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Apr 23, 2012 - Nanomanufacturing systems: opportunities for industrial engineers, IIE Transactions, 44:7, 492-495, DOI: 10.1080/0740817X. ... have started to take center stage. ... high production rate and volume) manufacturing processes.
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Nanomanufacturing systems: opportunities for industrial engineers a

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Satish Bukkapatnam , Sagar Kamarthi , Qiang Huang , Abe Zeid & Ranga Komanduri

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School of Industrial Engineering and Management , Oklahoma State University , Stillwater , OK , 74078 , USA b

Department of Mechanical and Industrial Engineering , Northeastern University , Boston , MA , 02115 , USA c

Department of Industrial and Systems Engineering , University of Southern California , Los Angeles , CA , 90089 , USA d

School of Mechanical and Aerospace Engineering , Oklahoma State University , Stillwater , OK , 74078 , USA Published online: 23 Apr 2012.

To cite this article: Satish Bukkapatnam , Sagar Kamarthi , Qiang Huang , Abe Zeid & Ranga Komanduri (2012) Nanomanufacturing systems: opportunities for industrial engineers, IIE Transactions, 44:7, 492-495, DOI: 10.1080/0740817X.2012.658315 To link to this article: http://dx.doi.org/10.1080/0740817X.2012.658315

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IIE Transactions (2012) 44, 492–495 C “IIE” Copyright  ISSN: 0740-817X print / 1545-8830 online DOI: 10.1080/0740817X.2012.658315

Nanomanufacturing systems: opportunities for industrial engineers SATISH BUKKAPATNAM1,∗ , SAGAR KAMARTHI2,∗ , QIANG HUANG3,∗ , ABE ZEID2 and RANGA KOMANDURI4 1

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School of Industrial Engineering and Management, Oklahoma State University, Stillwater, OK 74078, USA E-mail: [email protected] 2 Department of Mechanical and Industrial Engineering, Northeastern University, Boston, MA 02115, USA 3 Department of Industrial and Systems Engineering, University of Southern California, Los Angeles, CA 90089, USA 4 School of Mechanical and Aerospace Engineering, Oklahoma State University, Stillwater, OK 74078, USA

1. Introduction Recent years have seen the emergence of new technologies for processing materials and creating artifacts with features having at least one dimension in the nanometer range. These technologies are collectively termed nanomanufacturing processes. These novel technologies offer opportunities for developing material structures and products with unprecedented combinations of physical, chemical, and mechanical properties. Such material structures and products are of vital interest to a broad spectrum of industries, including automotive, aerospace, defense, biomedical, and security sectors. As these technologies have started to mature, the systems issues necessary to translate them into technologically and economically viable manufacturing processes have started to take center stage. The National Science Foundation (NSF) sponsored one of the first workshops on nanomanufacturing and processing in 2002, which was co-organized by one of the authors (Dr. Ranga Komanduri). The systems-level issues pertinent to the Industrial Engineering (IE) community were articulated in several follow-up workshops. For example, an NSF-sponsored workshop in 2008 identified several systems issues for scaling up the current nanomanufacturing technologies to commercially viable (perhaps high production rate and volume) manufacturing processes. Among these, the issues pertaining to quality and reliability, metrology, sensing, and control as well as process planning are of immense relevance to researchers in IE and related disciplines. In recent years, the Manufacturing Enterprise Systems program of the Civil, Mechanical and Manufacturing Innovation Division at NSF supported ∗

research projects addressing various aspects of the aforementioned issues. Following these activities, the NSF sponsored a workshop in November 2009 to focus exclusively on the issues that can benefit from the contributions of IE researchers (www.coe.neu.edu/nanophm). A brief overview of this workshop and its outcomes is provided in the following section.

2. NSF workshop on nanomanufacturing This workshop was held in Boston in November 2009. It was co-organized by Sagar Kamarthi and Abe Zeid of Northeastern University with Ranga Komanduri and Satish Bukkapatnam of Oklahoma University. It attracted over 50 researchers from academia, industry, and government; the majority were drawn from IE departments in U.S. universities. This workshop articulated issues and opportunities in the following five themes, all of which are considered to be immensely relevant to IE discipline: (i) yield and process design; (ii) quality and reliability; (iii) sensing and prognostics; (iv) systems planning and control; and (v) cost and scale-up issues. Addressing these issues is vital for translating and scaling up the current (lab-scale) nanomanufacturing technologies toward technologically, environmentally, and economically viable manufacturing processes. The workshop participants collectively identified the following set of challenges to scaling up nanoscale synthesis technologies into viable nanomanufacturing processes and provided a set of recommendations and research directions pertinent to the IE community. 2.1. Status quo and challenges in nanomanufactuering

