Design Manufacture and Industrial Innovation DMII Overview

1
Design Manufacture and Industrial Innovation
(DMII Overview)

• Kesh Narayanan
• (Acting) Division Director

2
Outline
Manufacturing in the context of Service to
Society

• Introduction to DMII
• Academic Programs
• Small Business Programs
• Divisional Overview with emphasis on
  Nanomanufacturing

3
DMII Creation

• The Division started off as DDM (Design and
  Manufacturing) in 1985
• Research in Manufacturing Processes and Systems
• Response to the need for US Competitiveness
• Automotive
• Semiconductors
• In 1992,the division absorbed Small Business
  Research for the entire NSF to become DMII

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Small Business Innovation ResearchSmall
Business Technology Transfer
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NSF Strategy

• People - A diverse, internationally competitive
  and globally-engaged workforce
• Ideas - Discovery across frontiers, connected to
  learning, innovation and service to society
• Tools - Accessible, state-of-the-art information
  bases and shared tools

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Employment of Scientists Engineers
18.50
36
E
Government
Sector
S
13
G
Large
Business/Industry
Sector
L
Small
Business/Industry
Sector
32.50
1997 Data from NSF Science Indicators
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Market DrivenInvestment / BusinessFocused
SBIR/STTR Topics

• Advanced Materials and Manufacturing (AM)
• Biotechnology (BT)
• Electronics (EL)
• Information-Based Technologies (IT)

Nanotechnology
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Academic DMII Programs

• Materials Processing and Manufacturing (MPM)
• Manufacturing, Machines and Equipment (MME)
• Engineering Design (ED)
• Integration Engineering (IE)
• Operations Research (OR)
• Production Systems (PS)
• Innovation and Organizational Change (IOC)
• Grant Opportunities for Academic Liaison with
  Industry (GOALI)

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Materials Processing and Manufacturing (MPM)

• Delcie R. Durham
• Program Director

Melissa Orme, U.C. Irvine
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Material Processing

• Shaping Process
• Material Removal Process

SEM image of CD-type features by Ion
Machining Tom Bifano- B.U.
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Material Processing

• Shaping Process
• Material Removal Process
• Material Additive Process
• DMII leadership in early research
• Solid Free Form Fabrication evolutione.g. Ely
  Sachs, MIT

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Environmentally Benign Manufacturing

• World Technologies Evaluation Center (WTEC) Study
  conducted on Environmentally Benign
  Manufacturing
• Opportunities for Collaboration with Europe
  Japan
• Disassembly and Take Back Legislation of Germany
• Total Cycle Analysis
• NTE Initiative Environmentally Benign
  Manufacturing and re-Manufacturing

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Manufacturing Machines and Equipment (MME)
Program

• K. P. Rajurkar
• Program Director

Cryogenic Machining S. Hong, Columbia University
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Economical Cryogenic Machining

• S. Hong, Columbia University
• Develop an economical machining process to
  eliminate both health problems and environmental
  contamination due to cutting fluids.
• Process uses liquid Nitrogen to cool the cutting
  tool.
• Tool life extended up to five times.
• 1 Patent and 18 publications.

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Nanogate Project
Slocum, MIT A New Micromechanical Mechanism for
Valves and Relays
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Sub-Atomic Measuring Machine
Bob Hocken, UNCC Dave Trumper, MIT
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Engineering Design and Integration Engineering

• George A. Hazelrigg
• Program Director

Meshfree Design Analysis Professor Shapiro,
University of Wisconsin
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Synthesis of Joint-Less Compliant Mechanisms -
Design for No Assembly (DNA)

• Professor Kota, University of Michigan - Theory
  of design for compliant mechanisms has been
  developed, providing design tools for mechanisms
  that rely on compliance as opposed to
  articulating parts

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Operations Research and Production Systems

• Ron Rardin
• Program Director

COMBINATORIAL CONSTRAINT SHARPENING
Nemhauser (Georgia Tech), Balas (Carnegie Mellon)
and Sherali (Virginia Tech)
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Neural Network Optimization in Manufacturing
SchedulingPeter B. Luh and L. S. Thakur, UConn

• Highly parallel scheduling procedure reduced to a
  chip
• Could be Web based
• Can generate near optimal schedules
• 50,000 operations within ten minutes on a PC
• An order of magnitude in reduction in time from
  design to manufacture of circuit board

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Scalable Enterprise Systems Initiative

• Research deals with designing, planning and
  controlling extended enterprises in a period of
  very rapid change
• Examples
• Where to position inventories in supply networks
• When to outsource part and component production
• How to share forecast information to reduce
  inventories
• How to structure networks to produce
  build-to-order products with minimum delay and
  inventory
• How to design electronic markets for materials,
  parts and transportation

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Engineering Transport Systems Initiative

• DMII examples
• Capacity planning for distributing bulk coal
• Real-time solution of large-scale logistic
  problems
• Air traffic management
• Robust vehicle routing

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Future Academic Programs

• Systems
• Enterprise Systems
• Engineering the Service Sector
• Operations Research
• Engineering Design
• Process
• Manufacturing Process
• Manufacturing Machines
• Nanomanufacturing

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Future Directions for Manufacturing Enterprise
Large Enterprise Scale Engineering
the Service Sector
Small Nano Scale Nano-manufacturing
Distributed Manufacturing Enterprise
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Nanotechnology - White House Initiative

• Paradigm shift - find materials to meet the
  design instead of todays restrictions by the
  types of materials available
• Environmental impact
• eliminate process steps to final product
• produce less waste

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NanoScience

• NanoScience unravelling unique properties
• Surface Area dependent Properties
• Chemical, Biological
• Flaw Size dependent Properties
• Mechanical, Electrical
• Feature Size dependent
• Magnetic, Electrical, Mechanical
• Van der Waal Forces
• Frictional

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Nanomanufacturing

• Current commercial nanotechnology in Simple one
  or two dimensional products
• Particle Chemical pigments
• Surface Electronic memory storage disks

STM image of a quantum corral
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Nanomanufacturing Base

• Nanomaterials Processing
• Nanomachines and Metrology
• Nanosystems and Design

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NanomanufacturingBase

• Nanomanufacturing extension to 2 1/2 D
• Nanotubes for polymer composites
• Nano-fiber electrospinning for fiber coatings
• Nano-film deposition processing
• Nanosintering of sol-gel
• modified ink-jet Solid Free Form processes
• Nanogate Valves

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Nanomanufacturing

• Timing is right for 3-D nanomanufacturing
  research
• Manufacture of Complex Nano-products
• Assembly in to micro/macro components
• Integration in to macro-world

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Nanomanufacturing Issues

• Connectivity
• Assembly
• Joining
• Integration
• Product Realization
• Robust
• Design for Manufacturability
• Reliably Reproducible
• Economical, Environmentally friendly

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Opportunity

• There is a tremendous opportunity to do parallel
  research in nanomanufacturing concurrent with
  advances in Nanoscience
• Scale up and Testing become pre-requisite to
  speedier introduction
• Commercial breakthroughs and significant benefit
  to the society from Nanotechnolgy

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Future of DMII

• Leadership in pushing the envelope
• Drive manufacturing into the Nano world and bring
  the connection to societal benefits
• Expand into the world of Service Sector building
  on a strong foundation of manufacturing knowledge
  base