2D PCB WITH 3D PRINT FABRICATIONS FOR RIGID-CONFORMAL PACKAGING OF MICROSENSOR IMAGING ARRAYS BASED ON BIOINSPIRED ARCHITECTURES

Abstract

Macro sensor systems typically measure a localized space above a single sensor element. Expanding these single sensor elements into arrays permits spatial distribution measurements of a particular parameter and allow flux visualizations. Furthermore, applying microsystems technology to macro sensor systems yields imaging arrays and high resolution spatial/temporal sensing functions. Extending the high spatial resolution imaging over large areas is a desirable feature for new “vision” modes on autonomous robotic systems and for deployable environmental sensors. Rigid-flexible PCB's are desirable for miniaturization and integration of systems for mobile technology. The hybrid substrates provide substantial flexibility in systems design and integration of multiple functions into limited spaces. Using this design and construction approach allows lightweight, complex, and space efficient systems. Flex microsystems based on structured, fiber or non-fiber filled PCB laminates permits packaging to occur at two levels, at the local (micro) substrate scale and at the macro scale with the ability to flex the system across millimeter to centimeter lengths on real everyday systems. We continue to explore the use of PCB and PCBMEMS technology for new sensing concepts. In order to create rigid-conformal, large area imaging “camera” systems we have merged flexible PCB substrates with rigid constructions from 3D printing. This approach merges the 2D flexible electronics world of printed circuits with the 3D printed packaging world. Furthermore employing architectures used by biology as a basis for our imaging systems we explored naturally and biologically inspired designs, and their relationships to non-visible imagery, and alternate mechanical systems of perception. Radiolaria are extremely tiny ocean organisms that utilize a similar additive construction process to 3D printing. Their cell bodies secrete a substance mainly composed of silica to form intricate exoskeletons used as a system of protection. A correlation can be made between the radiolaria's construction process and the plastic extrusion system of the 3D fused deposition model printer. The benefits of additive construction are efficient use of materials, reduced cost and energy, and ability to customize forms. Through the use of bio-inspiration, a framework is laid out to base further research on (DFP)-design for packaging. Radiolarian exoskeletons take on a grid-like pattern while creating a cage around each microsensor interior and producing strong scaffolding. Using the 3D printed exoskeleton's form and function with flexible printed circuits one can create systems that are both rigid and form fitting with three-dimensional shape and enable new camera systems for various sensory applications.