Assembly of Micro Products

....WEDM and EDM for micro scale components

Adam Clare, University of Nottingham

www.precisionmanufacturing.co.uk

Markets for Micro Assembly - MST Products

Nebulizer

Pennymotor
Needle less
injector

RF MEMS

Pressure
Sensor

Bio Chip

Minimotor

Pressure
Sensor

Finger print
sensor

Optical MEMS

Optical MEMS

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Airbag sensor

Infrared
Sensor

Pressure
Sensor

Automotive Sensor

Connectores

Tyre Pressure
Sensor

Acceleration
Sensor

Assembly in the Micro World

Required high positional accuracy of

automatic assembly machines

Difference in the mechanics of

object interactions due to scaling
effects

Limits of human capability

Cost of manipulation in the micro

world (serial versus parallel
assembly)

Clean room environment

Limited standard equipment

R. Fearing, Berkeley

Surface
effects
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Electrostatic
force

Van der
Waals force

Fantoni et al., University of, Pisa

Design for -Assembly

Need for a sound Design for Micro Assembly

methodology that aims to facilitate the efficient assembly
of complex three-dimensional miniaturised devices
Design rules and guidelines for micro world
Consideration of key assembly process features in early
design stages
Selection of suitable processes
Development of supporting processes and models

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Reconfigurable Plug and Produce Micro

Assembly Systems

A vision for cost effective volume assembly of customised mini and

microproducts applicable to high-cost high-value manufacture

Intelligent Reconfigurable
Control

A methodology for design of plug-and-produce reconfigurable

microassembly systems
Robust microassembly processes
The concept of microassembly for hire or power by the hour

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EU IP EUPASS - Evolvable Micro-Assembly

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Equipment Design and Simulation

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Integration of Muti-vendor Micro-Assembly Systems

PV1 Test Platform EU IP EUPASS
Target accuracy: 5 m
Achieved accuracy: 1.5 m
Contributors:
Philips (NL)
Festo (D)
IEF Werner (D)
Flexlink (S)
Finetool Automation (CH)
Beckhoff (D)
Bosch (D)
Masmec (I)
TQC (UK)
University of Nottingham (UK)

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EUPASS PV1 Platform

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Test Case 1: Minifluidics: Typical Requirements

Assembly
5+ discs; no rotational alignment necessary
Loose x/y positional tolerances ~20m
Retained in position during joining
No delicate features to hamper gripping
Joining
Excellent seal between layers
Maintain perpendicularity of features to first surface
Clean operation (medical application)
Rapid operation (enable mass-production)

T h e des ig n an d m an u factu re o f 3 D m in iatu rised inte g rated p ro d ucts

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Test Case 1: Minifluidics: Typical Requirements

Assembly
5+ discs; no rotational alignment necessary

Loose x/y positional tolerances ~20m

Retained in position during joining

No delicate features to hamper gripping

Joining

Excellent seal between layers

Maintain perpendicularity of features to first surface
Clean operation (medical application)

Rapid operation (enable mass-production)

5

T h e des ig n an d m an u factu re o f 3 D m in iatu rised inte g rated p ro d ucts

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Proposed Solution
Ultrasonic joining
2 Parts stacked in a fixture, large
surface down
Welding head (Horn) presses onto
top surface for 1-2s
Join produced following shape of
horn

HORN

Excellent strength, localised

heating and no adhesive required.

PARTS
FIXTURE

T h e des ig n an d m an u factu re o f 3 D m in iatu rised inte g rated p ro d ucts

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Redesign for Ultrasonic Joining

FLASH
TRAP

0.1mm
FUNCTIONAL FACE
ENERGY
DIRECTOR
(Feature that melts
to provide joint)

T h e des ig n an d m an u factu re o f 3 D m in iatu rised inte g rated p ro d ucts

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0.05mm

Results of Machining
[Kern Evo]

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Integrated Ultra Precision Assembly Platform

Integration of automated
assembly processes with
sub-micron accuracy
Key applications
Folding and handling of flat
micro-parts
Handling of sub-millimetre parts
Development, Integration and
testing of smart material based
micro-grippers

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T h e d es ig n an d m an u factu re o f 3 D m in iatu rised in te g rated p ro d u cts

Test Case 2: Microassembly of CMM probe

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T h e des ig n an d m an u factu re o f 3 D m in iatu rised inte g rated p ro d ucts

The microassembly system

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T h e des ig n an d m an u factu re o f 3 D m in iatu rised inte g rated p ro d ucts

WEDM and EDM

300m

200m shim steel (foil) cut with

30m brass coated steel wire on
AP200L.
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-Assembly
- Conclusions
Design for -assembly - critical requirement for
success in micro manufacture
Technology push vs demand pull
Bridging the gap between lab and industrial
applications
Systems scalability and adaptability
Assembly must be directly related to near net
shape realisation of components
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Questions?

DeptofManufacturing,MechanicalandMaterialsEngineering(M3)
CoatesBuilding,A49
UniversityofNottingham
http://www.precisionmanufacturing.co.uk/team.asp?ID=47
http://www.nottingham.ac.uk/Engineering/People/adam.clare

DrAdamClare adam.clare@nottingham.ac.uk
DrAdamClare
AdamClare

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