Skip to main content
Log in

Some recent advances in multi-material micro- and nano-manufacturing

  • SPECIAL ISSUE - ORIGINAL ARTICLE
  • Published:
The International Journal of Advanced Manufacturing Technology Aims and scope Submit manuscript

Abstract

The increasing demand for micro-products and components can be met only partly by the lithography-based micro-electromechanical systems fabrication processes that originated from the silicon-based microelectronics revolution of the late twentieth century. In particular, such processes have limitations when applied to new micro-devices which require the use of a variety of materials and complex 3D microstructures with high aspect ratios. In this context, the paper presents technologies complementary to lithography-based processes for the manufacture of devices or components incorporating micro- and nano-scale features. More specifically, special attention is given to the main findings obtained over the last 5 years from the authors’ research programme on a range of micro- and nano-manufacturing technologies, namely, micro-electrodischarge machining, laser ablation, micro-milling, focussed-ion beam machining, micro-injection moulding, nano-imprint lithography, hot embossing and electroforming.

This is a preview of subscription content, log in via an institution to check access.

Access this article

Price excludes VAT (USA)
Tax calculation will be finalised during checkout.

Instant access to the full article PDF.

Similar content being viewed by others

References

  1. Alting L, Kimura F, Hansen HN, Bissacco G (2003) Micro engineering. CIRP Ann 52(2):635–657

    Article  Google Scholar 

  2. Dimov SS, Matthews CW, Glanfield A, Dorrington PA (2006) Roadmapping study in multi-material micro manufacture. Proceedings of the Second International Conference on Multi-Material Micro Manufacture, 4M2006, Grenoble, France, 20–22 September, pp xi–xxv

  3. Madou MJ (2002) Fundamentals of microfabrication: the science of miniaturization, 2nd edn. CRC, New York

    Google Scholar 

  4. Masuzawa T (2000) State of the art of micro-machining. CIRP Ann 49(2):473–488

    Article  Google Scholar 

  5. Brinksmeier E, Riemer O, Stern R (2001) Machining of precision parts and microstructures. Proceedings of the 10th international conference on precision engineering, ICPE, Yokohama, Japan, 18–20 July, pp 3–11

  6. Pham DT, Dimov SS, Bigot S, Ivanov A, Popov K (2004) Micro-EDM – Recent developments and research issues. J Mater Process Technol 149(1–3):50–57

    Article  Google Scholar 

  7. Dimov SS, Pham DT, Ivanov A, Popov K (2003) Tool-path generation system for micro-electro discharge machining milling. Proc Inst Mech Eng, B J Eng Manuf 217(11):1633–1637

    Article  Google Scholar 

  8. Pham DT, Ivanov A, Bigot S, Popov K, Dimov SS (2007) An investigation of tube and rod electrode wear in micro-EDM drilling. Int J Adv Manuf Technol 33(1–2):103–109

    Article  Google Scholar 

  9. Pham DT, Ivanov A, Bigot S, Popov K, Dimov SS (2007) A study of micro-EDM electrode wear. Proc Inst Mech Eng, C J Mech Eng Sci 221(5):605–612

    Article  Google Scholar 

  10. Ivanov A, Ferri C, Petrelli A, Popov K (2007) Electrode wear ratio and its effects on process modelling and processes capability. Proceedings of the third I*PROMS virtual international conference on innovative production machines and systems, IPROMS2007, 02–13 July, pp 337–344

  11. Ivanov A, Ferri C, Petrelli A (2007) Micro EDM—identification and analysis of two sources of natural tolerance. Proceedings of the eight international conference and exhibition on laser metrology, machine tool, CMM and robotic performance, Lamdamap 2007, Cardiff, UK, 25–28 June, pp 159–168

  12. Ferri C, Petrelli A, Ivanov A (2007) An exploratory data analysis estimation of the effects of the electrode material on the electrical discharge in micro-EDM. Proceedings of the third I*PROMS virtual international conference on innovative production machines and systems, IPROMS2007, 02–13 July, pp 329–336

  13. Rees A, Dimov SS, Ivanov A, Herrero A, Uriarte LG (2007) Micro-EDM: factors affecting the quality of electrodes dressed on the machine. Proc Inst Mech Eng, B J Eng Manuf 221(3):409–418

