OUR R D JOURNEY for Industry 1
Logo Rationale The SIMTech 20th anniversary logo symbolises the institute’s two decades of R&D partnership with the Singapore manufacturing industry in growing the Intellectual Capital, Industrial Capital, and Human Capital (three Cs) to enhance its competitiveness. The figure ‘20’, formed by the three Cs, morphs into a dynamic human icon accelerating towards the journey of greater R&D success denoted by the red star. The SIMTech buildings in the background house the foundation of its rich R&D talent, technologies, and resources for industry.
Contents 0 1 Message 05 About SIMTech 08 Major Milestones 1 5 Research@SIMTech 47 Engaging Industry 65 Our People 75 Moving Forward
MESSAGE “From its inception, SIMTech has been at the vanguard of R&D in a wide spectrum of areas in engineering with a strong impetus for translation to industry. ” - Dr Raj Thampuran, Managing Director, A*STAR 2
Message MESSAGE managing director Agency for Science, Technology and Research It is my pleasure to congratulate the The A*STAR research institutes constantly seek to balance the near-term technology support Singapore Institute of Manufacturing for companies to raise their competitiveness, productivity, and the longer-term goal of Technology (SIMTech) on the occasion of its accumulating capabilities ready for emerging opportunities. The innovation centres such as the 20th anniversary. Precision Engineering Centre of Innovation, the Manufacturing Productivity Technology Centre, SIMTech was the first of the Agency for Science, and the Sustainable Manufacturing Centre address Technology and Research (A*STAR) Science the more immediate needs of the industry while and Engineering research institutes to be set up SIMTech’s researchers continue to advance in the early 1990s as part of the national initiative science. I am happy to see a steady rise in the to restructure Singapore into a knowledge-based patents filed and a healthy increase in the number and technology-driven economy. Over the last of licenses taken out by companies and staff to start two decades, Singapore has made great strides up companies. in moving up the global R&D scale. The gross expenditure on R&D (GERD) grew by more than 10- I would like to convey my appreciation to SIMTech fold and the current GERD/GDP places Singapore management and staff for their sterling efforts and among the league of research-intensive countries achievements over the last two decades and wish such as the United States, France, and Taiwan. The them every success as they continue to make Singapore Government continues to be committed important contributions to industry development to research, innovation, and enterprise, with the and growth. allocation of S$16.1 billion over five years starting from 2011, an increase of 20% over the last five- Dr Raj Thampuran year tranche. From its inception, SIMTech has been at the vanguard of R&D in a wide spectrum of areas in engineering with a strong impetus for translation to industry. 01
MESSAGE “In recent years, SIMTech has become more proactive in bringing its research outcomes to serve the industry needs in capabilities development, technology, knowledge, and productivity.” - Dr Lim Ser Yong, Executive Director, SIMTech 02
Message MESSAGE Executive Director Singapore Institute of Manufacturing Technology SIMTech’s mission is to develop high-value Consolidation: In recent years, SIMTech has alumni are working in the industry, in start-ups, SMEs, become more proactive in bringing its research and MNCs, delivering impacts directly to the industry. manufacturing technology and human capital outcomes to serve the industry needs in capabilities development, technology, knowledge, Moving Forward: In the next phase of our journey to enhance the competitiveness of Singapore’s and productivity. We have opened three industry of R&D for industry, our aim is to reach out to more innovation centres to better address the needs companies to enhance their competitiveness through manufacturing industry. of the industry; launched collaborative industry world-class R&D and technology innovation to achieve projects and consortia to bring companies together our vision of being the R&D lab for the Singapore In its 20-year journey of R&D for industry, SIMTech in R&D projects; engaged MNCs and SMEs in manufacturing industry. We will expand our outreach has gone through several phases of evolution and supplier development programmes; and partnered to serve more companies, especially the SMEs, by transformation: with the Singapore Workforce Development Agency forging strategic partnership with industry associations; to introduce case study-based continuing education we will deepen our research through establishing Building Up to Serve the Industry: Gintic courses. Technology roadmapping was used to joint research labs in strategic themes with local and Institute of Manufacturing Technology was formed better align our research with industry needs and overseas universities; we will enhance capabilities in 1993. Much effort was devoted to building up more effort was made to develop our IPs for industry integration through multi-disciplinary research to a world-class R&D Institute through international adoption. Relationship with the universities was attract and anchor new industries; we will broaden and local recruitment of a core team of research strengthened through the setting up of joint research our manpower development