High Volume Mass Production Research Articles

Miniaturized nanoelectrospray interface for coupling capillary electrophoresis with mass spectrometry detection.

A miniaturized electrospray interface consisting of a microfluidic nanosprayer and nanospray module is reported in the presented short communication. The nanosprayer was fabricated using silicon (Si) technology suitable for cost-efficient high-volume mass production. The nanospray module enabled the positioning of the nanosprayer in front of a mass spectrometry entrance and its coupling with capillary electrophoresis based on the liquid junction principle. A case study of top-down and bottom-up proteomic analyses of intact cytochrome c and its tryptic digest demonstrates the practical applicability of the developed interface.

Chemo-Mechanical Durability of Reinforced Fuel Cell Membranes in the Presence of Metallic Foreign Particles

High-throughput production is vital to achieve cost-effective proton exchange membrane fuel cells (PEMFCs) at scale1. The high-volume mass production of PEMFCs using industrial manufacturing machinery may however introduce unwanted material in the final product due to the wear and tear of the machinery. As an example, roll-to-roll processes applied to the manufacture of catalyst coated membrane (CCM) generally use Fe alloys such as stainless steel2 components that could release fine metallic particles or related debris that may affect the product quality3,4. Therefore, it is important to understand the fundamental impact of such non-uniformities on PEMFC performance and durability.This work focusses on the impact of slightly oxidized iron (Fe) and stainless steel 316L (SS316L) micro-particles entrapped between the cathode catalyst layer (CCL) and a GORE-SELECT® Membrane A. Fe cations are considered as Fenton’s catalyst/reagent which enhance harmful radical generation and ionomer attack, known to weaken its mechanical strength and ionic conductivity5. Therefore, membrane electrode assemblies (MEAs) containing solid Fe and SS316L particles were prepared to conduct in-situ PEMFC experiments and identify their impact on membrane degradation and durability. The chosen particles were placed carefully on the bare membrane at selected locations based on the flow field design of the graphite bipolar plates. Later, the assembled MEAs were tested using a small-scale fixture (SSF) fuel cell in a combined chemical and mechanical AST after beginning-of-life (BOL) conditioning and diagnostics6.X-ray computed tomography (XCT) has been shown to be a powerful and non-invasive 3D characterization tool for analyzing membrane degradation7,8. Thus, periodic same-location XCT visualization of the CCL-membrane interface was performed after every 10 AST cycles. According to the Fe Pourbaix diagram9, Fe oxidizes to Fe2+ at 0.77 V and indeed, in this work, complete dissolution of the Fe-50µm particles was observed leaving cavities at the CCL-membrane interface. This dissolution manifested as a distinct black spot in CT imaging, as highlighted by the enclosed red circle in Figure 1. In contrast, corrosion of SS316L particles is usually prevented by a native oxide layer formation during fuel cell operational conditions10. The Fe particle laden AST reached membrane failure within 30 cycles and indicates an escalation of degradation by global membrane thinning. This is substantially lower than the baseline AST without particles. The XCT images for Fe-50µm AST seen in Figure 1 show that severe global membrane thinning occurred in the Fe-50µm MEA, which contributed to a high electrochemical leak detection (ELDT) signal exceeding test failure criteria. In contrast, the SS316L MEA did not reach the threshold failure criteria for the AST duration, however, the average OCV remained lower as compared to the baseline MEA AST. XCT imaging showed that the SS316L- 50µm particles did not dissolve throughout the AST duration and the membrane thinning was more pronounced near the particle rather than globally. Additionally, we have evaluated whether chemically and mechanically mitigated GORE-SELECT Membrane® B could enable more robustness and minimize impact of multiple metallic particles. Analysis of combined chemo-mechanical AST with a larger dimension SS316L-500µm present on mitigated GORE-SELECT® Membrane B suggest that chemical and mechanical mitigation can reduce impact of large particles and enable lifetime response at the level close to baseline. In conclusion, the membrane lifetime and failure mode were found to be strongly dependent on the particle chemical composition and membrane degradation mitigation strategies, which are therefore should be considered at PEM design stages to reduce risks and improve CCM and MEA production quality. Keywords: PEM durability, quality control, cost reduction, XCT Acknowledgments This research was supported by the Natural Sciences and Engineering Research Council of Canada, Canada Foundation for Innovation, British Columbia Knowledge Development Fund, Western Economic Diversification Canada, Ballard Power Systems, and W.L. Gore & Associates. This research was undertaken, in part, thanks to funding from the Canada Research Chairs program. References H. Tsuchiya and O. Kobayashi, Int. J. Hydrogen Energy, 29, 985–990 (2004).J. Chen, H. Liu, Y. A. Huang, and Z. Yin, J. Manuf. Process., 23, 175–182 (2016).A. Phillips et al., Fuel Cells, 20, 60–69 (2020).A. Phillips, M. Ulsh, K. C. Neyerlin, J. Porter, and G. Bender, Int. J. Hydrogen Energy, 43, 6390–6399.J. G. Goodwin, K. Hongsirikarn, S. Greenway, and S. Creager, J. Power Sources, 195, 7213–7220 (2010).Y. Chen et al., J. Power Sources, 520, 230673 (2022).Y. Chen et al., J. Power Sources, 520, 230674 (2022).Y. Singh et al., J. Power Sources, 412, 224–237 (2019).R. Tolouei et al., Phys. Chem. Chem. Phys., 18, 19637–19646 (2016).N. Kumar et al., Int. J. Energy Res., 44, 6804–6818 (2020). Figure 1