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surfaces but are barely adequate to meet the requirements of high-volume nanomanufacturing. For example, an Atomic Force Microscope (AFM) gives nearly atomic-level surface resolution, albeit at a very slow rate; it would be impossible to use AFM to characterize surfaces in commercial-scale high-rate operations. Nanomanufacturing processes that can fabricate nanodevices on a large scale are at their infancy, and the industrial capacity for producing nanomaterials falls short of the market demand levels. Moving mechanical parts in micro and nanotechnologies are subject to new failure modes such as sticktion, fatigue and cracks. Mechanisms that cut across multiple scales make observation and characterization of nanomaterials and nanoprocesses difficult. Nano-scale processes and systems pose many challenges for sensing: (i) accessibility to signal source is not easy; (ii) in-situ sensing is almost impossible; (iii) signals are short, evanescent and weak; (iv) quantization of signals makes transduction difficult; and (v) signal-to-noise ratio is low. What nanomaterials might or might not be harmful is not well understood. Currently, nanotechnology is being pushed by scientists’ interest in promising material properties and functionalities rather than pulled by consumer interest in nano-enabled products. Though the public is interested in nanotechnology, the market for nano-based product is not well understood.

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2.2. Recommendations for nanomanufacturing research

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and hierarchical physics and nonlinearities should be developed. These realistic models will enable monitoring, diagnostics, prognostics, and reliability analysis. Several coupled physical domains, such as mechanical, electrical, optical, fluidic, and barometric domains should be examined to assess the reliability of nanodevices. A systematic set of methodologies of quality engineering should be developed to provide the following: (i) guidelines for the design and analysis of experiments to optimize nanoprocess settings; (ii) on-line monitoring and diagnosis techniques to reduce nanoprocess variation and downtime during production; and (iii) strategies for continuous improvement for high yield and quality. Probability distributions of critical nanoprocess variables, quality response variables, and failures should be established. Methods for accelerated degradation testing under multiple stresses along with efficient test plans (design of experiments) should be investigated.

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impedance spectroscopy, and other spectroscopic methods such as Fourier transform infrared and fluorescence spectroscopy should be investigated for chemical species sensing. A lexicon for sensors for nanomanufacturing should be developed. Methods for studying non-linear/non-stationary dynamics, chaos, rare-event detection, and spatio-temporal distribution of state variables should be developed. Methodologies for self-assembly should be improved to precisely place nanoelements at the desired positions in dimensionally large-scale systems. Design for manufacturing (DFM) and design for assembly (DFA) and other DFx principles should be developed to enable scalable nanomanufacturing processes. Since nanomanufacturing is likely to require specialized production techniques and safety and health precautions, an increased premium should be placed on manufacturing flexibility. Stringent specifications for nanomaterial properties, special processing requirements for nanointermediates, and precise control requirements for critical performance parameters should be developed to make the nanomanufacturing supply chain efficient and cost-effective in the long run. Product models and geometric standards (e.g., IJES, STEP), tolerance standards (e.g., American Society of Mechanical Engineering (ASME) Y14.5), engineering requirements (e.g., ASTM and International Organization for Standardization (ISO) standards), physical property specifications (e.g., conductivity, chirality), biological property specifications (e.g., toxicity, bioactive character), and other performance standards should be defined to scaleup nanoprocesses. Process specification languages, such as the ones that exist for chemical vapor deposition and molecular beam epitaxy, should be developed for nanomanufacturing processes such as nano-electrical discharge machining, direct-write e-beam, block copolymer patterning, and dispersion. Nanoinformatics research, similar to bioinformatics research, should be pursued to uncover data-driven discoveries. Instrumentation and analytical tools for comprehensive characterization of nanomaterials for on-line process control should be developed and characteristics required for specific applications defined. Applications either to replace/improve the existing products or to offer new devices should be identified. The potential of such applications for successful commercialization should be assessed and costs of such applications at a commercial scale determined.

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consumer products should be developed to offer significantly improved functional performance and reduced life cycle costs. Governmental incentives should be sought to effect a quantum jump in nanoprocess capabilities. Complete life cycle planning and control issues should be investigated as nano-enabled products pose end-oflife disposal concerns. Occupational hazards, workplace safety issues, and hazards associated with using nano-enabled products should be rigorously investigated. Occupational Health and Safety Administration (OSHA) requirements for nanomaterials should be established and procedures for handling nanomaterials defined. By studying the effects of naturally occurring nanoparticles in the environment on human health, safe levels for exposure to nanomaterials in industrial settings should be defined. Opportunities should be created to develop partnerships among the academic community to pursue collaborative research. Nanofabrication and nanomanufacturing should be introduced in higher education coursework. Multidisciplinary research culture, opportunities for information sharing and partnerships, collaboration and broad discussion of issues among a variety of perspectives—IE, materials engineering, physicists, statisticians, etc.—should be encouraged. A collaborative innovation network should be established to address the science and technology issues associated with nanomanufacturing.