programme to include scientists and engineers, and the development of labs. Multi-disciplinary research programmes industry immersion to serve the industry needs for industry-compatible infrastructure and facilities. The were started with the aim of developing new more manufacturing research scientists and engineers. Institute has cultivated a strong culture to serve the manufacturing technologies for future industries. industry through various outreach and engagement Last but not least, I would like to acknowledge the mechanisms. Our Impacts: The impact of our R&D and contributions by our past Executive Directors, Drs industry development efforts is multifaceted. Our Frans Carpay and Lim Khiang Wee, for building up Realignment to Enhance Research: With the technologies, the fruits of our R&D efforts, are the strong foundation of the Institute and establishing consolidation of research institutes under the used in manufacturing shop-floors and in end- a strong culture of serving the industry and R&D A*STAR Family, Gintic Institute of Manufacturing user products; our assistance have helped many collaboration with the universities. I would also like to Technology was renamed as Singapore Institute of companies overcome their manufacturing problems, thank all our research and industry partners for their Manufacturing Technology (SIMTech). While staying reducing downtime and improving manufacturing strong support for SIMTech in the past twenty years relevant and continuing to serve the manufacturing efficiency and productivity; our knowledge is and we look forward to continuing our close partnership industry, greater emphasis was given to upstream transferred to manufacturing engineers and in the future. research and technology development through managers through case study-based continuing partnership with the universities and other research education courses enabling the timely sharing of Dr Lim Ser Yong organisations. More attention was given to training best practices and solutions; our graduates and of research students, publication of research results in scientific journals, and filing of patents. 03
04
ABOUT SIMTech Where research creativity and technological innovations synergise 0505
ABOUT SIMTech ABOUT SIMTech The Singapore Institute of Manufacturing Technology (SIMTech) is a research institute of the Science and Engineering Research Council (SERC) of the Agency for Science, Technology and Research (A*STAR). SIMTech develops high-value manufacturing technology and human capital to enhance the competitiveness of Singapore’s manufacturing industry. It collaborates with multinational and local companies in the precision engineering, aerospace, automotive, marine, electronics, semiconductor, medical technology, logistics, and other sectors. 06
oRGANISATION ABOUT SIMTech The strategic direction of SIMTech is set by the Management MREUSLETAI-RDCISHCPIPRLOIGNRAARMY MESManufacturingPrecisionSustainable Committee headed by the Executive Director. At the operational Productivity Engineering Manufacturing level, the Research Liaison Office (RLO), the Industry Technology Development Office (IDO), the Knowledge Transfer Office Centre of Centre (KTO), and the Corporate Affairs Office (CAO) formulate the Centre Innovation policies and standard operating procedures that run the various key functions of the institute. INNOVATION CENTRES Research work is carried out within the Manufacturing Management Manufacturing Automation Division, the Manufacturing Process Division, Committee Process and the Manufacturing System Division. Each of these three divisions consists of two to four Research Groups, which are Manufacturing in turn sub-organised into Research Teams, each working in a System specialised area of technology. Manufacturing Two multi-disciplinary Research Programmes, namely the Large Area AutomationRESEARCH DIVISIONS Microfluidics Manufacturing Programme and the Large Area Processing Processing Programme, have been established, with the Biomanufacturing Focused Interest Group in the nascent stage of scoping. The Manufacturing Productivity Technology Centre, the Manufacturing Precision Engineering Centre of Innovation, and the Sustainable Manufacturing Centre serve as contact points to support the local manufacturing industry. Biomanufacturing Focused Interest Group 07
MAJOR MILESTONES MAJOR MILESTONES | 20 years of cutting-edge GINTIC INSTITUTE OF MANUFACTURING TECHNOLOGY Merger GINTIC Institute of Computer Integrated Manufacturing and Institute of Manufacturing Technology merged to form Gintic Institute of Manufacturing Technology (GIMT) Appointment of Dr Frans Carpay as Managing Director, GIMT 1993 Inaugural Consortia Consortia Award - Plastic Ball Grid Array - Ceramic Ball Grid Array 3rd ASEAN Engineering Achievement Award - Flip Chip on Glass - Printed Circuit Board Assembly for CONCERT, a concurrent engineering project for construction industry 1994 1995 1996 Inaugural Industry Training Programme Industry Programme Master of Science in Computer Integrated Aerospace Technology 1st Spin-off Manufacturing, and Precision Engineering Integrated Decision System Consultancy Pte Ltd Programme Launch Marine Technology 08