Is Additive Manufacturing an Environmentally and Economically Preferred Alternative for Mass Production?

The manufacturing sector accounts for a large percentage of global energy use and greenhouse gas emissions, and there is growing interest in the potential of additive manufacturing (AM) to reduce the sector's environmental impacts. Across multiple industries, AM has been used to reduce material use in final parts by 35-80%, and recent publications have predicted that AM will enable the fabrication of customized products locally and on-demand, reducing shipping and material waste. In many contexts, however, AM is not a viable alternative to traditional manufacturing methods due to its high production costs. And in high-volume mass production, AM can lead to increased energy use and material waste, worsening environmental impacts compared to traditional production methods. Whether AM is an environmentally and economically preferred alternative to traditional manufacturing depends on several hidden aspects of AM that are not readily apparent when comparing final products, including energy-intensive and expensive material feedstocks, excessive material waste during production, high machine costs, and slow rates of production. We systematically review comparative studies of the environmental impacts and costs of AM in contrast with traditional manufacturing methods and identify the conditions under which AM is the environmentally and economically preferred alternative. We find that AM has lower production costs and environmental impacts when production volumes are relatively low (below ∼1,000 per year for environmental impacts and below 42-87,000 per year for costs, depending on the AM process and part geometry) or the parts are small and would have high material waste if traditionally manufactured. In cases when the geometric freedom of AM enables performance improvements that reduce environmental impacts and costs during a product's use phase, these can counteract the higher production impacts of AM, making it the preferred alternative at larger production volumes. AM's ability to be environmentally and economically beneficial for mass manufacturing in a wider variety of contexts is dependent on reducing the cost and energy intensity of material feedstock production, eliminating the need for support structures, raising production speeds, and reducing per unit machine costs. These challenges are not primarily caused by economies of scale, and therefore, they are not likely to be addressed by the increasing expansion of the AM sector. Instead, they will require fundamental advances in material science, AM production technologies, and computer-aided design software.

Processing plastic-glass blend in injection molding equipment

On January 19, 2023, ENGEL and Glassomer announced to jointly develop new applications for glass injection molding. The two companies have concluded a cooperation agreement for this purpose. ENGEL is providing an injection molding machine to Glassomer for the joint development work and for customer orders. Founded in 2018 as a start-up, Glassomer GmbH – headquartered in Freiburg, Germany, specializes in the manufacture of injection molding-capable quartz glass and the production of premium glass parts. “The technology offers huge potential, not least for the optical, medical technology, solar, chemical and automotive sectors. Our goal is to tap this potential,” as Clemens Kastner, Product Manager Technologies at ENGEL emphasizes. “Together with Glassomer, we are lowering the barriers for getting started with this new technology and paving the way for high-volume mass production.”

Data-Driven Predictive Modeling of Tensile Behavior of Parts Fabricated by Cooperative 3D Printing

Abstract 3D printing has been extensively used for rapid prototyping as well as low-volume production in aerospace, automotive, and medical industries. However, conventional manufacturing processes (i.e., injection molding and CNC machining) are more economical than 3D printing for high-volume mass production. In addition, current 3D printing techniques are not capable of fabricating large components due to the limited build size of commercially available 3D printers. To increase 3D printing throughput and build volume, a novel cooperative 3D printing technique has been recently introduced. Cooperative 3D printing is an additive manufacturing process where individual mobile 3D printers collaborate on printing a part simultaneously, thereby increasing printing speed and build volume. While cooperative 3D printing has the potential to fabricate larger components more efficiently, the mechanical properties of the components fabricated by cooperative 3D printing have not been systematically characterized. This paper aims to develop a data-driven predictive model that predicts the tensile strength of the components fabricated by cooperative 3D printing. Experimental results have shown that the predictive model is capable of predicting tensile strength as well as identifying the significant factors that affect the tensile strength.

