Engineering 165/265: Advanced Manufacturing Choices. Lecture 1. Introduction to the Course

UCI Open
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12 Video Views·Oct 22, 2023
Marc J. Madou, Ph.D.
Recorded April 1, 2013.
Introduction to the Course
License: Creative Commons CC-BY-SA
For more information and to access the complete course, please visit http://ocw.uci.edu
Let me start kind of by trying to get some order in this chaos.
So there were some mistakes made, obviously, on the web.
MAE 165 and MAE 265, or one and the same class, teared together.
Now, MAE 165 knew there was a class every Monday,
which is kind of a class, a discussion class, which is only 50 minutes.
Now, the graduates did not know that.
Am I right? Is that all you're understanding?
I want to see a lot of nods.
Yes.
Yes, yes, yes. OK.
Because if I don't get nods, I still have it wrong.
So you all understand that.
Now, there might be some of you that have a problem
because you didn't plan for that one hour.
Many people have written me emails.
I didn't know about that, so I cannot come today.
That's why probably we will not get a full 54 or 58 students.
But in any event, this class will get a bigger, more comfortable class to work in together.
We need these extra Mondays.
There will often not be discussion, but there will be preparation for a practicum.
Because this being about advanced manufacturing, we want to give you hands-on.
We want you to do things, to make things.
Because it's about bringing advanced manufacturing back to the U.S.
And this is why this class has blessing from the dean all the way to the vice chancellor.
And we actually want to make it next year an engineering class.
Not MAE, but engineering, 265, 165.
So we can get everyone, bioengineering, chemical engineering,
anyone who thinks that manufacturing is important to this country
and maybe to your career.
So that's kind of the background.
So forgive me if I will have to repeat that tomorrow.
I will try to say it slightly different so you don't get too bored.
So I will try to go over the topics we want to cover.
So this is my name.
Some people pronounce it Madao.
It's Madhu.
Can you do that?
We're pretty good.
And Swati Sharma will be your TA.
This is also new.
Normally in a class like this we don't get a TA.
But because the dean is so interested in this happening, we even got a TA.
She will mostly help you when we have the practica, the scheduling.
Why don't I go through that first actually to tell you what the practica will involve.
So in terms of practica, so you guys will tell them what I already said, right?
But probably I will repeat most of it tomorrow anyways.
So the practica will be this.
You will be introduced to CNC machining.
Who knows what CNC machining is?
One, two, raise your hand.
You don't have to be embarrassed if you don't know it.
So what does it stand for?
Computer, C, N?
Numerical.
And C?
Control.
So you will be actually going to a workshop and show how you go from a design to actually machine something.
Number two, you will do soft lithography.
Who knows what soft lithography is?
Maybe two or three of you guys, right?
But don't worry, right?
That's the idea of this class.
You're going to learn practically what soft lithography is and do it in the lab.
We're going to have, this is kind of easy.
You're going to have a clean room visit.
So for those people that hear about dry etching, plasma, CVD, metal deposition station, at least you see it.
You see the machine where these things happen.
So that's number three.
Fourth, you will do rapid prototyping.
So what is that?
You're going to do one of these 3D printing things.
You all heard about that.
That's become very popular in the news.
In the building across here, on the fourth floor, we have an organization called Rapid Tech.
And they will guide you all the way from the design to a Bluetooth device.
So you're going to design it and then you're going to make it.
You're going to print it.
So I'm going to give you a bad story of something that happened with this in previous years.
We might have to turn off the video because it's kind of bad.
So you know how these things are supposed to look, right?
They fit in your ear, right?
And they have like this little loop.
So some of the people had designed it so that the thing was coming, was standing, came on this side.
So you would put it on and instead of going in your ear, it pointed outwards.
Design error.
But you also have to have the size in mind.
And someone had the size wrong by a factor of 10.
And you know what it looked like.
Man, it was so embarrassing.
So I had all of these printed prototypes and I had to give them back to the students, right?
And everyone was kind of laughing.
By the way, it was purple.
And I knew just by looking who had made that device.
And that girl didn't want to come forward.
