descriptions The View of Local Industry   For Reference: Previous Draft of this Plan Summary of the Planning Effort

Introduction At the onset of the 21st century, information technology, DNA and protein engineering, and micro-electro mechanical systems promise technological enhancements of the human condition in remarkably innovative ways. The past century has seen the technologies of electric power, mass transportation, and personal and broadcast communication evolve from curiosities into essential components of our communities. The next century will witness an "explosion" of mechanical devices with unprecedented complexity and utility at sub-micron dimensions. A major challenge is the precision and reliable manufacturing and design of these complex, micron-scale devices. The recent evolution of (1) computational methodologies, (2) control methodologies, (3) sensor methodologies, and (4) micro fabrication technologies provides a fertile foundation upon which to build a new era of manufacturing. This proposal recommends that the Department of Mechanical and Aerospace Engineering aggressively pursue the development of a research and educational program in High-Tech Sub-Micron Manufacturing and Design. Goal and Objectives The goal of this High-Tech Sub-Micron Manufacturing and Design Program is to develop and apply the fundamental science and engineering required (through research and education) to manufacture and design the new devices of the 21st century. The objectives are to (1) develop, utilize, and integrate computational methods, miniaturization for fabrication and materials technologies, and controls and sensors, and (2) couple the manufacturing design with the product demands associated with the emerging micro-scale products based on nano-scale mechanical and fluid systems, biotechnology, and biochemistry. Challenges The emergence of micron-scale devices will drive a new generation of manufacturing. The forces of international competitiveness will drive a substantial improvement in the efficiency and precision of manufacturing. And an increased demand for "life-cycle" considerations will push manufacturing toward the minimization of waste and consideration of the reuse and recycling materials at the product design stage. The challenges facing the manufacturing have to respond to each of these forces with strategies to achieve economically competitive and environmentally sound devices and products. A report by the National Academy of Sciences, "Visionary Manufacturing Challenges for 2020," discusses the challenges faced by manufacturing engineers in the future. They report: "Customers will require that suppliers of goods and services maximize the value relationships among quality, service, and price. The goal of successful enterprises will be to find the optimum position in this "better-faster-cheaper" competitive triangle. A "we can have it all" attitude among consumers will force corporations to become extremely flexible and adaptable. As large numbers of consumers in newly developed countries gain economic power, this attitude will be prevalent worldwide." The report goes on to describe "six grand challenges" and "ten priority technology areas." Perhaps more relevant to our concern is the "long term research focus" which centers on (i) Submicron Manufacturing with an emphasis on miniaturization, micro-electro-mechanical systems, nano-fabrication and biotechnology; and (ii) Modeling and Simulation of Manufacturing Systems with an emphasis on rapid reconfiguration of a dynamic amalgam of human and machine intelligence, knowledge, materials, equipment and processes. This proposal seeks to build research and educational expertise in both of these research areas and to establish a High-Tech Sub-Micron Manufacturing and Design Program that engages: the emerging high-tech industry of Orange County; the emerging micro-fabrication facility resident in the School of Engineering; the emerging UCI biomedical engineering and biochemical engineering programs; and the emerging interest and demand emanating from the United States and international marketplace. The Future of Mechanical Engineering Mechanical Engineering has been described as "the knowledge, development and use of processes and devices for transforming energy from one mode into another in order to produce a product of value to society." Traditionally, this is viewed as the application of the Laws of Thermodynamics and Newtonian Mechanics to the design of power systems and mechanical devices ranging from automobiles to electrical power generators to airplanes to rockets. While these examples employ "combustion," "engines," and "turbo machinery" to achieve the needed transformation and produce motive power and electrical power, manufacturing takes the electrical power and adds additional transformation steps to produce a manufactured product. During the 20th Century, conveyer belts and large machine tools evolved to serve this role; and in recent years sophisticated robotic systems have dramatically increased the quality and quantity of production. In the future world of miniature products (many allied with bio-technology), an integrated understanding of modern Physics, Chemistry, Biology and Computer Science will be necessary to model, simulate, analyze, measure, construct and control the physical phenomena that underlie the manufacture of these devices. Within the traditional domains of Mechanical Engineering it is possible to identify the areas of Solid Mechanics and Dynamical Systems as disciplines fundamental to the knowledge base for of sub-micron manufacturing and modeling and simulation of manufacturing systems. Solid Mechanics A significant number of the miniaturization process are can be described as controlled deposition processes that provide direct construction of a product without waste or final machining or polishing. This general class of processes is termed "net form manufacturing." The strength of the inter-particle shear forces at sub-micron dimensions determines the reaction of elements of any device to an applied load, in particular, its strain, accumulated damage and eventual failure. The constitutive relations that reflect materials properties at the scale of grains and even molecules must be the focus of new research. The ability of these processes to generate unique material systems with complex geometry requires new models for the prediction of mechanical fatigue and failure. Dynamical Systems Manufacturing as a discipline clearly implies more than simply modeling the mechanics of physical systems. The reference to "products for customers" implicitly includes the notion of performance. The NAS study reports that in the competitive world of 2020: "New manufacturing systems will be required for adaptable and reconfigurable manufacturing processes that can meet the changing demands of the marketplace. Research in self-organizing manufacturing systems could include the development of autonomous manufacturing modules; bioprocessing technology; chaos theory; holonics; and new concepts and models for partitioning manufacturing equipment, tools, human/organizational