High strength injection molded thermoplastic composites

The use of injection molding to impregnate fabric reinforcements and produce carbon or glass reinforced thermoplastic composites opens the way for high volume mass production at reasonable cost, high strength, and lightweight products. Variable mold temperature together with non‐standard injection parameters allows the proper impregnation of woven carbon and glass reinforcements with standard low viscosity polymers. Testing of the injected composite parts showed a clear increase in mechanical strength. POLYM. ENG. SCI., 58:560–567, 2018. © 2018 Society of Plastics Engineers

Optimization of Low-Power Brushless PM-Machines for Automotive Applications With Focus on High-Volume Mass Production

This paper deals with the optimization for performance and cost of the low-power permanent magnet synchronous machines used in automotive applications with focus on particularities of high-volume mass production and the constraints that arise. The described optimization loop is used to compare different 12/8 and 12/10 designs of interior permanent magnet (IPM) type. After showing that the 12/10 IPM exhibits the best performance–cost ratio, results obtained at different stages in the process (i.e., sensitivity analysis and constrained single-/multiobjective optimizations), for both no-load and load case, are provided. Finally, different aspects for reducing the complexity of the multidomain optimization problem (e.g., 3-D effects, iron losses, and effects of tolerances on the motor characteristics) are addressed.

Micro convexity elimination of tungsten carbide in electrical discharge milling for lens moulds

Electrical discharge milling (ED milling) using spherical electrode is considered to fabricate tungsten carbide (WC) lens moulds for high volume and cost efficient mass production comparing with hemispherical electrode whose wear is noticeably larger. However, micro convexity with dome shape generating in the center of the mould leads to poor surface quality of moulds when using spherical electrode. Therefore, based on boundary layer theory, the forming mechanism of the micro convexity is analyzed in detail by measuring its height and profile by virtue of 3D laser scanning microscope and scanning electron microscope (SEM). The relationship between the boundary layer thickness and the discharge gap is subsequently established, which can be utilized to reduce the convexity to improve the surface quality of lens mould. Then a method to eliminate the micro convexity is proposed. In addition, experiments of different discharge gaps were carried out to confirm the boundary layer theory. Results show that the height of micro convexity can be reduced to 4 μm when the discharge gap was specified to the boundary layer thickness at certain rotational speed.

A simple fabrication process for disposable interdigitated electrode arrays with nanogaps for lab-on-a-chip applications

In this paper, we introduce for the first time a novel fabrication process for interdigitated electrode arrays (IDA) with nanogaps on polymer substrates. The IDA sensor for disposable lab-on-a-chip (LoC) applications employs an amperometric detection principle which allows a signal amplification by redox cycling. Our fabrication sequence is based on a lift-off free process and therefore, reduces the number of process steps and simplifies the fabrication and increases the yield. This innovative approach consists of an initial structure followed by two deposition processes. The initial structure, which is transferred into the polymer, is in the micrometer range and is formed by hot embossing. A silicon stamp is fabricated by mask aligner lithography and a subsequent dry etching step. An imprint template was prepared from the master and the structures are transferred into a 1mm thick cycle-olefin polymer (COP) sheet. A subsequent sputter deposition process was carried out to form an undercut of the finger structures, which should guarantee a separation of the electrodes. A 90nm thick gold layer was deposited by thermal evaporation to pattern the electrodes. The presented fabrication procedure represents an approach to fabricate disposable nanogap interdigitated electrode arrays allowing high signal amplifications in LoC applications. Furthermore, it demonstrates a low-cost method to fabricate IDAs with nanogaps for high volume mass production.