    Article  Google Scholar 

  14. Masuzawa T, Fujino M, Kobayashi K (1985) Wire electro-discharge grinding for micro-machining. CIRP Ann 34(1):431–434

    Article  Google Scholar 

  15. Rees A, Brousseau E, Dimov SS, Gruber H, Paganetti I (2008) Wire electro discharge grinding: surface finish optimisation. Proceedings of the fourth international conference on multi-material micro manufacture, 4M2008, Cardiff, UK, 09–11 September, p 233–236

  16. Petkov P, Dimov SS, Minev R, Pham DT (2008) Laser milling: pulse duration effect on surface integrity. Proc Inst Mech Eng B J Eng Manuf 222(1):35–45

    Article  Google Scholar 

  17. Pham DT, Dimov SS, Petkov PV (2002) Laser milling. Proc Inst Mech Eng, B J Eng Manuf 216(5):657–667

    Article  Google Scholar 

  18. Pham DT, Dimov SS, Ji C, Petkov PV, Dobrev T (2004) Laser milling as a ‘rapid’ micro-manufacturing process. Proc Inst Mech Eng, B J Eng Manuf 218(1):1–7

    Article  Google Scholar 

  19. Dobrev T, Dimov SS, Thomas AJ (2006) Laser milling: modelling crater and surface formation. Proc Inst Mech Eng, C J Mech Eng Sci 220(11):1685–1696

    Article  Google Scholar 

  20. Pham DT, Dimov SS, Petkov PV (2007) Laser milling of ceramic components. Int J Mach Tools Manuf 47(3–4):618–626

    Article  Google Scholar 

  21. Quintana I, Dobrev T, Aranzabe A, Lalev G, Dimov S (2008) Micromachining of amorphous and crystalline Ni78B14Si8 alloys using micro-second and pico-second lasers. In: Proceedings of the fourth international conference on multi-material micro manufacture, 4M2008, Cardiff, UK, 09–11 September, p 183–186

  22. Dobrev T, Pham DT, Dimov SS (2008) Techniques for improving surface quality after laser milling. Proc Inst Mech Eng, B J Eng Manuf 222(1):55–65

    Article  Google Scholar 

  23. Dimov S, Pham DT, Ivanov A, Popov K, Fansen K (2004) Micromilling strategies: optimization issues. Proc Inst Mech Eng, B J Eng Manuf 218(7):731–736

    Google Scholar 

  24. Popov KB, Dimov SS, Pham DT, Ivanov A (2006) Micromilling strategies for machining thin features. Proc Inst Mech Eng, C J Mech Eng Sci 220(11):1677–1684

    Article  Google Scholar 

  25. Popov KB, Dimov SS, Pham DT, Minev RM, Rosochowski A, Olejnik L (2006) Micromilling: material microstructure effects. Proc Inst Mech Eng, B J Eng Manuf 220(11):1807–1813

    Article  Google Scholar 

  26. Gandarias E, Dimov SS, Pham DT, Ivanov A, Popov K, Lizarralde R, Arrazola PJ (2006) New methods for tool failure detection in micromilling. Proc Inst Mech Eng, B J Eng Manuf 220(2):137–144

    Article  Google Scholar 

  27. Popov KB, Dimov SS, Ivanov A, Pham DT, Gandarias E (2007) New technology for setting up the working coordinate system in micromilling. Proceedings of the third international conference on multi-material micro manufacture, 4M2007, Borovets, Bulgaria, 03–05 October, pp 323–326

  28. Minev RM, Ilieva M, Kettle J, Lalev GM, Dimov SS, Dermendjiev I, Shishkov R (2007) FIB milling and characterization of CrC coatings on tool steel substrate. Proceedings of the third international conference on multi-material micro manufacture, 4M2007, Borovets, Bulgaria, 03–05 October, pp 293–296

  29. Li W, Minev RM, Dimov SS, Lalev G (2007) Patterning of amorphous and polycrystalline Ni78B14Si8 with a focussed-ion-beam. Appl Surf Sci 253(12):5404–5410

    Article  Google Scholar 

  30. Li W, Lalev G, Dimov SS, Zhao H, Pham DT (2007) A study of fused silica micro/nano patterning by focussed-ion-beam. Appl Surf Sci 253(7):3608–3614

    Article  Google Scholar 

  31. Lalev GM, Dimov SS, Kettle J, Van Delft F, Minev R (2008) Data preparation for FIB machining of complex 3D structures. Proc Inst Mech Eng, B J Eng Manuf 222(1):67–76

