Chip to Wafer Hybrid Bonding with Cu Interconnect: High Volume Manufacturing Process Compatibility Study

2019 ◽  
Author(s):  
Guilian Gao ◽  
Pawel Mrozek ◽  
Thomas Workman ◽  
Laura Mirkarimi ◽  
Gill Fountain ◽  
...  
Keyword(s):  
Manufacturing Process ◽  
High Volume ◽  
Compatibility Study ◽  
Cu Interconnect ◽  
Process Compatibility

The Hybrid Compression Moulding of Structural Composite Materials for Automotive Applications

2020 ◽  
Vol 843 ◽  
pp. 3-8 ◽  
Author(s):  
Helena C. Simmonds ◽  
Neil C. Reynolds ◽  
Kenneth N. Kendall
Keyword(s):  
Composite Materials ◽  
Manufacturing Process ◽  
Fibre Composite ◽  
Material Design ◽  
High Volume ◽  
Ford Motor Company ◽  
Compression Moulding ◽  
Cycle Times ◽  
Class Project ◽  
Automotive Suspension

The Innovate-UK-funded Composite Lightweight Automotive Suspension System (CLASS) project, led by Ford Motor Company and partnered by Gestamp UK, GRM Consulting and WMG, investigated the use of carbon fibre reinforced composite materials to decrease the weight of a complex automotive rear suspension component in support of reduction in vehicle emissions. A multi-material design comprising discontinuous fibre composite (C-SMC), aligned fibre composite laminate (prepreg) and steel was developed. A high volume hybrid compression moulding manufacturing process was developed at WMG, achieving total press cycle times of around 5 minutes. Prototype parts were manufactured and evaluated using materials characterisation techniques to validate the manufacturing methods. The optimum C-SMC charge pattern was investigated to achieve complete fill with minimal pre-processing. Destructive and nondestructive analysis of the hybrid parts was performed to understand resultant hybrid material macrostructure. This innovative design and manufacturing process resulted in a component 35% lighter than the original multi-piece steel design.

Silicon and Dopant Ink-Based CMOS TFTs on Flexible Steel Foils

MRS Advances ◽  
2017 ◽  
Vol 2 (23) ◽  
pp. 1259-1265
Author(s):  
Aditi Chandra ◽  
Mao Takashima ◽  
Arvind Kamath
Keyword(s):  
Complementary Metal Oxide Semiconductor ◽  
High Volume ◽  
Oxide Semiconductor ◽  
Large Area ◽  
Process Flow ◽  
Additive Materials ◽  
P Type ◽  
Process Compatibility ◽  
Stainless Steel Foils ◽  
Steel Foils

ABSTRACTPolysilicon complementary metal oxide semiconductor (CMOS) thin film transistors (TFTs) are fabricated on large area, flexible stainless steel foils using novel ink depositions within a hybrid printed/conventional process flow. A self-aligned top gate TFT structure is realized with an additive materials approach to substitute the use of high capital cost ion implantation and lithography processes. Polyhydrosilane-based silicon ink is coated and laser crystallized to form the polysilicon channel. Semiconductor grade P-type and N-type unique dopant ink formulations are screen printed and combined with thermal drive in and activation to form self-aligned doped source and drain regions. A high refractory top gate material is chosen for its process compatibility with printed dopants, chemical resistance, and work function. Steel foil substrates are fully encapsulated to allow for high temperature processing. The resultant materials set and process flow enables TFT electrical characteristics with NMOS and PMOS mobilities exceeding 120 cm2/Vs and 60 cm2/Vs, respectively. On/Off ratios are >107. Reproducibility, uniformity, and reliability data in a production environmental is shown to demonstrate high volume, high throughput manufacturability. The device characteristics and scheme enable NFC (13.56MHz) capable circuits for use in flexible NFC and display-based smart labels and packaging.