Evaluation of Repeatability and reproducibility of CMM equipment

Requirements for measurement accuracy are constantly increasing, as are the requirements for evaluating quantifiable characteristics measurement systems. Among engineering fields, the highest requirements are placed on measuring systems in the automotive and aerospace industries. Specialized automatic control and measurement devices that evaluate specific parameters of components are being increasingly used in high-volume mass production. The issue of variation and uniformity of measurement results within the supply chain of today is an everyday topic of discussion among quality assurance representatives of both parties.The article describes an experiment, in which an experimental test pattern was gradually measured using CMM in a controlled environment of metrology laboratory and then the test part was measured by a workshop CMM, which was equipped with temperature compensation system, in an uncontrolled environment. After securing a statistically relevant amount of data, both measured files were analyzed to verify repeatability and reproducibility, the parameters which are crucial in terms of production practice.

High Thermal Conductive Die Attach Paste Using Polymer and Micron Size Silver for Power Semiconductor Package

Abstract Power semiconductor package manufactures and electronic device suppliers have been looking for Pb-free alternative to traditional high Pb solder die attach adhesives. Lead solders have high thermal conductivity, 30–50W/mK, and known process with some difficulties in high volume mass production such as void, bond line control, and requiring reducing atmosphere such as forming gas. Lead is now categorized as hazardous substance to human body and environment and its products are scheduled to be banned within a few years. Standard silver epoxy pastes and Electrically Conductive Adhesives (ECSs) are other forms of die attach adhesives but the thermal conductivity is not adequate for Power devices. Eutectic gold-tin solder (80Au20Sn) has 57W/mK but it is high cost material. Currently Silver sintering material has become popular for electronic device because it has high thermal conductivity (150~250W/mK) by using nano silver sintering. But it requires high bonding temperature and pressure. It makes brittle bonding structure and has limitation in die size due to high stress. New silver sintering material in this paper is composed of micron size silver and organic polymer. This technology overcomes all the limitations of conventional silver epoxy, eutectic gold thin solder and silver sintering product by using the unique design of polymer composition. This new silver sintering technology using polymer and micron size silver is a cost effective solution to replace Pb solder for power device and the thermal performance is almost same as nano silver sintering products. The application process is the same as standard silver epoxy and does not require new equipment. It is a cost effective drop in solution.

Fabrication of microoptical freeform arrays on wafer level for imaging applications.

Miniaturized imaging systems combining an ultra-compact form factor in combination with the ability of refocusing and depth imaging have gained much interest in the field of mobile imaging. Therefore, artificial compound eye cameras are an extremely promising approach for the realization of compact monolithic camera modules on wafer level. Up to now, their imaging performance was limited to low resolution in the range of VGA format according to fabrication constrains given by the established microoptical fabrication methods, namely the reflow of photoresist. In order to overcome these classical limitations, the use of refractive freeform arrays (RFFA) instead of conventional microlens arrays is inevitable. To enable high volume and cost efficient mass production of artificial compound eye cameras for mass markets like the consumer electronics industry, their fabrication on wafer level is essential, but has not been published up to now. We present a wafer level based process chain enabling the fabrication of these elements for the first time.

Engineering, management and economics: a case study in alloying disparate elements

Although the Model T went out of production in 1927, its genesis and production had effects lasting long after the car. Its technical production evolution formed the basis for the first High-Volume Mass Production (HVMP) system in the world. This, in turn, engendered competition with General Motors, where the managerial advances by Alfred Sloan brought the modern corporation into being. These two advances, catalysed by the Model T, gave the USA a mature HVMP system, in place and producing, by 1935, when the rest of the world was still stuck in the craft-moving-to-mass-production transition era. The increased productivity that this gave the USA went far in helping to win World War II, forming today's nation and world. Not only the engineering, the management and the economics, but also an interactive mix of the three – and its emergent effects – was responsible.

Micro-flood (MF) technology for sustainable manufacturing operations that are coolant less and occupationally friendly

