Design and manufacturing of micro products – a framework based on process chains and metrology

Hans Nørgaard Hansen*

*Corresponding author for this work

Research output: Book/ReportDoctoral thesis

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This work presents a systematic framework for design and manufacturing of micro products.

In particular, it describes how tolerances and process chains are interconnected. It addresses a number of key challenges related to the dimensional scale from 1 μm to 1 mm, in some cases down to 100 nm. The framework focuses on the problems arising when geometrical product specifications meet function oriented tolerancing, when precision manufacturing technologies meet MEMS processing technologies and when dimensional metrology meets functionality testing. The designer of micro products needs to take into consideration different design traditions, the integration of different technology platforms and also there is a need to acknowledge the importance of metrology as a key tool to control process chains and product quality.

The framework describes the correlation between product specification, manufacturing and validation at this particular scale. In the context of the above mentioned challenges four research questions are identified under this framework. These research question are summarized as follows:

• Setting the tolerance – how can micro products and components be developed and specified?
• Establishing traceable metrology solutions – how can traceable metrology solutions be developed to assure micro product verification and validation as well as process validation in micro manufacturing?
• Process stability – how can micro manufacturing processes be analyzed, monitored and optimized based on metrological approaches?
• Process validation – how can single processes as well as process chains in micro manufacturing be verified and validated?

The work establishes methods and tools for operating in the specific dimensional interval with two different technology traditions and toolsets including product and process development and quality assurance methods. It couples the product and process side of quality assurance and control by presenting a systematic methodology based on the use of traceable metrological tools and techniques applied to process chains. It demonstrates how complex quality assurance and control can be implemented in this dimensional interval by bringing specific examples and recommendations.

All together, this work establishes a coherent framework for design and manufacturing of micro products. It allows the designer to undertake a systematic design approach where micro manufacturing possibilities and capabilities are considered. The process chain perspective combined with a metrological methodology allows production engineers to analyze and optimize complex micro manufacturing process chains to meet required specifications of the produced components. Finally, quality engineers are given tools to enter into dialogue with designers and production engineers at an early stage of the design process. The work helps move from a pure experience based setup to a formal method for design and manufacturing of micro products.
Original languageEnglish
Place of PublicationKgs. Lyngby
PublisherTechnical University of Denmark
Number of pages215
ISBN (Electronic)978-87-7475-637-8
Publication statusPublished - 2021

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