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May/Jun 2013  

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News/Features: Features

With an all-time high of $197 billion in revenue projected for 2012, the U.S. consumer electronics industry is throwing down the gauntlet, calling for designers and manufacturers throughout the supply chain to meet the increasing demands of an ever-shorter consumer electronics product life cycle.

Imec, an international consortium focused on micro and nano technology, has a large global staff, and that’s a good thing because it has a lot on its plate.

Laser forming has provided unique solutions for a variety of manufacturing-related challenges. Among the examples are correcting out-of-plane deviations in metal plate and removing weld-induced distortions.

“Manufacturing matters,” as Bennett Harrison, my graduate advisor at Carnegie Mellon University, used to say. It was a main theme of The Deindustrialization of America, a book he co-authored with Barry Bluestone describing the demise of manufacturing jobs in the United States. Today, as I see it, “MEMS matters”—and not just in the U.S. MEMS manufacturing matters worldwide.

Choosing the right micro machine tool can be a bit of a conundrum. Machining micro parts and features doesn’t always require a machine with a small volumetric capacity, nor is a bigger machine necessarily the optimal choice. As in the Goldilocks fairy tale, however, if micropart manufacturers look hard enough, they can find a machine that is “just right” for their particular application.

Precious metals such as platinum, gold and palladium are used to make critical medical parts. These materials work well in such applications for several reasons, including their biocompatibility and radiopacity, which allows them to be seen inside the body via a fluoroscope or an X-ray.

Some consider it exotic and pricey, but a nimble, six-legged device has the moves to make it a useful addition to many micromachining operations.

Stylus and optical surface metrology: the best of both worlds

Stylus profilers have been the primary tools for surface-finish measurement for many decades, providing cost-effective, rapid and quantifiable surface roughness and form information via single or multiple traces across samples. Most surface-finish standards are based on 2-D stylus parameters such as Ra, Rpm or Rz.

MEMS device makers increasingly outsource fabrication

Keeping up with the growing demand for microelectromechanical systems used inside devices such as smartphones will require MEMS makers to make some new fab friends—as in foundries that can fabricate the devices, help drive down costs and speed time to market.

Microextrusion: mainstay of medical device manufacturing

The extrusion process is great for making tubes, and microextrusion is great for making really small tubes. The smallest are drug-eluting tubes and those used in brain surgery or cancer surgery, which can have ODs as small as 150µm to 200µm. Some steerable catheters have sublumens (voids within the tube) with diameters of 10µm and layers as thin as 3µm to 5µm. The smallest extruded fibers and hollow fibers have diameters of 700nm.