So that one thing remained there.
So I still have it.
Anyway, so make sure that you also take the size of things in mind.
Anyway, so we're going to do rapid prototyping.
And then finally, in my own group, we use compact disc CDs to do microfluidics.
And you're going to be learning on how to make a CD, not to put music on it or videos, but actually to do a diagnostic test with it.
So these are the practica you will have.
You're a big group.
So there will be some challenges in organising this.
So I hope you guys are patient with us.
It's the first year we are doing this.
So do tell me what's going well, what's going wrong as we go along.
So one of these things is the temperature is too high.
We have too many people in the class.
I already told you.
We hope to take care of that by Monday.
So what topics are we trying to cover instead of going through this boring list?
And this will all be on the web, by the way.
So probably by Wednesday or Thursday, if you visit the BioMEMSnet website, you will find all of the class notes.
Print those out and put them in a folder.
And so you will find the syllabus there.
But I'd rather have the syllabus incorporated in my class one material, which I will start now.
I just told you so far about the practica you will do.
How many are we now?
Forty-two.
Forty-two, okay.
Suppose it failed.
Suppose we turn off the light a little bit.
Can you control it from that side?
I think you got it on your screen.
Is it here?
Yeah.
I think you're right, yeah.
Usually people don't all show up, and now they do.
What's wrong with you guys?
So who knows what manufacturing is?
You're going to start with that, like with some definitions and so.
Could I have someone volunteering to do that while I'm trying to call up this class?
Isn't manufacturing just a process of making something?
Yeah, right.
That's kind of a simple.
Yeah, yeah.
Instead of talking about it, and instead of this big digital revolution we have had, right,
we have come in an age where everyone thought things can all be done virtually.
Isn't it?
Mechanical engineering got less and less students.
They went all to electrical engineering or bioengineering because they thought, you know, making things is dirty.
Isn't it?
There's a little bit of attitude, especially in the United States.
That attitude, by the way, you will not find in Germany, Japan, and Korea.
And now China, countries that are doing very well.
And it might have something to do with the fact that they recognize to create a country wealthy
and maintain the wealth in a country, you can do a couple of things.
Three things.
Let's try to find out.
What are the three things we can do?
You can mine things.
You mine it out of the ground.
Petroleum, metals, you sell them.
You can make things, right?
What's the third thing?
Sorry?
Sell things?
I'd like you guys to find out what the third thing is.
It's going to be homework.
Three things that really make the wealth of a country.
Manufacturing.
Yeah, but that's manufacturing, right?
Making things.
So, we got it in these categories.
Innovate.
Maybe that's part of manufacturing, right?
Invade.
Sorry?
Invade.
We invade other countries.
Easy.
Do we do that?
I hope we don't do that anymore.
You're not serious, are you?
Are you?
That's how Rome gets so big.
Yeah, but look what happened.
You don't want to be there, do you?
Even now, look.
Italy, what happened with it?
Britain, what happened with it?
It's a good discussion, though.
I agree.
It's kind of all part of the same thing.
I'm not finding this yet.
We can still talk about this concept.
Why is manufacturing becoming so important?
So, I'm going to ask this question again.
Obama administration, what have they started doing?
Have you followed the news a little bit?
Yeah, but they want to stop outsourcing.
They want to bring some of the manufacturing back.
So, there's these huge initiatives where they have announced,
we're going to create institutes in the United States
that allow the U.S. to not only invent,
but also make the things they invent.
In other words, they want to make the loop between design
and making a product shorter,
so you have more chance that the investment of the government,
be it NSF, NASA, NIH, that you can actually profit from it.
My own field is MEMS and nanotechnology.
And what we have witnessed,
that actually most of the money made on these things,
on micromachining and nanotechnology,
is made in Bosch in Germany,
Olympus in Japan, in Korea,
and now more and more in China.
And it has a lot to do with the fact that this country
has lost the nerve, so to speak,
of actually making things,
and has considered manufacturing more and more of a dirty word.
And now it's odd,
because if you go in a manufacturing plant today,
it doesn't look like a manufacturing plant of 50 years ago.