research, industry collaborations, and innovative manufacturing solutions MAJOR MILESTONES Award 1st Patent National Technology Award for 3D grinding Submergible pumping system with thermal- technology sprayed polymer surfaces Technology Achievement World’s thinnest magnesium die-cast part of 2000 0.38mm thickness Consortium Industry Achievement 1998 1999 Lead-free Process Qualification and Implementation Flip-Chip-on-Board technology for hearing aids Industry Programme 2D to 3D CAD/CAM Migration 1997 Industry Training Programme Industry Achievement Technology Infusion Programme On-the-Fly Ball Grid Array Inspection System 09
MAJOR MILESTONES MAJOR MILESTONES | 20 years of cutting-edge GIMT renamed as SIMTech under A*STAR Technology Achievement Cutting steel directly with diamond tool to mirror finish 2001 Appointment of Dr Lim Khiang Wee Celebration of SIMTech’s 10th Anniversary Technology Achievement as SIMTech’s 1st Executive Director FDA-approved biocompatible polymer Technology for Enterprise Capability Upgrading bones using 3D printing technique Pioneer batch 2002 Technology Achievement 2003 2004 Sol-gel for iron soleplates Reseach Foundry Low Temperature Co-fired Ceramic Consortia - Cold Forging - Injection Moulding - Equipment Industry Achievement Award Consortium Completion of real-time automated National Technology Award for sol-gel Substrate and Micro-Packaging Research for inventory control system for Singapore technology Industry and Military Applications Airport Terminal Services Award 10 Flight International Aerospace Award (Maintenance and Modification Category) for robotic aircraft wing inspection system
research, industry collaborations, and innovative manufacturing solutions MAJOR MILESTONES Licensing Titanium Dioxide Photocatalytic Coating Appointment of Dr Lim Ser Yong Launch of SIMTech Membership Industry Innovation Centre Consortium as Executive Director Patent National Radio Frequency Identification Science, Engineering, and Research Council (SERC) Liquid Forging Centre Aerospace Programme 2005 2006 2007 Award Singapore Quality Class Inauguration of SIMTech Annual Multi-disciplinary Research Programme Manufacturing Forum Microfluidics Manufacturing Licensing 11 Gintic Scheduling System for Discrete Manufacturing
MAJOR MILESTONES MAJOR MILESTONES | 20 years of cutting-edge Licensing Inaugural Collaborative Industry Programme 3D Wirebond Inspection System Gun Drilling Industry Training Programme Workforce Skills Qualification (WSQ) Specialist Training course Award Multi-disciplinary Research Industry Training Programme Industry Training Programme National Technology Award for liquid Programme 1st batch of WSQ Graduate Diploma courses Operations MaNagement and Innovation (OMNI) forging technology Large Area Processing Industry Innovation Centre 2009 2010 2008 Precision Engineering Centre of Innovation Industry Innovation Centre Award Consortium Sustainable Manufacturing Centre WSQ Distinguished Partner SERC Capabilities for Automotive Award for outstanding Research (A*CAR) contribution to the development and expansion of the WSQ system 12
research, industry collaborations, and innovative manufacturing solutions MAJOR MILESTONES Joint Labs Industry Innovation Centre Industry Achievement Industry Achievement Manufacturing Productivity 3 with Nanyang Technological Technology Centre 800 engineers successfully trained 100 technologies licensed 9 PE WSQ courses University Industry Achievement 2013 2012 2011 100 T-Ups Launch of SIMTech’s 20th Anniversary logo and celebration Licensing Research Foundry Liquid Forging Microfluidics 13
1414
RESEARCH @SIMTech Pushing the boundaries in manufacturing technology research 1515
RESEARCH@SIMTech RESEARCH@SIMTech A significant portion of the institute’s annual budget In-house research projects, on the other hand, are aimed at scaling up is allocated to the development of technologies technologies to a point where industry partners can see the potential and benefits that will help companies enhance their capabilities, of adopting them in their products or processes. The outputs of in-house research improve operational effectiveness, and increase projects are in the form of Technology Disclosures that are subsequently filed as their competitive edge. At SIMTech, research patents or retained as trade secrets. projects are of two genres: Collaborative and In- house. Conducting clearly-defined and targeted research for industry applications is a carefully planned process at SIMTech. Each research group follows a five-year Collaborative research projects (CRPs) are pre-competitive technology roadmap that is reviewed annually. During this research planning in nature (Technology Readiness Indices of one to three) and exercise, inputs from the various technology and commercial intelligence (TCI) usually carried out in collaboration with universities, A*STAR teams, along with insights from the research programmes and centres, are research institutes, and/or other research organisations. In considered. The updated roadmaps are formulated into the annual work-plan. many cases, graduate and undergraduate students work The views of the Scientific Advisory Board are also taken into account. with SIMTech researchers with outputs mainly in the form of papers in high impact journals and presentations at academic conferences. 16
Research @ a glance Over the years, the excellent work of SIMTech RESEARCH@SIMTech scientists, engineers, and research students has JOINT LABS generated many new and high-impact technologies. These outcomes are published in good quality 6 journals, filed as patents or technology disclosures, or kept as trade secrets. Research Projects Publications Patents granted >1570 >2600 >88 Students Supervised INTERNATIONAL COLLABORATORS >2020 >110 17