This paper presents a new technology for minimizing the use of metalworking fluids (MWFs) during the machining process that is atomization-less and occupational friendly. Micro-flood (MF) technology utilizes direct contact between the cutting tool and the MWF without the interaction of a gas medium. Experiments were conducted in high volume mass production environment turning HSLA (high strength low alloy) SAE 070Y steel. Machining performance and total air mass particulates were investigated in dry machining, Near dry machining (NDM) via atomized spray mist and MF technology. Open-atmosphere air monitoring indicated that total mass particulates behaved in an almost linear fashion with respect to gas atomization pressure, whereas the MWF flow rate demonstrated logarithmic trends in NDM applications using an atomized spray. Nozzle orientations directed upward into the air also produced higher mg/m 3 concentrations (such as flank) than chip and rake face orientations that were directed down. Greater separation existed at higher gas atomization pressures, MWF flow rates and by changing the MWF type. At extreme limits, nozzle orientation affected mg/m 3 concentration as much as 4–5 mg/m 3 for water-miscible MWFs and 15–22 mg/m 3 for non-water-miscible MWFs. Tool-life performance varied greatly among MWF type and flow rate, and in all cases MF technology performed better than NDM using an atomized spray mist. Direct and consistent MWF penetration to cutting zone using MF technology lowered tool-wear on the average of 12–75% compared to NDM at the same MWF flow rate. Compared to dry machining, NDM improved tool-wear on the average by 20–243%. In one case, tool-wear performance was improved by 616% at 0.15 mm using MF technology compared to dry machining at a nominal 0.925 mm tool-wear. Overall, a large mass reduction of particulates can be achieved employing MF technology that would have been unrealistic for an open-atmosphere machining environment employing an atomized spray mist. On the average, MF technology can maintain a total air mass particulate of less than 0.4 mg/m 3 in the occupational work zone using MWF flow rates up to 1260 ml/h, regardless of the MWF classification. Atomized spray mist applications are capable meeting the 5 mg/m 3 OSHA limit if MWF flow rates are less than 160 ml/h, air pressures are less than 0.137 MPa (20 psi) using water-miscible MWFs and air pressures are less than 0.0344 MPa (5 psi) using non-water-miscible MWFs.

Process window of micromachined gyroscopes subjected to vibrational frequencies

A micromachined gyroscope (or gyro) is used to measure angular velocities for many applications such as automotive, robotics, navigation, military and consumer electronics applications. For our specific automotive applications, the gyro is used to sense the yaw, roll, and pitch angular rates for ride stabilization and rollover detection. The process window is very important to the goal of achieving high volume mass production and cost reduction of the devices. The purpose of this study is to perform modal analyses, validate the simulation results with testing data, and provide a design tool for quick gyro element resonant frequency predictions. Then the process window and design limit can be quickly evaluated and optimized before the final wafers are built.

CO–CH 4 selectivity enhancement by in situ Pd-catalysed microwave SnO 2 nanoparticles for gas detectors using active filter

Nanosized tin oxide powders were obtained using microwave procedure for their application on gas sensor technology. This technology allows taking advantage of low cost and high volume mass production for the easy in situ introduction of the palladium catalytic additive. The effects of a controlled high palladium catalysation, reaching active filter properties, are reported showing an enhancement of the selectivity for CO and CH 4. In this work, electrical results of the sensor performances are discussed and correlated with their structural parameters and the used technological procedures. Especial emphasis has been devoted to the active filter efficiency deduced from CO consumption measurements. The applicability to the present state of the art in sensor technology of such active-filter catalysed SnO 2 is shown by means of its implementation in micromachined substrates operated in pulsed mode.

Beyond the Fordist/Post-Fordist Dichotomy: Working Through The Second Industrial Divide

The publication of The Second Industrial Dividehelped to initiate a sustained inquiry into the transformation of work under industrial capitalism in the late twentieth century. The argument that the breakdown of Fordist mass production ushered in a new production paradigm in the shape of flexible systems of work organization is reexamined. The dominant role of high-volume mass production and its craft-based counterpart can continue to coexist well into the future. Nevertheless, current income and employment trends appear to disadvantage the traditional blue-collar Fordist worker and industrial unions. The cause of these trends may not, however, be directly linked to skills associated with computer technology. Finally, the type of flexibility most closely associated with the work of Piore and Sabel—flexible specialization—is discussed. It is argued that flexible specialization within industrial districts that (a) foster the development of socially informed economic action and (b) constrain competitive behavior may form the basis for the creation of different employment opportunities that challenge the dominant logic of capitalist development through which flexible employment strategies are used in tandem with corporate downsizing and increased managerial control.

Some Aspects of the Outline Design Specification of a 0.5 kW Stirling Engine for Domestic Scale Co-Generation

This paper describes the design considerations that were involved in the production of a prototype Stirling engine, primarily intended for use in a domestic scale combined heat and power (CHP) system. These are discussed in terms of the specification of basic design parameters—configuration, working fluid, etc. First the particular requirements of this application are considered, primarily a power output of 1 kW or less, suitability for high-volume mass production, ultra long life and as high an efficiency as possible. The design that emerges is relatively simple, of low specific power output and with rather conservative operating parameters—temperature, pressure and speed.