It's actually very clean.
It almost looks like a clean room.
And you need more and more educated people,
very high level,
that know how to design
and put that design into a manufactured good.
So we need to bring up
the level of our students dramatically,
even to get into manufacturing.
Because you know that some of the companies from abroad
that come to the US,
they can actually not staff the companies,
because they don't find people that are competent enough
to actually do the technician jobs.
That's a very sorry state of affairs.
So in a way,
I'm trying to make you guys a little bit more realistic.
We have bet too much on everything is going to be digital, virtual.
That's not true anymore.
Because nowadays,
there's a lot of countries that are as rich as us,
maybe richer,
and anything we invent,
they can implement faster than us.
So all we can do is get back to education,
to bring our students in the US
up to the top level,
as high as we can bring them.
So now I'm going to try to see if I can get my class.
I couldn't find it yet.
Any questions on what I just said?
It sounded like philosophy, isn't it?
It's a little bit philosophy.
By the way,
you people that came in late,
don't worry.
We're looking for a much bigger class.
I see you looking kind of like,
what is this?
So you can sit here.
You're okay.
Please come sit here.
You're so uncomfortable right there with the camera.
Oh, now I embarrassed you, did I?
Sorry.
Any question?
Yeah, that's up to you guys.
You're going to tell me three things
that make a nation rich and wealthy
and hopefully sustainable.
What are the two so far?
Oh, come on.
I know.
You're a good student, you know.
Manufacturing.
We mine something.
We make something.
And the third one,
by the end of the class,
we will have it.
That's another M.
M?
You think it's all...
Mining, manufacturing.
Damn, I'm thinking about a bad one.
Anyways.
So advanced manufacturing.
You can organise manufacturing
in many, many different ways.
And one way how you can organise them
is by the way,
the energy you apply to a material
is categorised.
You know, there's various forms of energy
that you can consider.
It could be mechanical energy,
so you drill something
or you carve something.
That would be mechanical.
It could be electrical energy.
It could be heat energy,
such as with laser cutting.
It could be chemical energy.
You will see that
manufacturing processes that are out there,
we can probably organise in seven,
eight different ways.
This is one
where we do it in terms of the energy
you use to make something.
So mechanical, electrical,
heat energy or chemical.
Now we will find
in the course of this class,
this is not always very easy
to apply rigorously
this kind of classification
because sometimes a process
will have something chemical
but also something electrochemical
or it will have some mechanical
together with some chemical, etc.
So it turns out that
in most of the cases
it's not just one of those four.
It's a mixture.
And especially
if you want to categorise
processes between subtractive
and additive,
we will find that in the case
of subtractive techniques
we can apply these four methods
but when it's additive we cannot.
Okay, I already overwhelmed you
with new words.
Right?
One way of categorising
manufacturing is in these four terms
the energy involved.
Another one is,
you just saw it,
additive versus subtractive.
Now that's kind of easy.
Right?
What will it mean?
Additive manufacturing means
you have a workpiece
and you keep on adding material
to make something.
That's additive.
What's subtractive then?
You take parts away.
Right?
And so we will see
that in the case of
subtractive techniques
applying on top of
saying it's subtractive
that it happens mechanically
is rather easy.
But if you try to do the same
in the case of additive manufacturing
you'll get in trouble
quite a few times.
Okay, first exercise.
What you're seeing here
is a human hair.
So what is the thickness
of a human hair?
Diameter?
Small.
Very small.
Today is, by the way,
vectoring your intuition
a little bit in sizes
for bigger things.
Right?
A human hair,
you're getting closer.
Between 80 and 100 microns.
I forgot,
red hair is thinner.
It doesn't mean you have less of it,
but it means it's thinner.
And I think
blonde is next
and black is the thickest.
I think it goes up to 100 microns.
So 100 microns.
By the way,
write that number down.
100 microns,
for some reason,
in manufacturing
is like a critical cutoff
to switch from
one manufacturing technique
to another one.
100 microns.
So this means
this thing is 100 microns
and some guy,
for some reason,
cuts holes
into the hair.
