10-00 Welcome Paul Morantz Cranfield Dynamically controlling the position and distortion of transparent flexible film (to microns) Reel to
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1 Centre for innovative manufacturing in ultra precision Metrology Technologies to Enable Reel to Reel Processing of Emerging Products 20 th November 2013 National Physical Laboratory The EPSRC Centre for Innovative Manufacturing in Ultra Precision is managed by Cranfield and Cambridge Universities Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 1
2 10-00 Welcome Paul Morantz Cranfield Dynamically controlling the position and distortion of transparent flexible film (to microns) Reel to reel production of capacitive touch panels on thin flexible glass BREAK Metrology for in process metrology for roll to roll production of flexible photo voltaics Fabrication processes for flexible display backplanes, current requirements for metrology and challenges for future R2R processes LUNCH Paul Morantz Cranfield Phil Rumsby M-Solv Liam Blunt Huddersfield Simon Ogier CPI Precision surface for day lighting Nick Walker ixscient Metrology challenges for highly parallel micro-manufacture Richard Leach NPL Closing remarks Richard Leach/ Paul Morantz Optional tour Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 2
3 Overview of the EPSRC Centres for Innovative Manufacturing Dr Antony Chapman Portfolio Manager, Manufacturing the Future Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 3
4 Background Manufacturing is currently a political hot topic. Manufacturing has been an important component of the UK economy for at least 250 years. The nature of manufacturing is changing. The EPSRC Centres for Innovative Manufacturing (EPSRC Centres) are the latest in a line of EPSRC funding to support manufacturing research in UK universities. Innovative Manufacturing Research Centres (IMRC). Innovative Manufacturing initiative (IMI). Application of Computers to Manufacturing Engineering (ACME). Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 4
5 Aims of the EPSRC Centres To create, deliver and disseminate world-leading research. To address major long-term manufacturing challenges/and or emergent manufacturing opportunities. To provide strong support for UK manufacturing industries. To enhance the global profile and significance of UK research. To create a national network of expertise in manufacturing research knowledge. To provide outreach to other centres and relevant research groups. Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 5
6 Details of the EPSRC Centres calls There are 16 EPSRC Centres, funded through three separate calls. Typical EPSRC Investment for a Centre is 5-6m over 5 years. The total EPSRC investment is in excess of 80m.. Over 200 UK and international business partners drawing in significant additional investment. Multinationals to SMEs. Financial contributions from host universities. Links with HVM Catapult institutions, trade bodies, KTN etc. No more calls for EPSRC Centres within the current spending review. Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 6
7 What is an EPSRC Centre? Strategic investment: a focus for existing manufacturing strengths in the UK. National focus for the UK. Significant outreach programmes: A Centre must be more than just research projects it must have its own identity. Flexible budget: flagship projects and trailblazer projects. Centres can also apply for responsive mode projects in EPSRC. Continuation beyond the initial period with a mixture of funding sources. Regulated by Advisory board and management board. Subject to mid-term review. Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 7
8 Regenerative Medicine Ultra Precision Laser-Based Production Liquid Metal Engineering Industrial Sustainability Photonics Intelligent Automation Medical Devices Advanced Metrology Composites Additive Manufacturing Food Large-Area Electronics Through-Life Engineering Macromolecular Therapies CMAC Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 8
9 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Liquid Metal Engineering Regenerative Medicine Photonics Additive Manufacturing Ultra Precision Emerging Macromolecular Therapies Advanced Metrology Through-Life Engineering Services Composites Continuous Manufacturing and Crystallisation Intelligent Automation Industrial Sustainability Laser-Based Production Processes Medical Devices Large Area Electronics Food Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 9
10 Lead Universities University of Strathclyde Continuous Manufacturing and Crystallisation Heriot Watt University Laser-Based Processes University of Leeds Medical Devices University of Huddersfield Advanced Metrology Loughborough University Intelligent Automation, Regenerative Medicine Cranfield University Through-Life Engineering Services, Ultra-precision University of Nottingham Additive Manufacturing, Food, Composites University of Cambridge Industrial Sustainability, Large-area Electronics UCL Emerging Macromolecular Therapies University of Southampton Photonics Brunel University Liquid Metal Engineering Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 10