RESEARCH@SIMTech Technology Journey Over the past two decades, research Plasticity Forming in relevant technology fields has evolved in keeping with the trends Research on plasticity forming began with burrless metal stamping that utilised double action technology. and needs of the manufacturing The next development was on sheet forming and cold forging of high strength parts. This was followed by industry. This section traces some bulk metal forming of components with complex internal features using rotary and spin forming techniques. of the significant achievements in a Currently, attention is focused on hybrid forming that combines stamping and forging to fabricate parts with number of disciplines. multi-wall thicknesses and fine features. Progressive Die Stamping Sheet Forming of AI, Rotary Forming Steel and Mg 1993 1998 2003 2008 2013 Burrless Stamping and Hybrid Forming Double Action Stamping Cold Forging 18
Technology Journey RESEARCH@SIMTech Laser Processing Cladding and Laser Aided Additive Manufacturing Research in laser processing started with the use of the laser as a tool to machine features and holes not easily achieved with conventional machining. In the work on laser marking, a significant breakthrough was the discovery of a colour-change process whereby different colours could be produced on metal surfaces. This technology was patented and deployed by a multinational company. Recent work concentrates on selective surface hardening, machining of composite materials, surface texturing, and the dicing of silicon. Machining Composites 2013 (FR4 and Carbon Fibre Reinforced Polymers) Precision Machining 2003 2008 1998 Laser Texturing and Silicon Dicing 1993 Advanced Marking Sealing and Hardening 19
RESEARCH@SIMTech Technology Journey Metal Joining Early work on metal welding was on overcoming challenges to the efficient welding of difficult-to-weld materials such as aluminium alloys. The next stage of development was in microjoining, particularly in applications for electronics packaging and in low temperature Cu-Cu bonding. More recent investigations are focused on cladding for remanufacturing, precision welding for applications such as hermetic sealing, and higher-productivity welding with automation and robotics. Arc Welding of Plasma Welding Laser Welding Repair of Turbocharger Aluminium Alloys Component Using Laser Aided 1998 2003 1993 Additive Manufacturing Wire Bonding and Soldering 2008 Robotic Friction Stir Welding Bonding of Cu-Cu Interconnects 2013 Laser Additive Welding 20
Technology Journey RESEARCH@SIMTech Polymer Processing Work on plastic injection moulding commenced with precision lens moulding, gas-assisted moulding, and thin wall moulding. Microinjection moulding was started to address the microelectronics and life science industries. Currently, the R&D projects focus on developing precision moulding techniques for a wide range of high-precision and high-value added components for water filtration, medical, automotive, and aerospace industries Microprecision Moulding of High-value Added Components (for Microfluidic, MedTech and Aerospace Applications) 2013 Moulding Simulation 2008 Precision Moulding 1998 2003 Processing of Nanocomposites, Biocomposite and Natural Fibre Composites 1993 Micromoulding 21
RESEARCH@SIMTech Technology Journey Sol-Gel Work on sol-gel started with the development of scratch-resistant, high hardness, and good adhesion sol-gel coatings for aluminium substrates. This was successfully achieved and applied to the soleplates of the Philips high-end irons. This technology won the National Technology Award in 2002. The next development concentrated on anti-slip coating for glass surfaces. More recently, the focus has been on printable sol-gel, corrosion-resistant coatings, and controlled surface energy functional coatings for the consumer electronics and construction industries. 1993 Sol-gel Scratch-resistant Coating Corrosion-resistant Coating for Steel Superhydrophobic Coating 1998 2003 2008 2013 Flat Heating Technology Anti-fingerprint Coating Anti-slip Coating for Glass Before After 22
Technology Journey RESEARCH@SIMTech Image Processing for METROLOGY Early work was focused on developing rapid 2D automated inspection methods and tools for the assembly of electronics devices and components. The focus next shifted to 3D vision inspection techniques for wire bonding and other applications. Currently, the work has been extended to the use of X-rays and X-ray optics, in addition to visible light. This is to develop computer tomography reconstruction and visualisation along with 3D image processing technologies for sub-surface inspection and measurement. X-ray 3D Sub-surface Measurement 2008 2013 2D Vision Inspection 2003 1993 1998 3D Measurement of Surface Features 23
RESEARCH@SIMTech Technology Journey Robotic Force Control for Contact Type Operations Research in this area began with the development of a robotic system to replace the manual grinding operation for aero-engine blades. The resulting system won the National Technology Award in 1999. Subsequently, effort was made to apply the task-based operational space formulation to achieve active force control capabilities for robotic manipulators. This knowledge was demonstrated in the precision finishing of a free-form aircraft canopy and has since been adopted by the aerospace industry to perform material-removal processes such as chamfering, deburring, and polishing. The current focus is on using add-on force control to realise high bandwidth, good response, and fine resolution operations. 1993 Passive Compliance 1998 2003 Active Compliance (Around-the-Arm) Active Compliance (Through-the-Arm) 2008 2013 24