How did he do that?
So I hope by the end of the class
you will figure out
maybe even now
some of you guys have an idea
how this person managed
to cut square little holes
in the hair.
Oh, by the way,
is it an additive technique
or a subtractive technique?
Yeah, good.
We got that right.
But now,
which one of those
did we apply?
Did we use your father's drill?
How big is the smallest drill
you think people use
mechanically, typically?
Actually, it's the same number
I mentioned a bit earlier.
It's that 100 microns.
That's kind of the smallest drill bit
you will have.
And we will see
if you want to machine something
below 100 microns,
you're going to go from
mechanical machining
to lithography.
You cannot do it anymore
with mechanical means.
So one of the classes
will be lithography.
How come you can make
these small things
if you use lithography
instead of mechanical machining?
So anyone has a better idea?
We have two questions already
for you guys, right?
The first question was
that third way
you make countries rich.
You were going to do it
by invading.
Maybe you will say
what country to invade.
And the second question is
how do you think
this actually was done?
I know this is
very early, right?
We are still talking
about the syllabus,
but come on.
We can get you thinking, right?
Anyone has an idea by now
what could be used?
We know already
not the drill, right?
Not the drill.
Drill is much bigger
than a human hair.
And probably the hair
will also go around the drill.
Anyway, so things
that we want to achieve
in this class is this.
So students guided
by specification and a design
will be able to decide.
So you will have a design
to make something.
And you will be able
to decide
when to apply
mechanical machining
versus lithography
based machining.
You actually have a clue now
on this first one, right?
What would be a clue?
The 100 microns, right?
Good.
Two, what type,
suppose you decide
it needs to be mechanical,
what type of mechanical
machining to use
and what type of lithography
to use?
Number two.
Three, when to employ
bottom-up versus
top-down manufacturing.
Again, new words.
We have introduced
already two ways
to classify manufacturing.
The first one was by
energies, right?
Second?
Yeah.
Third one,
bottom-up versus
top-down.
Now what is that?
Bottom-up versus
top-down.
This is a really
interesting one.
You see,
everything around us,
including ourself,
we are made
top-down or bottom-up?
Bottom-up.
Nature works bottom-up.
You know, it built
things by starting
from amino acids,
goes to proteins,
goes to bigger
and bigger structures.
We don't build things that way.
We take a chunk
of silicon,
carve it,
make it smaller and smaller,
make a nice C.
Just the opposite.
Interesting, right?
So, human manufacturing
until about 20 years ago
was all top-down.
Nature always has been
bottom-up.
Now you guys are living
in a very interesting era
because many objects now
we can make either way.
We can make them
top-down or bottom-up.
And so there's more and more
overlap between
these two techniques.
So in this class,
we will learn about
some ways
that you will call
bottom-up,
and other ones top-down.
So there you go.
We have already
three ways
of manufacturing
classifications.
Four,
when to choose
serial, batch,
or continuous manufacturing.
Okay.
Yet another way
of categorizing manufacturing.
What are the words
we have here?
Serial, batch,
or continuous?
The words are kind of
self-explanatory.
Serial will be,
okay, I'm making skis
to go skiing.
You'll make one
at a time, right?
What is batch?
Batch, for example,
is the silicon process.
In integrated circuitry,
on one silicon wafer,
we have 600 chips.
That's a batch.
Continuous is
newspaper printing.
Where is the world
leading to?
It's moving from
batch to continuous.
For example,
if I want to make
glucose sensors
for any patient,
or I want to make
sensors that are
embedded in your cloths,
I need to make them
very inexpensive.
I cannot make them
with batch.
I need to make them
continuous.
So,
that's the fourth method,
actually.
And then fifth,
you will learn
what kind of
rapid prototyping
method to select.
That will be
these classes
that we give in
respect to
3D printing.
And actually,
you will get
to do it yourself.
But you will
figure out
there's a lot of,
there's at least
seven different methods
of rapid prototyping.
Which one should I use
if I have that design
and that product
I'm trying to make?
We will give you
a logical decision tree.
