Flexible system for micro-clinching processes design and analysis

With the development of microprocessors, actuators and structural micro-components, new concepts of micro-electro-mechanical systems/machines are constantly being introduced. One of the consequences of this tendency is seeking for best techniques to connect metal micro-components. Because of tools simplicity, no additional fastening parts and the undisturbed structure of the material, clinching appears to be a promising method for joining in micro-scale. A procedure for the analysis of micro-clinching process is proposed in the paper, and unique, support flexible tooling system designed. This system allows to easily change key parameters of the process. With the use of flexible micro-tooling, a successful micro-clinching of silver sheets of thickness 0.18 mm has been conducted. An effective numerical method - Rapid Numerical Strength Test - for modelling the process of tearing the joints has been presented. Compliance of key phenomena recognized in modelling with experimental results was obtained.

Fabrication Techniques for Production of Thermoplastic-Based Microfluidics Devices

Microfluidics is a multidisciplinary technology which enables the face-lift crossing a wide range of applications such as life science research, point-of-care diagnostics and personal medicine. Polymer materials, especially thermoplastics, are dominating this emerging market due to the low material cost and the ease of mass production. This paper reviews the major fabrication technologies for making polymer, especially thermoplastic microfluidic chips, such as micro tooling, injection molding, bonding and surface treatment. The paper also summarizes the key challenges in fulfilling the needs of next generation microfluidic products.

Custom Micro Tooling for Mechanical Ductile-Mode Micro/Nano Machining of Hard and Brittle Materials

Hard and brittle materials such as WC, SiC, and single crystal silicon or germanium are widely used in die/moulds for very high accuracy glass products, medical devices, and sensors for MEMS. Mechanical ductile-mode micro/nano milling is an effective method to create three dimensional geometries on these materials. One of the key factors affecting successfully ductile-mode machining is micro tooling. Due to limitations of commercially available micro tools, custom micro tooling is brought forward to give an active solution to this issue. This paper is a further study on custom micro tooling by the author, and several aspects associated with custom micro tooling have been discussed. Experimental results show the feasibility and effectiveness of the successful ductile-mode machining of hard and brittle materials by custom micro tooling. At last, this paper summarizes the techniques associated with custom micro tooling and point out the key aspects for further research on custom micro tooling.