    Article  Google Scholar 

  32. Matovic J, Kettle J, Brousseau E, Adamovic N (2008) Patterning of nanomembranes with a focussed-ion-beam. Proceedings of the 26th international conference on microelectronics, MIEL 2008, Nis, Serbia, 11–14 May, pp 103–106

  33. Uriarte L, Herrero A, Ivanov A, Oosterling H, Staemmler L, Tang PT, Allen D (2006) Comparison between microfabrication technologies for metal tooling. Proc Inst Mech Eng, C J Mech Eng Sci 220(11):1665–1676

    Article  Google Scholar 

  34. Rajurkar KP, Levy G, Malshe A, Sundaram MM, McGeough J, Hu X, Resnick R, DeSilva A (2006) Micro and nano machining by electro-physical and chemical processes. CIRP Ann 55(2):643–666

    Article  Google Scholar 

  35. Sha B, Dimov SS, Griffiths C, Packianather MS (2007) Micro-injection moulding: factors affecting the achievable aspect ratios. Int J Adv Manuf Technol 33(1–2):147–156

    Article  Google Scholar 

  36. Sha B, Dimov SS, Griffiths C, Packianather MS (2007) Investigation of micro-injection moulding: factors affecting the replication quality. J Mater Process Technol 183(2–3):284–296

    Article  Google Scholar 

  37. Monkkonen K, Hietala J, Paakkonen P (2002) Replication of sub-micron features using amorphous thermoplastics. Polym Eng Sci 42(7):1600–1608

    Article  Google Scholar 

  38. Yu L, Koh CG, Lee J, Koelling KW, Madou MJ (2002) Experimental investigation and numerical simulation of injection molding with micro-features. Polym Eng Sci 42(5):871–888

    Article  Google Scholar 

  39. Griffiths CA, Dimov SS, Brousseau EB, Hoyle RT (2007) The effects of tool surface quality in micro-injection moulding. J Mater Process Technol 189(1–3):418–427

    Article  Google Scholar 

  40. Griffiths CA, Dimov SS, Brousseau EB, Packianather MS (2008) The finite element analysis of melt flow behaviour in micro-injection moulding. Proc Inst Mech Eng, B J Eng Manuf 222(9):1107–1118

    Article  Google Scholar 

  41. Griffiths CA, Dimov SS, Brousseau EB (2008) Micro injection moulding: the influence of runner systems on flow behaviour and melt fill of multiple micro-cavities. Proc Inst Mech Eng, B J Eng Manuf 222(9):1119–1130

    Article  Google Scholar 

  42. Kettle J, Hoyle RT, Dimov SS, Perks RM (2008) Fabrication of complex 3D structures using step and flash imprint lithography (S-FIL). Microelectron Eng 85(5–6):853–855

    Article  Google Scholar 

  43. Kettle J, Coppo P, Lalev GM, Tattershall C, Dimov SS, Turner ML (2008) Development and validation of functional imprint material for the step and flash imprint lithography process. Microelectron Eng 85(5–6):850–852

    Article  Google Scholar 

  44. Griffiths CA, Bigot S, Brousseau E, Heckele M, Nestler J, Auerswald J (2007) Polymer inserts tooling for prototyping of micro-fluidic components in micro injection moulding. Proceedings of the third international conference on multi-material micro manufacture, 4M2007, Borovets, Bulgaria, 03–05 October, p 305–308

  45. McGeough JA, Leu MC, Rajurkar KP, De Silva AKM, Liu Q (2001) Electroforming process and application to micro/nano-manufacturing. CIRP Ann 50(2):499–514

    Article  Google Scholar 

  46. Heckele M, Schomburg WK (2004) Review on micro molding of thermoplastic polymers. J Micromechanics Microengineering 14(3):R1–R14

    Article  Google Scholar 

  47. Guo LJ (2007) Nanoimprint lithography: methods and material requirements. Adv Mater 19(4):495–513

    Article  Google Scholar 

  48. Whatmore RW (2001) Nanotechnology: big prospects for small engineering. Ingenia 9:28–34

    Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to E. B. Brousseau.

Rights and permissions

Reprints and permissions

About this article

Cite this article

Brousseau, E.B., Dimov, S.S. & Pham, D.T. Some recent advances in multi-material micro- and nano-manufacturing. Int J Adv Manuf Technol 47, 161–180 (2010). https://doi.org/10.1007/s00170-009-2214-5

Download citation

  • Received:

  • Accepted:

  • Published:

  • Issue Date:

  • DOI: https://doi.org/10.1007/s00170-009-2214-5

Keywords

Navigation