So,
if it's like this,
let's say it's
much bigger than,
much smaller than
100 microns,
yes or no?
I do mechanical lithography.
Right, so we make
a decision tree
that helps you
through all of this.
And so examples
will include
products
going all the way
from nanometers
to centimeters.
So,
this is
a very ambitious class.
So,
I talked a moment
ago about
size of things.
We'll talk about
making products
ranging in size
from nanometers
to centimeters.
So,
I'm giving you
this little video
to kind of
just broaden your mind.
To think about
nanotechnology,
MEMS,
and manufacturing
all in the same vein.
Manufacturing
and nanotechnology,
you know,
is actually the same thing.
If I cannot manufacture
nanoproducts,
I'm not a nanotechnologist.
I want you to feel proud
that you're interested
in manufacturing.
This video
kind of gives you
an idea of,
we call,
the scale of things.
To start having
these ideas,
when I asked you
what's the size
of a human hair,
you immediately have a number.
The size of a cell
in your body.
Size?
A couple microns.
Yeah.
Five, six microns,
right?
So,
let's see if I can
figure out the lights here.
I also
would need a
sound.
Maybe this can be,
you guys are going
to be very quiet,
right?
So, maybe if I put this
very loud,
you will hear it.
And this lady
pronounces things
very well.
She has no accent
like mine.
Who knows
where my accent is from?
Too many people
know that now.
Usually,
no one knows.
Something is wrong.
How come so many
people know?
That's absolutely true.
Who told you that?
What are some
good Belgian beers?
Stella.
No, it's not.
You know, this is all
Budweiser.
This is not a good beer.
In the past,
there were scientists
who studied the stars.
Do you hear it?
And scientists
that studied atoms.
And even today,
there are scientists
called cosmologists.
Is there a switch there?
And scientists called
particle physicists.
Yet,
there is a direct
connection between
the physics
of the very large
and the physics
of the very small.
Because even the
largest objects
in the universe
are made of exactly
the same building blocks
as the smallest things.
Oh, you can't see anything.
Just give me a second here.
I tried to...
We're going to do this live.
So, don't worry.
I'm going to replay it
until I need to find
how to do this here.
Do you see anything at all?
No.
Maybe.
Liverpool.
14 kilometers across.
Okay.
I'm going to try to interpret.
Street in Liverpool.
Size?
One-fourth of a kilometer long.
The house?
Ten meters.
Easy, right?
The kid?
One meter.
The eye?
The head?
Fifteen centimeters.
Ah, pupil.
Yeah, one centimeter.
Good.
Now, we're going to go
in the eye.
Cells?
Approximately eight meters.
Five microns.
Ten to the minus six.
Five, ten to the minus six.
DNA?
Ten to the minus nine.
And by the way,
we can build with DNA.
We can make things with DNA.
DNA is making things.
You know that
through protein expression.
Hydrogen?
What was it?
Hello?
Okay.
What was the smallest thing?
Hydrogen.
Then?
The nucleus?
Nucleons?
Size?
Should I redo it?
You don't need to remember it,
but you need to have
so far one number in mind.
Only one so far.
No, two.
Hundred microns?
Right?
And five to six microns
for a biological cell.
Let's keep those in mind.
Kind of as our
anchors.
She's talking about
a bunch more things.
She's talking about
how scientists
are now getting
more and more better
at understanding
huge things.
But when they understand
huge things,
they also start understanding
better very, very small things.
What we talk about
is making these things
from the small to the large.
How you make them.
We will find
that technology
often is actually driven
by what we will talk about
in this class.
I'll give you an example.
You know when nanotechnology
really took off?
That is when we built
an instrument called
an atomic force microscope.
An atomic force microscope
is able to build
atom by atom,
bottom up.
Things are bigger and bigger.
That was the start
of nanotechnology.
A machine,
something that could
make things,
could manufacture things.
Write that down.
AFM.
We're going to have
a class about that.
Atomic force microscopy.
Syllabus topics.
So,
finally get to syllabus.
But it's better like
than going through
this dry syllabus
you'll find on the web
and make it part of my class.