11 Partner Universities Heriot Watt University Continuous Manufacturing & Crystallisation University of Manchester Composites, Large-Area Electronics University of Liverpool Laser-Based Processes Keele University Regenerative Medicine Loughborough University Industrial Sustainability, Additive manufacturing, Continuous Manufacturing & Crystallisation, Regenerative Medicine, Food University of Birmingham Liquid Metal Engineering, Food Cranfield University Intelligent Automation, Composites, Industrial Sustainability. Laser-Based Processes University of Oxford Liquid Metal Engineering Swansea University Large-Area Electronics University of Glasgow Continuous Manufacturing & Crystallisation University of Edinburgh Continuous Manufacturing & Crystallisation Newcastle University Medical Devices Durham University Through-Life Engineering Services University of Bradford Medical Devices University of Sheffield Medical Devices University of Nottingham Regenerative Medicine, Medical Devices University of Cambridge Ultra Precision, Continuous Manufacturing & Crystallisation, Laser-Based Processes Imperial College London Emerging Macromolecular Therapies, Industrial Sustainability National Physical Laboratory Advanced Metrology, Ultra Precision University of Bristol Composites University of Bath Continuous Manufacturing & Crystallisation STFC Advanced Metrology Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 11
12 Training: CDTs/IDCs Continuous Manufacturing and Crystallisation University of Strathclyde Composites Manufacturing University of Bristol Ultra Precision University of Cambridge Macromolecular Therapies UCL Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 12
13 Conclusions The EPSRC Centres are the flagship investment of the EPSRC Manufacturing the Future Theme. 16 Centres covering a range of key manufacturing research topics. 27 different institutions with a wide geographical spread. Links with other EPSRC strategic activities. Initial five year investment of ca. 5m plus match-funding. Long-term investment with the intention of continuation beyond the initial funding period (Not necessarily EPSRC). Focal point for similar research activities across the UK. Manufacturing the Future still provides funding for other research (Calls and Responsive Mode). Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 13
14 UP Centre s Aim To be the world s foremost research centre for innovation in next generation ultra-precision production systems and products, with global outreach. Foster and accelerate development of emerging high value products through its dedicated production compatible ultra precision process research platforms and internationally leading research portfolio. Facilitate the engagement of the UK precision manufacturing supply chain into the future wealth creating opportunities of emerging sectors. Act as a UK knowledge hub for next generation production systems and establish a network with a supporting UK (and wider) capabilities/facilities data base Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 14
15 Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 15
16 National Strategy Martin O Hara Enza Giaracuni Glasgow Edinburgh PETEC Huddersfield UPS 2 Cranfield Cambridge Brunel NPL Southampton Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 16
17 Selected future events National Strategy Precision Engineering Short Course November 2013, EPSRC Centre in Ultra Precision, Cranfield Plastic Electronics Fabrication Technologies 19 February 2014, CPI, Sedgefield Future Display Technologies and Production Demand, EPSRC Centre in Ultra Precision, Cambridge Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 17
18 Research Portfolio Strand 1) Ultra Precision Processes i. Combined laser / focused ion beam processing ii. Miniaturisation of plasma processes iii. High speed fine feature creation iv. Nano-imprint, micrometre embossing, resist application and curing v. Diamond machining of large scale multi-material substrates Strand 2) Ultra Precision Machines i. Energy beam monitoring technologies ii. Control system integration of plasma, laser, imprint, etc iii. Process alignment, thermal management, vibration suppression systems iv. Systems for adopting nano-imprint/embossing in ultra precision m/cs v. Rapid in-process quality control systems for pattern recognition, feature size, shape and distribution analysis, tool shape/beam monitoring vi. In situ process feedback techniques vii. Plasma processing machine development viii. Ion beam figuring developments ~ 24 PhD students or research assistants will be engaged Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 18
19 Research Platforms (proposal Oct 2010) Plasma, Laser, Ion Diamond, Plasma, Print, Imprint Coat, Laser Diamond, Plasma, Print Coat, Imprint Emboss Laser Nano FIB Platform (vacuum) Meso scale Platform (atmospheric) Macro r2r Platform (atmospheric) Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 19
20 Platform 1 - Nano-FIB Platform Process Chain Metrology RAP Laser Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 20
21 Platform 2 - Meso-scale Platform Microwave plasma processing Laser assisted plasma processing Nano-imprint processing Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 21