Influence of multiple scan fields on the processing of 316L stainless steel using laser powder bed fusion

2020 ◽  
pp. 146442072094854
Author(s):  
TC Leça ◽  
TEF Silva ◽  
AMP de Jesus ◽  
Rui L Neto ◽  
Jorge L Alves ◽  
...  
Keyword(s):  
Additive Manufacturing ◽  
Manufacturing Process ◽  
Metal Cutting ◽  
High Volume ◽  
Processing Parameters ◽  
Powder Bed ◽  
Multiple Scan ◽  
Laser Systems ◽  
Sharp Growth ◽  
Single Field

The sharp growth that additive manufacturing has been showing recently has broadened its application field and resulted in more varied demand of high-volume parts as well as a general increase in part series. The current focus on productivity enhancement of additive manufacturing has imposed the implementation of multiple-laser systems with larger scan fields. Its usage, combined with adequate layer thickness and laser power selection, makes high-volume parts less challenging to obtain. This paper focuses on understanding the influence of using multiple-scan fields for the fabrication of large components, especially on the parts region corresponding to scan field interface. The microstructure as well as mechanical behaviour of the multi-field manufactured samples are compared with parts fabricated using a single-field, for distinct processing parameters. Moreover, given the unreliability of additive manufacturing regarding dimensional and geometrical tolerances with increasing build rates, post-processing metal-cutting operations were studied towards additive manufacturing process hybridization. Despite the typical additive manufacturing process variability, a set of parameters, within testing conditions, could be identified as the most appropriate solution towards mechanical strength enhancement. Nonetheless, porosity levels can significantly impact the ductility of parts, which may be additionally compromised by its occurrence in the scan-field interface region.

Process analysis of spray atomization of dissolved polymers for manufacturing of blood-compatible textile implants

2017 ◽  
Vol 48 (5) ◽  
pp. 926-940 ◽  
Author(s):  
Ingo Nadzeyka ◽  
Eleonore Bolle ◽  
Martin Moos ◽  
Paula Kunitz ◽  
Ulrich Steinseifer ◽  
...  
Keyword(s):  
Manufacturing Process ◽  
Process Analysis ◽  
High Volume ◽  
Porous Polymer ◽  
Polymer Materials ◽  
Vascular Prostheses ◽  
Positioning Systems ◽  
Basic Parameters ◽  
Woven Structures ◽  
Pressure Nozzle

The use of porous polymer materials for vascular prostheses demonstrates promising results. Fleece-like non-woven structures can be generated by atomization of dissolved polycarbonate urethanes. This article focuses on the manufacturing process for the fleece structures. The solution is atomized through a high-volume low-pressure nozzle. The solvent evaporates during time of flight to target, so that small fibres are formed from each drop of solution. By using different rotating molds and positioning systems, tubular shapes or open surfaces can be generated. The manufacturing process is described in detail. The usability of different grades of polycarbonate urethane is tested and the time necessary for evaporation of the solvent from the mesh is assessed. The influence of several basic parameters on the mechanical properties of the generated non-woven material is analysed and discussed.

scholarly journals A Novel Methodology for Fault Identification of Multi-stage Manufacturing Process Using Product Quality Measurement

2020 ◽  
Vol 8 (1) ◽  
Author(s):  
Xiaorui Tong ◽  
Hossein D. Ardakani ◽  
David Siegel ◽  
Ellen Gamel ◽  
Jay Lee
Keyword(s):  
Product Quality ◽  
Manufacturing Process ◽  
Statistical Approach ◽  
High Volume ◽  
Fault Identification ◽  
Manufacturing Processes ◽  
Data Sets ◽  
Basic Product ◽  
Multi Stage ◽  
Quality Measurements