3. The special issue on nanomanufacturing In addition to the aforementioned recommendations, the workshop participants and the NSF discerned a need for a special issue in a prominent journal to promote and present the emerging research work addressing the quality, reliability, sensing, planning, and control issues in nanomanufacturing. With the support and encouragement from the editors of Manufacturing and Design as well as Quality and Reliability Engineering-focused issues of IIE Transactions, this special issue was initiated and co-edited by Satish Bukkapatnam, Sagar Kamarthi, and Qiang Huang. In response to the call for papers, the editors received very good response from the IE community. After a rigorous review process, eight papers were selected for publication. The papers featured in this special issue contribute to quality assurance and design of nanomanufacturing processes, including those for the synthesis of nanoparticles, nanoparticle composites, nanoscale grains, films,

presenting combined data and physics-driven modeling approaches for process design, monitoring, inspection, and reliability. Data-driven approaches typically use images and other measurements of the morphology and distribution of nanostructures in a matrix, as well as the physical and mechanical properties of the resulting nanostructural elements. However, the size-effects associated with nanoscale elements significantly impede the precision levels of the measurement systems. This challenge is compounded by the sensitivity of the yield rate of nanostructures to small variations in the parameter settings of nanomanufacturing processes and expensive nature of the experiments. In this special issue, new approaches are also reported to model the morphology of particle distribution in a nanocomposite structure. Unlike traditional manufacturing, nanomanufacturing involves product characteristics and process variables at multiple length scales, ranging from atomistic-scale molecular structures to the product scale. The process and product variations are spread over multiple scales as well. This multi-scale product/process variation presents the multi-scale and multi-phenomenon challenge in nanomanufacturing. However, control of nanomanufacturing process and product performance is hampered by the scarcity of measurement data, confounding effects during processing, and limited physical knowledge. A multiscale modeling approach based on resolution-constrained images of nanoparticle-dispersed composite elements to characterize the distribution of particles in the matrix as a space–time random (e.g., Poisson) field is presented. Lack of uniform dispersion of nanoparticles in a composite is another pertinent issue in nanomanufacturing. Particles are often concentrated around grain boundaries. One of the papers in this issue presents an approach to quantify the uniformity of the nanoparticle dispersions in multi-grain nanostructures. Additionally, estimation of the nanoparticle count and distributions can be challenging whenever the dispersion is very dense, and significant occlusion effects are present. A statistical pattern analysis-based approach is presented in one of the papers to quantify the local distribution of nanoparticles of various geometries. Similar to morphology determination, mechanical property estimation can be challenging due to the underlying limitations and uncertainties associated with measurement systems. An approach combining physical models with small experimental adjustments is reported for the estimation of mechanical properties of nanocomposites. Apart from characterizing the morphology, distributions, and mechanical properties, advances in methods are also reported for design and analysis of nanomanufacturing process experiments to account for the uncertainty in the factor settings, high costs of nanomanufacturing experiments, nesting and split-plot nature of the treatment conditions to optimize the yield rate, as well as morphological and physical properties of nanostructures. In addition to

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Nanomanufacturing systems measurements from physical experiments, atomistic molecular dynamics and Monte Carlo simulations can be used to characterize and design nanomanufacturing processes. The use of molecular dynamics simulations is reported in a paper to study the formation of nanodroplets, which are vital elements of various tip-based nanomanufacturing processes. In addition to modeling and design issues, quantifying the reliability and hazard rates of components and devices from nanomanufacturing processes can be challenging, especially when the established characteristic curves and their parameterizations do not capture the failure modes of nanoscale devices, and limitations exist on data availability. A non-parametric Bayesian approach is presented to model the hazard rate function to assess the reliability of devices and components fabricated using certain nanomanufacturing processes. The articles featured in this special issue are just a sample of IE-related advancements in design, yield, quality, and reliability of nanomanufacturing processes. We believe that dissemination of body of knowledge that address the needs in nanomanufacturing systems would be beneficial to both academe and industry. In addition, we hope that this special issue will attract a broad spectrum of nanomanufac-

495 turing researchers to consider IIE Transactions as a journal of choice for publishing research contributions addressing systems, quality, and control issues in nanomanufacturing. Finally, the special issue co-editors wish to thank the NSF for the support of the nanomanufacturing workshop that has led to the creation of this special issue, as well as for its generous support of their research. In particular, the inputs from Dr. Cerry Klein in promoting the idea of a special issue are highly appreciated. The co-editors also thank Dr. Susan Albin, the Editor-in-Chief of IIE Transactions, for her support and encouragement, and for the help in liaisoning with the publishers. The constant support and technical advice of Dr. Jan Shi, the Editorin-Chief of IIE Transactions Focused Issue on Quality and Reliability Engineering, Dr. Placid Ferreira, former Editorin-Chief of IIE Transactions Focused Issue on Design and Manufacturing, and Dr. Shiyu Zhou, the Editor-in-Chief of IIE Transactions Focused Issue on Design and Manufacturing are deeply acknowledged. The co-editors also thank the nanomanufacturing community, especially the various IE researchers for their interest and inputs, and thank the publisher, Taylor & Francis, for all the logistic support with the review and publication of this special issue.