22 Platform 2 - Micro-beam processing. Identified product demands indicate the following target specification: Laser / Plasma figuring: & structuring Rapid fine feature creation but on λ/40 form surfaces in ULE / Silica, SiC & Si Plasma beam footprint 1-5mm 1 hour processing time for 150mm surface from 2 um P-V form error Laser assist : Temperature enhancement C Laser beam footprint mm Plasma processing from below Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 22
23 Platform 3 - Reel to Reel Platform Based on a modular concept with 48 width capacity and roll diameter capacity of mm. Critical functional requirements: Precision multi stage embossing module with pseudo constant throughput, 200nm re-positioning accuracy Precision alignment module for 2 or 3 film lamination at 500nm Alignment measuring module with 100nm accuracy Apply processes: Lacquer application, embossing, UV/flash cure, inkjet, laser, precision lamination Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 23
24 Why are we here? And what is it all for? Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 24
25 Why are we here? And what is it all for? Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 25
26 Why are we here? And what is it all for? Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 26
27 The past... Polymer foam Release papers Glue film Polymer backing Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 27
28 The future? Welcome Paul Morantz Cranfield Dynamically controlling the position and distortion of transparent flexible film (to microns) Reel to reel production of capacitive touch panels on thin flexible glass BREAK Metrology for in process metrology for roll to roll production of flexible photo voltaics Fabrication processes for flexible display backplanes, current requirements for metrology and challenges for future R2R processes LUNCH Paul Morantz Cranfield Phil Rumsby M-Solv Liam Blunt Huddersfield Simon Ogier CPI Precision surface for day lighting Nick Walker ixscient Metrology challenges for highly parallel micro-manufacture Richard Leach NPL Closing remarks Richard Leach/ Paul Morantz Optional tour Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 28
29 Related Research Projects R2R Platform R2R machine and process technology studies Precision low-cost hydrostatic bearing support Active magnetic supported roll technology Delicate film handling processes Film on film alignment technologies Precision multi film laminating processes In-situ metrology for control of positioning & distortion Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 29
30 R2R Platform Achieve functional ability to control 2 films in lateral positioning to a sub-micron level so they can be laminated at good speed. Work with partners to create processing stages. Status 1) Gravure printing station 2) Inkjet - laser processing station 3) Coatings station 4) Lamination station 5) Metrology capabilities i) Built a low expense test rig using MSc student group project ii) Establishing an affordable ultra precision spindle technology to develop R2R platform iii) Created design concepts for R2R platform, established sub-systems awareness gained iv) Procured some long lead items Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 30
31 Steerable Ultra Precision Air-Spindles Air-spindle 2 Air-spindle 1 φ Thin Flexible Web Adjustable Devices S 2 ψ S 1 Diamond Turned Rollers Roll-off Station Granite Machine Bed Metrology Station Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 31
32 Steerable Ultra Precision Air-Spindles Air-spindle 1 Air-spindle 2 Metrology Station Adjustable Devices Diamond Turned Rollers Thin Flexible Web Roll-off Station Granite Machine Bed Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 32
33 High dynamic control rotor technology for multi step micro surface texturing and feature creation Film on film precision alignment technology, active measurement and R2R compatible adjustment Precision and delicate multi film laminating process In-situ metrology for large area micro structured surfaces R2R Platform Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 33
34 R2R Platform Spindle system concept developed, detail design performed, manufactured parts ordered and some delivered Test drums designed and materials ordered Large metrology grade granite plinth delivered Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 34
35 Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 35
36 Film Steering Actuators Reading Heads Air/Vac flat bed Air Turn Rollers Film Steering Actuators Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 36
37 Metrology to support production Dynamic control of flexible film requires on-line metrology feedback of position in at least 2 axes in at least two positions Relative positioning uncertainties approaching 100nm may be required Film with integrated metrological gratings is suggested These gratings can be introduced onto/into the film using existing technology Metrology Technologies to Enable Reel to Reel Processing of Emerging Products - Organised by the EPSRC Centre for Innovative Manufacturing in Ultra Precision - 20 November 2013 at the National Physical Laboratory, Teddington, UK 37
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