resources, and software systems. Finally the development of new manufacturing systems must include a taxonomy and metrics for manufacturing systems that address open system architectures, mass customization, optimized system value, maximum use of available assets (including human, intellectual and knowledge assets) and environmental impact." We do not propose that the Department of Mechanical Engineering pursue all of these areas, however, it is clear that the "systems theoretic" point of view is a fundamental component of Manufacturing for the next century. Research in dynamical systems, control theory and optimization theory are disciplines in Mechanical Engineering that are clearly fundamental to the knowledge base for our Sub-Micron Manufacturing Program. Proposed Position Descriptions The primary goal of this document is to identify the importance of High-Tech Sub-Micron Manufacturing and Design to society and to the growth of our Department. We propose that the details of this plan including the indentification of faculty positions be developed in consultation with experts from both Academia and Industry. Colleagues in and out-side of UCI have already expressed their willingness to assist in a more precise characterization of this program. In what follows, we present examples of the types of positions that might be required to support the proposed program. It is also useful to note that UCI presents a unique opportunity for a completely new thrust in Sub-Micron Manufacturing; and one can imagine attracting a distinguished senior researcher with a package that includes three or more faculty positions designed to provide immediate prominence to the new program. 1. Finite Element Modeling and Simulation of Micro Devices. This position integrates constitutive modeling of material components and mechanical simulation of assembly to evaluate and optimize the performance of sub-micron mechanical system design.   2. Net-form Manufacturing at Sub-Micron Dimensions. This position studies the characterization of controlled deposition and etching processes methodologies for modeling and simulation of these processes in conjunction with miniature product design.   3. Cumulative Damage and Failure of Sub-Micron Components. This position focuses on modeling the wear and failure modes of components of miniaturize devices resulting from processes as micro-machined silicon, net-form manufacturing, and protein engineering.   4. "Smart" Materials for Micro-actuators. This position integrates the design and processing materials, which integrate actuation, sensing and control as the sub-micron level for miniature engineering devices.   5. Micro Robotics and Automation. This position integrates computer control and materials handling to achieve automated mechanical movement at sub-micron dimensions.   6. Biomaterials Processing and Design. This position integrates the design and processing of materials derived from protein engineering. This includes tissue engineering and genetic engineering process design and control, as well as the use of these materials in novel products.   7. Design and Manufacturing Informatics. This position integrates computer-aided design, engineering analysis, manufacturing planning and simulation together with cost evaluation and optimization for miniaturized product design.   8. Design of Micro-Electro Mechanical Systems. This position focuses on the development of silicon based devices that integrate computation and mechanical actuation. The focus is on computer-aided design and simulation tools to achieve the integration of silicon machining technology and semi-conductor device design into micro-electro mechanical devices The View of Local Industry Wallace Walrod, research director for the Orange County Business Council, 25% of Orange County's payroll is derived from manufacturing activities. Furthermore, he reports that Orange County will soon face an annual shortfall in the neighborhood of 5,000 to 10,000 engineers. Clearly if this level of effort is to be sustained well into the next century, Orange County must adapt to the manufacturing technologies of the future. He states "it is obvious to us that Orange County needs additional education and training opportunities in such specific areas as Manufacturing and Design Engineering." Representatives of seven local companies added their endorsement for a program in Manufacturing and Design at UCI: Dr. Eric Jensen, Packard Hughes Interconnect: Notes that his company has invested $20m expansion of manufacturing facilities in Irvine and states that continued growth and expansion "requires that we have available to us competent, well trained engineers in both design and manufacturing." and "I strongly encourage and support your efforts to develop a much needed Manufacturing Engineering discipline within the department." Mr. John Pratt, Vice President of Research and Development, Textron Aerospace Fasteners: Recommends academic preparation in manufacturing, stating that "on-the job training does not adequately prepare these folks for the challenges we face" and "I highly recommend the development of an Academic Program in Manufacturing at UCI. William Schley, IR&D Supervisor, Control Systems Division, Parker Aerospace: "Currently in the field of aerospace, the primary facilitators of new technology seem to be 1) new manufacturing methods/processes; 2) new materials, and 3) new integrated systems approaches. There has been a surprising shift in our market toward products having lower risk and much lower cost, and yet safety and reliability must remain absolutely uncompromised." He goes on to say "It is my opinion that a need exists for graduate engineers who think of design and manufacturing as more of a continuum." Bud DeVries, Manufacturing Superintendent, Steelcase Inc. "We are excited about the prospect of your engineering program growing and would recommend an academic program in Manufacturing be considered for the future. It will be significant for our company as well as many others who are located in Orange County." Wally Marsh, Vice President, PCB Manufacturing, Toshiba, Inc. " The current program in our estimation has been a total success and serious consideration should be made in developing a course of study for Manufacturing Engineering. Like the Intern Program, an academic program in Manufacturing Engineering will provide additional exposure to students on real-world situations by providing them with the tools to easily enter the manufacturing environment, not to mention the benefits to the industry." Scott Huston, Director, Process Engineering, Printronix: "We are very pleased to hear that UCI is considering addition of a curriculum in the Design and Manufacturing field." And "We are committed to hiring new grads who have selected Manufacturing Engineering as their career choice. Currently, we have to recruit from outside the immediate area to find candidates with this goal." Tom Weisel, Director of Engineering, Micro Motors. Inc.: "This letter is confirm my support for the creation of an engineering program at UC Irvine that has a strong design and manufacturing emphasis."