Technology Journey RESEARCH@SIMTech Planning and Scheduling Early work on planning and scheduling was based on mass production lines, where periodic batch splitting and merging were necessary to improve job throughput and machine utilisation. This evolved into the Gintic Scheduling System, which is covered by four patents and has been applied to the semiconductor industry. The work was then directed to optimise high-mix low-volume manufacturing. So far, the research outcomes have been licensed to four companies. Current focus is on planning and scheduling for remanufacturing. Production Planning and Scheduling for High-Mix Low-Volume Manufacturing 2008 2013 Gintic Scheduling System 1998 2003 1993 Production Planning and Scheduling for Backend Assembly 25
RESEARCH@SIMTech Technology Journey Shop-floor Execution Technology The initial phase of development entailed the derivation of an advanced supervisory control methodology to control the critical assets in a plant. This flagship supervisory system was deployed in a mission-critical material warehouse as well as in a number of airfreight terminals. Next, research was carried out on realising the real-time visibility of production throughput, quality, and machine availability. This RFID-based tracking technology has been adopted by the logistics and construction industries. More recent work covers prognostic health management to achieve better equipment maintenance and reduce machine downtime. Also in the pipeline is research on data analytics to provide improved insights in shop-floor operations. Remote Condition Embedded Sensing Machine Tool System Monitoring 2008 Prediction Uncertainty Compensation Monitoring Using Fleet Data 1998 2003 1993 2013 Production Data Warehousing, Network Supervisory Visualisation and Data Mining Control Production Order RFID-based Tracking Prescriptive Data Analytics, Tracking of Resource and Asset Utilisation Fusion and Visualisation 26
Technology Journey RESEARCH@SIMTech Large Area Processing To align Printed Circuit Board Assembly and electronics packaging activities with emerging industry needs, research on substrate technology was started in 2002. This was followed by a major effort in the Strategic Research Programme on Substrate and Micro-Packaging Research for Industry & Military Applications, funded by A*STAR and Defence Science Technology Agency. This led to the setting-up of the Low Temperature Co-fired Ceramic (LTCC) programme that provided the foundation for functional printing and embossing technologies. The Large Area Processing programme was initiated to capture research opportunities in the roll- to-roll manufacturing of functional films and printed electronics. Advanced Substrates 2008 Large Area Processing Technologies 1998 2013 Printed Circuit Board LTCC Substrates 2003 Assembly Large Area Processing Line 1993 27
RESEARCH@SIMTech Technology Journey Microfluidics Manufacturing The printed circuit board assembly work introduced pioneering technologies such as the flip chip, ball grid array, chip scale package, and lead-free solders through several research consortia. Efforts shifted to MEMS and MEMS packaging that was later extended to BioMEMS with the development of a reconfigurable microsystem integration platform. This subsequently led to the launch of the Microfluidics Manufacturing Programme, focusing on the development of manufacturing technologies for polymer devices and microfluidics function elements. Printed Circuit Board Microroller Embossing for Multilayer Fluid Channel Microanalyser Micromixer Packages Microfluidic Devices and Electrode Network 1998 2013 1993 2003 2008 Protein Detection Chip Pressure MEMS Packaging Optical Switch MEMS 28
Research Achievements RESEARCH@SIMTech Over the years, SIMTech scientists, Liquid Forging for Complex Geometries engineers, and research students have generated a myriad of new and Liquid forging enables the fabrication of intricate and structurally- high-impact technologies. A selection superior components that are not attainable with traditional die are presented in the following pages. casting and extrusion. This unique process entails the introduction of a predetermined volume of molten material into a die cavity that is subsequently pressurised during solidification in a single cycle. Liquid Forged AI Parts The result is the production of pore-free parts with fine-grained microstructures. This is ideal for components that require thin wall widths and high aspect ratios to minimise their weight and material. The liquid forging technology received the National Technology Award in 2008 and has since been successfully licensed to companies to produce light-weight and high- performance products for thermal management and structural applications. Gravity Die Cast Liquid Forged Liquid Forging Process Produces Porosity-free and Liquid Forging Process Finer Grained Mircostructures 29