Data-driven modeling and fault detection of multi-stage manufacturing processes remain challenging due to the increasing complexity of the manufacturing process, the lack of structural data, data multi-dimensionality, and the additional difficulty when dealing with large data sets. The implementation of add-on sensors and establishing data acquisition, transfer, storage and analysis has the potential to facilitate advanced data modeling techniques. However, besides the associated costs, dealing with high-volume multi-dimensional data sets can be a major challenge. This paper presents a novel methodology for early fault identification of multi-stage manufacturing processes using a statistical approach. The major advantage of the proposed methodology is its reliance on only the product quality measurements and basic product manufacturing records, given the presence of peer sets. This leads to a feasible faultidentification solution in a sensor-less environment without investing costly data collection systems. The developed methodology transforms the end-of-process quality measurements to a process performance metric based on a density-based statistical approach and a peer-to-peer comparison of the machines at one stage of the process. This approach allows one to be more proactive and identify the problematic machines that could be affecting product quality. A case study in an actual multi-stage manufacturing process is used to demonstrate the effectiveness of the developed methodology.

scholarly journals Design and Manufacturing Process of Micro Air Vehicles

2019 ◽  
Vol 257 ◽  
pp. 01003
Author(s):  
Mateusz Rakiec ◽  
Aleksandra Kwiecien ◽  
Rafal Muchowski ◽  
Bartosz Kazmierski
Keyword(s):  
Reynolds Number ◽  
Carbon Fiber ◽  
Manufacturing Process ◽  
Micro Air Vehicles ◽  
High Volume ◽  
Flight Tests ◽  
High Lift ◽  
Theoretical Assumptions ◽  
Design And Manufacturing ◽  
Initial Research

This paper shows shortly the designing, optimization and manufacturing process of light and compact, carbon fiber MAV. It also covers testing and results. The main purpose was to make an innovative prototype of UAV which is easy to transport, assembly and carry as much high volume payload as possible. The optimization process started from defining the constrains. To gain information needed to choose the best solution and perform optimization, authors made many tests. The material, which was chosen, had to be as light and durable as possible - this characteristics were later checked in tensile test of carbon fiber samples. The main optimization algorithm do initial research about the rest parameters of aircraft. The point was to narrow the range of analyzed chord’s values and find the best motors. For better performance the original airfoil was developed. It works perfectly in low Reynolds number area and has perfect characteristics for high-lift airfoils, compared to similar. It was later checked in CFD. The special manufacturing process of carbon fiber airplane was designed. After all the construction was tested. The successful flight tests confirmed that design process was appropriate and done well. All theoretical assumptions were also right.

Online Poling of Thermoplastic-Compatible Piezoceramic Modules during the Manufacturing Process of Active Fiber-Reinforced Composites

2015 ◽  
Vol 825-826 ◽  
pp. 787-794 ◽  
Author(s):  
Anja Winkler ◽  
Niels Modler
Keyword(s):  
Manufacturing Process ◽  
Laser Scanning ◽  
Optical Measurement ◽  
High Volume ◽  
Thermoplastic Composites ◽  
Experimental Investigations ◽  
Fiber Reinforced ◽  
Sensors And Actuators ◽  
Component Structure ◽  
Active Fiber

Due to high specific properties and the ability for the realisation of short cycle times within the production process, the use of fiber-reinforced thermoplastic composites offers a high potential for high volume applications. Furthermore, the layered built-up and the according manufacturing processes of these materials give the possibility to integrate functional elements, like electronic components or piezoelectric sensor/actuator modules. Within the collaborative research center CRC/TRR 39 “Production Technologies for light metal and fiber-reinforced composite-based components with integrated piezoceramic Sensors and Actuators”, the integration of piezoceramic modules into lightweight structures ready for series production is investigated. This paper presents the manufacturing process of active fiber-reinforced thermoplastic composites. Here, the focus is on experimental investigations covering the process-integrated poling of novel piezoceramic modules during the manufacturing of active fiber-reinforced thermoplastic components. Therefore, laboratory and process-oriented tests are performed for the determination of appropriate parameters for the pressing and poling process. The functionality of the embedded and poled TPM is validated by the excitation of an active component structure and the optical measurement of the vibration behaviour using a laser scanning vibrometer.

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