We talk about
in the first class
hopefully today,
the difference between
sealed batch and
continuous manufacturing
processes.
That will be easy.
I already gave you
examples, right?
The second one will be
a little bit more complicated.
I want you to understand
the difference between
relative tolerance
versus absolute tolerance
in machining.
Then we'll talk about
principles of manufacturing
processes.
Mechanical energy
dominated.
Cutting, shaping,
forging, ultrasonic.
By the way,
the only thing we're
going to cover today
is one and two.
And as I told you,
because this class
is kind of in chaos,
I might have to repeat
some of that tomorrow.
Right?
But I still want you to come.
Okay?
But then in later classes
we will talk about
those processes.
Roman number one,
nanomechanical.
Then we'll talk about
Roman number two,
electrical,
energy based.
What were the four ones?
Mechanical,
chemical,
heat,
and electrical, right?
And so we'll go over
examples in each of those.
By the way,
this little car
you see here,
you'll see it better
when you print it out.
It's sitting on a dime
and it's a car
that actually runs
and it's been micromachined
with a set of technologies
we will specify.
And so here is four,
chemical energy.
Then we will talk about
next generation lithography tools.
We'll talk about
nanomachining tools.
Top down versus bottom up.
You already know
a bit about that.
Rapid prototyping,
also called layered manufacturing.
And then
this is this decision tree.
Matching manufacturing process
to product specification
and design
leading to the
manufacturing process
decision tree.
So are you ready for that?
That's what we're going to do
this quarter.
Definition.
So class one, now
we are on to class one.
So I gave you
the syllabus.
I gave you
a bunch of philosophy.
And I also told you
it's way too hot here
that I like Belgian beer.
What else?
I told you about
the hundred microns,
the five microns.
And two homework questions.
Two homework questions so far.
The third thing.
Right, good.
And?
And the hole in the hair.
How do you drill
that hole in those hairs?
So probably
tomorrow
I will just single
one of you guys out
and say
you know enough
or you figured it out.
So but all we will do today
is definition of manufacturing.
And as someone said
it's kind of like
isn't that like
too simple minded?
It's just making things, right?
So
then we'll
give you some examples
serial batch and continuous
manufacturing processes
and end up with
talking about
the difference between
relative tolerance
versus absolute tolerance.
I hate these slides
with just a bunch of words.
So someone is going to read it.
A good strong voice.
Mitch.
Read this for us loud.
I don't want to do it.
It's too hot.
Come on stand up.
He can.
Yeah.
Give it some.
Good.
Is most commonly applied
to industrial production
in which raw materials
are transformed into
finished goods
on a large scale.
Such finished goods
may be used
for manufacturing
other more complex products
such as
household appliances
or automobiles.
We're sold to wholesalers
who in turn
sell them to retailers
who then sell them
to end users
to consumers.
Credit to
Wikipedia.
So but yeah
it's about manufacturing
making things
and it's one of the three things
that makes a country
wealthy.
So
sealed batch
and continuous
manufacturing processes.
Things used to be
very expensive
even in the electronics area.
You know instead of
transistors we had
something called
lamps, bulbs
and they were made
one at a time.
Perhaps they costed
twenty dollars
thirty dollars.
Now we make
silicon chips.
I wonder if you guys
know that.
A MEMS silicon chip
an accelerometer
the one that goes
in your car
for the airbag release.
You know how much
that can cost nowadays?
One hundred?
Fifty cents.
Isn't that amazing?
And the complexity
in there is fantastic
it's amazing.
Why has that been possible?
Because we are not
making them in a
sealed fashion.
We don't make
one at a time.
We make
maybe two thousand
all at the same time
on a wafer
in the silicon process.
Starting with lithography
on one silicon wafer
you might produce
sometimes
six thousand
seven thousand devices.
That can mean that
you could have the whole
supply of the United States
of a certain
topic
object made
in one day.
So you can imagine
what happened to
the whole society
when we moved from
serial to batch.
Now the next thing
and more and more
people are looking at that
to actually make
clean rooms
continuous.