RESEARCH@SIMTech Research Achievements 3D Printing of Titanium Implants Metal implants commonly have modulus much higher than bone. When the implants’ modulus is higher than bone’s modulus, a phenomena called stress-shielding may occur, leading to implant loosening and bone re-modelling. In order to lower the metallic implants’ modulus to match the bone’s modulus, one solution is to include porosity in the implant design. 3D printing is an additive manufacturing process capable of manufacturing parts based on their Computer Aided Design (CAD) model representatives. Additive manufacturing parts offer a high degree of shape flexibility and are ideal for the fabrication of complex and customised medical implants. 3D printed porous titanium implants with modulus in the range of the bone’s modulus have been obtained by incorporating porosity to the implant CAD model and engineering its processing parameters. 3D Printed Titanium Scaffolds with Bimodal Pore Size for Tissue Engineering 3D Printing Process 3D Printed Femoral Prosthesis with Engineered Porosity for 30 Hip Replacement
Research Achievements RESEARCH@SIMTech Rapid Magneto-rheological Finishing Rapid magneto-rheological finishing (Rapid-MRF) uses magneto-rheological free- form slurry to polish surfaces efficiently. A novel conception of the magnetic tool enables the generation of consistently high pressure and in-process re-shaped magnetised slurry. This approach is able to remove the fractured layer of brittle material without generating scratches and residual stress on the surface. Free- form components made of non-magnetised metal can be polished without the need for specialised tooling, skilled craftsmen, or expensive polishing machines. This technology is set to have a huge impact on applications in general engineering components, aerospace components, and in the substrates of electrical devices. Magnetisation direction Setup of Rapid-MRF Magnetic tool MRF media Aluminium Alloy Sample Finished by Rapid-MRF Workpiece Double Magnetic Roller Tool Design 31
RESEARCH@SIMTech Research Achievements Sol-Gel-Derived Functional Coatings Work on sol-gel started with the development of scratch-resistant, high hardness and good adhesion coatings for aluminium substrates. This was successfully achieved and applied to the soleplates of Philips high-end steam irons. This technology won the National Technology Award in 2002. The next developments were on anti-slip coating on glass and marble substrates, printable sol-gel for flat heaters, and corrosion-resistant coatings for steel surfaces. Recently, the focus is on anti-fingerprint, hydrophobic, and hydrophilic coatings for the consumer electronics and aerospace industries. Anti-slip Coating on Glass Coating Thickness and Material Selection Optimisation Hydrophobic and Hydrophilic Coatings 32
Research Achievements RESEARCH@SIMTech Nanostructured super tough tribological coatings for wear protection A series of high performance nanostructured hard coatings such as Cr-, Ti-, and Al-based ceramics and C composites have been achieved by plasma- enhanced physical vapour deposition, which offer unique capabilities for wear protection in various applications. Such coatings, containing multiphases in composition and multi- or nanolayers in structure, provide a combination of super-high hardness and toughness, excellent chemical and tribological properties, as well as functions such as anti-sticking, self-lubricating, and resistance to corrosion and oxidation. These coatings have been used in the industry for precision tools (cutting tools, stamping tools, moulds, dies, etc) as well as in wear components to prolong tool/part life and improve productivity or product quality. Micropillar Compression Test of CrAlN (left) and CrAlSiN (right) Plasma-enhanced Physical Vapour Deposition of Nanostructured Composite Coatings 33
RESEARCH@SIMTech Research Achievements Differential X-ray Cone-Beam Computed Tomography (CT) for Planar Objects Traditional CT cone-beam reconstruction methods reconstruct the cylindrical field-of-view Close-up of the CT Slice of a Thin and Low-density Adhesive Layer formed by the area-detector while rotating the sample. This becomes inefficient when reconstructing and visualising a planar object such as a multilayered IC chip. SIMTech’s novel differential cone-beam reconstruction algorithm enables reconstructing only the object region by automatically determining the key scanning geometrical parameters in a scan and then precisely defining the differential reconstruction volume following the location and orientation of the object. Regardless of the original mounting orientation and position of the sample, the reconstructed planar object always has a concise volume and is well-orientated, making it efficient and convenient for visualisation, analyses, and dimensional measurements. T SIMTech V Area Detector CT Reconstruction Software Package Difference between Traditional and Novel CT Methods 34
Research Achievements RESEARCH@SIMTech Nanooptical Measurements and Sensing by Near-field Optics Setup of Scanning Near-field Photon Emission Nanoscopy A system theory framework of near-field optics has been established to achieve optical measurements beyond its traditional diffraction limit. A series of innovative nanoscale optical measurement technologies have been achieved. These technologies include dual-resonance AFM, second harmonic scanning near- field optical nanoscopy, near-field ellipsometry technology, near-field porosimetry technology, and near- field photon emission microscopy (SNPEM). SNPEM has demonstrated 50 nm in lateral resolution and 100 µA in sensitivity for detecting leakage current. This is a substantial breakthrough to Photon Emission Microscopy (PEM), which is currently limited to a resolution of 1 µm. The developed technologies have found applications in semiconductor device characterisation and biomedical cell diagnosis. The near-field plasmonics light is further explored in microstructured optics to achieve the high- sensitivity detection of surface-enhanced Raman scattering for ultra-sensitive molecular analyses. This approach provides reliable detection at an ultra-low molecular concentration of 1pM, which is superior to other methods such as the optical sensors using metal nanoparticles. This capability has a huge impact on applications such as endoscopes, water quality monitoring, and food safety screening. Photonics Cryptical Fibres with Inner Metallic Coating Fibre Flowers: Sensing Head for Raman Spectral Detection 35
