For a recent project designing microfluidic components, I researched a variety of new microscale rapid prototyping and manufacturing techniques looking for the most suitable processes for my application and estimated production quantities. What I found was a growing industry with various product design challenges. I also learned a few strategies on how to best meet those challenges.
Many of the micromanufacturing processes I investigated focused on glass because of its compatibility with techniques such as etching and laser drilling, but the materials and processes are costly. I continued searching for alternative materials better suited to low-cost, high-volume production. However, to determine the best alternative materials and processes to fabricate my component, I could not rely on just a few vendors to educate me on a burgeoning industry; I needed to learn about it as a whole.
Understand the challenges
In my research, I came across many challenges designers face when trying to understand the micromanufacturing industry. Communication can be confusing due to the lack of common terminology. It can be hard for a vendor to simplify complex concepts, especially as engineers try to comprehend them by relating them to the macroscale manufacturing techniques they know well. In the micromanufacturing world, these techniques may be irrelevant. Microfabrication and micromanufacturing are currently very specialized, so even minor customization may require some R&D by both the designer and the manufacturer. The entire industry is new to large-quantity production, so there are a few inherent problems a designer will likely come across, namely:
- There may only be a few companies practicing a specific process, so setting up plant tours at multiple manufacturers in one area may be difficult simply because of geography.
- A manufacturer may have a lot of experience with one-off parts but none in high-quantity production, so you need to allow for potential delays during volume ramp-up.
- If a manufacturer considers its process confi dential or proprietary, it may be difficult to fully evaluate until after you’ve signed a development contract.
- After the development process is complete, you may have limited production alternatives because of intellectual property restrictions, contractual obligations or simply because your vendor is the only one performing the process.
Suppliers’ challenges
Suppliers face challenges similar to designers because their industry is so new. Unlike vendors, designers do not usually advertise their latest research projects. This makes it hard to identify designers that might be interested in their processes. In addition, micromanufacturing costs are high, so vendors may have difficulty finding design partners.
However, as with any new technology, as processes are refined and production quantities increase, prices will surely drop. And, while the number of marketed applications are low, they are growing rapidly as investors draw products from academic research into the marketplace.
Work together
Th ere are several ways to overcome the challenges of designing parts for micromanufacturing. For one, you can gain exposure to industry concepts through online and print articles, conferences, trade shows and white
papers.
In addition to MICROmanufacturing magazine, there are several online resources, such as the Society of Manufacturing Engineers and Web sites sponsored by individual vendors. Whether designing macro- or micro-
scale parts, I try to consult with vendors early in the development process—including in-person meetings—to gain insight from their experiences and clarify the process.
While early communication is key, intellectual property must be protected for both parties. You both may have a lot to offer—and to lose. However, information must be shared as much as possible or you’ll likely get hung up later by overlooked details.
Make the eff ort to meet vendors halfway. They’re as interested in you designing a part for their process as you are in finding a process for your part.
Be flexible with your design and be and which cannot be changed. And, finally, be patient. You might be covering new ground for one or both parties.
The good news is that businesses are identifying microscale solutions and
investors are still interested in funding promising projects, such as developing an innovative microfl uidic diagnostic device. To improve your chances of sucthe design early in the process. µ
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About the author: Chad Schneider is a senior engineer at Key Technologies Inc., Baltimore, an engineering services and product development firm specializing in the design of electromechanical devices. He can be contacted via the company’s Web site,
www.keytechnic.com, or by telephone: (800) 803-1345.
4. Meeting the challenges of micropart design