So instead of one
silicon wafer
just like a newspaper
you have a band
of material you process
and that would be
continuous.
So single unit production
or serial production
next is batch
and the primary
characteristic of that
is that a group of
identical components
are completed
at the workstation
before they move
to the next one.
IC fabrication
is the best example
of that.
In other words
that same
PVD
physical vapor deposition
or CVD
does not happen
on one device
it happens at
thousand devices
all at the same time.
And you then also
have a good chance
that these devices
are all quite similar.
Right?
So you make
them more reproducible.
And then
continuous production
is a method
used to
manufacture, produce
or process materials
without interruption.
So
you do it
with a roll
that supplies
a material
a substrate
to another roll
and in going from
roll 1 to roll 2
take all this
all the way
also by the way
roll to roll processing
or continuous manufacturing
you continuously
make a product.
Just like you're
printing a newspaper.
So
examples follow
so making
pair of skis
one at a time
expensive
it would be hard
to miniaturize those
right?
Anyways
batch production
so
IC fabrication
and then
this could be
a continuous
process where
in this case
wood is being
laminated
and so you
literally make
kilometers
of the good
continuously.
So these are
examples of
each of these
so
how many
methods
we already have
identified so far
to categorize
manufacturing?
Can you name them?
So one was
in terms of the
energy use
right?
And we have
these four different
energy fields
then?
Additive, subtractive
then?
Top down, bottom up
then?
Serial batch
continuous
right?
It's all kind of
and you really
even see more
methods
on how to
so you might
categorize
laser machining
or will laser
machining work?
You will have
a laser
one hot spot
there
on your work piece
so
will that be
serial?
Will it be
continuous?
Is it batch?
Etc.
I could ask you
categorize laser
machining according
to these topics.
What kind of
energy is it?
Right?
Is it serial
or continuous?
Is it additive
or subtractive?
Is it top down
or bottom up?
So you have to
categorize according
to these
categories
what should I call
them?
Methods to categorize
them.
Okay so now
the only kind of
little bit of
math
numbers
very naive
simple
we're going to
talk about
relative versus
absolute
machining tolerances
and rather than
looking at this
I
I hate slides
with a lot of
words.
That's good for you
when you're at home
you read through it
and I'm going to
try to convey
you the intuition
the concept.
And so what I
will do is
I will jump
some slides ahead
and I go to this
weird curve here.
It's a strange
curve, right?
What I have here
is relative tolerance
versus the size
of things.
And what you see
it has like a
a peak, right?
I'm going to try to
explain where that
comes from.
And once you
understand that
you kind of have
a flavor of what
I'm trying to
convey to you.
Relative tolerance
so if I build
a house
and let's say
I design it
to be 10 meters
long
this dimension
but instead of
10 meters
you know it's
like off by
one centimeter
or two centimeter
I have an error
there, right?
So to measure
relative tolerance
you divide that
error by the
total dimension
by the size
of the thing.
That's relative
tolerance.
So now
for a long
long time
mechanical
engineers
called something
precision engineering
if the relative
tolerance was
about 10 to
the minus
four.
Now this is
kind of intriguing
because in
micromachining
nanotechnology
we can never
achieve this.
I'm going to try
to explain this.
I probably run
a little bit
too fast.
I see already
some of your
eyes glazing
over especially
yours.
So in
micromachining
I want to
make a line
that's 100
microns long
and instead
I end up with
99 microns.
What's
the relative
tolerance?
It's
99 or 101
so the relative
tolerance is
one percent,
right?
One over
100.
So you know
my micromachining
even my
nanotechnology
doesn't even
qualify as
precision engineering.
Strange,
right?
Let's think
about it
some more.
The objects
that mankind
make,
the relative
tolerance are
about the
size of a
human hand.
It's
interesting,
right?
And to me
that makes
sense because
for example
I build a
temple,
a huge
thing,
the relative
tolerance will
be getting
pretty poor.
I will
be somewhere
here.
Sorry,
100 metres,
let's say,
temple,
relative
tolerance.
I can
make a lens
with relative
tolerances that
are amazing.