RESEARCH@SIMTech Research Achievements Robotised Precision Finishing Robotic Edge Finishing Many precision finishing operations, such as deburring, chamfering, and polishing are still performed manually by skilled workers, resulting in high labour costs, inconsistent quality, and low productivity. Core robotic technologies have been developed to automate such finishing processes for large and complex components comprising comprehensive robotic work cell calibration and error compensation, a three-axis force- controlled end-effector module, force control-based material removal techniques, an integrated robot programming framework, and optimised key process variables. A robotised precision finishing work cell, used to validate these techniques, showed a finishing accuracy of ±0.2 mm. Robotised precision finishing technologies can be applied to the aerospace, marine, and precision engineering industries. An example of this is the successful deployment of the marine propeller polishing technology in an aerospace conglomerate. Multi-rate Operational Space Control of Compliant Motion in End-Effector Robotic Manipulators 36
Research Achievements RESEARCH@SIMTech Evolutionary Dynamic Fuzzy Neural Network for Tool Wear Prediction In the development of self-organising fuzzy neural network for cutting tool condition monitoring, the selection of optimal parameters is a key issue. A novel evolutionary dynamic fuzzy neural network (EDFNN) hybrid, with a generic algorithm, has been developed and applied to predict tool wear in high-speed machining of Inconel 718. The algorithm is implemented to obtain optimal parameters of traditional fuzzy neural networks so as to circumvent the complex time-varying property without prior knowledge or exhaustive trials. It works 11 times faster than traditional fuzzy neural network methods and is suitable for online machine condition monitoring. Data Acquisition Tool Condition Monitoring System 37 High Speed Milling
RESEARCH@SIMTech Research Achievements Operations MaNagement Innovation Methodology (OmniMethodologyTM) OmniMethodologyTM is a productivity planning methodology that integrates the three key components of business strategy, operations management, and productivity improvement of a company. With OmniMethodologyTM, operational improvements are achieved through a five-step approach: (i) determination of business strategy and objectives, (ii) identification of activity landscape, (iii) identification of improvement areas, (iv) generation of initiatives, and (v) development of action plans. This methodology has been adopted in the WSQ OMNI Programme to help companies achieve productivity improvement and operational excellence. Since its launch in 2010, 12 OMNI sessions have been conducted, benefiting more than 150 participants from 68 companies. 1STAGE 2STAGE 3STAGE Determine Identify Activity Identify Improvement Business Strategy Landscape Areas and Assess & Objectives Productivity Manufacturing Operations Control 4 Production Planner Production Supervisor STAGE Generate and 5STAGE Prioritise Initiatives Develop Action Plan 38
Research Achievements RESEARCH@SIMTech Production Scheduling Engine for Discrete Manufacturing The schedule engine translates the scheduling objectives into a two-stage procedure: The job prioritisation component that configures the job shop, flow shop, and bottlenecks, and the machine-selection component that utilises the technology to categorise machines within the same work centre and based on loading preference and constraints. Results from the applications of the engine to electronics and semiconductor backend assembly show significant reduction in the scheduling time (over 80%), work in progress (around 30%), and cycle time (more than 20%), as well as more than 20% improvement in machine utilisation. Shop-floor Production Scheduling Model Schedule Gantt Chart 39
RESEARCH@SIMTech Research Achievements Development of Graphene-based Ink for Large Area Processing The pristine graphene sheet is highly hydrophobic and cannot be dissolved in most solvents. Solution-processable graphene inks have been developed by chemically engineering and functionalising a graphene surface onto graphene-organic molecular composite ink, graphene-organic macromolecular composite ink, and graphene- inorganic composite ink. The physicochemical properties of these graphene-based single- and multi-component inks revealed significant improvements in their optical, mechanical, and electrical properties. The developed graphene-based inks can be potentially applied to LCDs, OLEDs, flexible solar cells, and touch panels. Highly Conductive, Transparent and Flexible Film made with Graphene-based Ink Modification Process Graphene-enhanced Polyvinyl Alcohol Nanofibre Membrane Prepared 40 by Graphene-based Ink
Research Achievements RESEARCH@SIMTech Flexible Printed Light-Emitting Devices Electrode (25 µm) Dielectric (35 µm) Flexible printed light-emitting devices were fabricated by printing on light-emitting materials to Light-emitting Particle (28 µm) achieve surface light emission. A novel slot deposition tool provides roll-to-roll coating and Transparent Electrodes (300 nm) patterning of the multilayer composite device structure comprising a transparent electrode, PET Substrate (100 µm) light-emitting particle, dielectric, and electrode layers on a plastic substrate. The integrated variable ink volume transfer control achieves non-contact ink deposition with scalable Device Composite Structure layer thickness of between 200 nm and 50 µm and scalable feature sizes from 100 µm (patterning) to 1 m (coating) of different material compositions. This approach enables the production of printed light-emitting devices that are flexible, rollable, and thermoformable. It’s broad applications include ambient lighting, displays, signages, and interactive media. Deposition Tool Functional Particle Web Direction and Binder Formulation Substrate Support Roller Roll-to-Roll Printed Lighting Film Slot Deposition 41
RESEARCH@SIMTech Research Achievements High Throughput Droplet Generation System for Generation of High Throughput Droplets Bioencapsulation The generation of uniform micron-sized droplets is needed for bioencapsulation where the microdroplets are converted to gelled microbeads with enzymes, drugs, or live cells embedded. The process must be contamination-free and with a high throughput to achieve consistent gelling conditions. A microfluidic-based droplet generator has been developed wherein gas bubbles agitate the fluid stream in a microfluidic chip to form droplets. The microfluidic chip is disposable and can be sterilised to eliminate contamination. The throughput is high (>1000Hz) compared to emulsion droplet formation. Microbeads have been produced from biocompatible polymers such as alginate, sodium cellulose sulphate, and cells encapsulated can be cultured as usual. This technology can be applied in the tissue engineering and the pharmaceutical industry. High Throughput Droplets Live Cell Encapsulation for Bioencapsulation 42
Research Achievements RESEARCH@SIMTech Rapid Microfluidic Mixing Novel microfluidic mixers have been developed to enhance fluid mixing at micro scale. Various mechanisms such as chaotic flow, viscous flow instability, and aero/hydro-elasticity effects have been used. Mixing of high-viscosity fluids, mixing of fluids with largely different viscosities, ultra-fast mixing within a few milliseconds, and rapid mixing of tiny-volume fluids can be achieved, thus overcoming the limitations of conventional mixing devices. The aero/hydroelasticity-based approach utilises the spontaneous vibration of an elastic diaphragm for microfluidic mixing in order to reduce the reliance on external controllers. All these micromixers can either work as standalone devices or integrated into microfluidic systems for various biological and chemical applications. Oscillator Mixer for Chamber Mixing Simulation of Cross-sectional Mixing in a Static Micromixer Chaotic-expansion Mixing of Liquids with Large Viscosity Variations 43
RESEARCH@SIMTech Scientific Advisory Board The Scientific Advisory Board (SAB) was constituted to guide and review the direction and outcomes of the research at SIMTech. The board comprises prominent leaders of the global manufacturing research community, drawing on their diverse research backgrounds and rich experience. Over the years, the SAB has included: Professor Taylan Altan - Ohio State University, Columbus Mr Howard Appelman - The Boeing Company Professor Lord Kumar Bhattacharyya - University of Warwick Professor John Bollinger - University of Wisconsin Professor Ekkard Brinksmeier - University of Bremen Dr Jean Colpin - United Technologies Research Center Professor Steven Danyluk - Georgia Institute of Technology Professor Placid Ferreira - University of Illinois, Urbana-Champaign Professor Lester Gerhardt - Rensselaer Polytechnic Institute Professor Robert Hocken - University of North Carolina at Charlotte Professor Fumihiko Kimura - University of Tokyo Dr Hamid Mughal - Rolls-Royce International Limited Professor Nabil Nasr - Rochester Institute of Technology 44
INTERNATIONAL COLLABORATORS RESEARCH@SIMTech Much benefit can be derived when research organisations work together to synergise their complementary expertise and resources. Research collaborations also provide opportunities for invaluable staff and students exchanges. SIMTech has established a Visiting Researcher Scheme wherein prominent scientists visit for short periods to help spearhead new research areas. Some of our collaborators include: Centre Suisse d’Electronique et de Microtechnique SA Professor Federico Capasso, Harvard University German Aerospace Research Centre Professor Christoph Hermann, Technische Universitat Braunschweig Institute of Materials Research, Tohoku University Professor Jay Lee, University of Cincinnati Korea Institute of Machinery & Materials Professor Frank Lewis, University of Texas, Arlington VTT Technical Research Centre of Finland Professor Li Lin, University of Manchester Warwick Manufacturing Group Professor Toshimichi Moriwaki, Setsunan University 45
Search