One ppm,
10 to the
minus 6,
10 to the
minus 7,
so I'm right
here.
So precision
machining is
0.001 but
there's technology
now out there
like FANUC
makes robotic
controlled CNC
machines that
works at the
one nanometre
level.
We cannot do
that with
micromachining.
It hurts your
teeth.
We always hear
micromachining,
nanotechnology,
we can make
such small
things.
Yes,
we can make
such small
things but
these are
absolute
tolerances.
In other
words,
I can make
one micron,
100 micron
but I
might be off
10%,
15%
whereas with
things that
are the size
of a human
hand,
I can make
100%.
Not much
sympathy here.
So,
trying it
again.
Why is it
difficult to
build huge
things with
an excellent
relative tolerance?
Maybe if I
can get
solicited that
answer,
I feel if you
understood it or
not.
How will you
measure it?
How will you
control it,
right?
So,
sorry?
Accessibility,
how do you put
this whole thing
on an XY table?
In a way,
it all has to
do with
measuring it.
How good can
I measure and
stay in control,
right?
And so,
if things become
very, very small
or very large,
you cannot
position them
very well.
You don't have
your human
hands to
control them,
right?
And so,
of course,
this barrier is
now more and
more being
broken.
Why?
Because we now
build things
atom by atom.
And so,
this whole paradigm
might actually
be shot through
and we might
get into an
era where we
can build with
atomic precision.
And that's why
nanotechnology and
advanced manufacturing
also coupled.
There's a big link.
It could be the
next step for us
to build things
with absolute
tolerance.
That's,
atom is there
or it's not there.
That's pretty good
relative tolerance,
isn't it?
So,
one more time,
can you word it?
Can you kind of
try to paraphrase it
for your friends?
So,
whatever it's
on a large scale
or a small scale,
it's really hard
to control measurements,
but as something
that's the regular size
and it's easier
to control everything
so you get the
tolerances a lot better.
Right.
And now I'm going
to tell you a secret
why all of manufacturing
is kind of connected,
all the way from
a lithography station
to a CNC machine.
What will they all
have in common?
They will have
an XY table.
And it's the control
of that XY table
that determines
your relative tolerance.
So,
how will you put
the temple
on an XY table?
And then,
when you go
so very small,
how will you
control the vibration
that mess up
your XY table?
So,
there's a sweet spot
in the middle
that allows you
to do the best job
and it's when you're
talking about sizes
of 10,
15 centimetres
and indeed,
the lenses
and a whole bunch
of objects there,
you can make
with exquisite tolerances
at that level.
So,
lithography,
such as silicon
micromachining
is excellent
for small
absolute tolerances.
We understand that now.
We can make it
small enough.
But,
for relative tolerances,
ultra-fine diamond
milling is better.
So,
if you have to decide
about the machining
technique,
you might actually
check
what is your
relative tolerance
you require
and say,
yeah,
if you want
to have a
relative tolerance,
don't make it
that small.
You'd better go
to diamond milling,
make it a bit larger
so that you can have
that relative tolerance.
That's what this
second bullet point
is saying.
And so,
the third bullet point,
in some cases,
we might want to keep
our micromachines
somewhat larger
to optimise
relative tolerances.
Right?
So,
that was really
the only difficult concept
we learned today,
isn't it?
All the rest,
wasn't it?
Like,
naive,
Stella,
things like that.
This curve,
I will come back to
tomorrow,
is a very important curve.
We will come to it
many times.
What it shows here
is the date
and here it shows
achievable
machining accuracy.
And look how we got
better and better
making smaller
and smaller items
either in normal
machining,
precision machining
or ultra-precision
machining.
I think
picking that back up
tomorrow
will make a good link
to that.
I think
picking that back up
tomorrow
will make a good link
to the class of today.
As we know,
I only have
50 minutes today.
And the last slide,
I will also come back
to tomorrow
because more people
arrived towards
the end of the class.
I will summarise
what I said
in the beginning
so don't make
any noise yet
in parting moves.
Parting moves.
That's a strange word.
So,
165
and 265
are one and the same class.
Unfortunately,
there were some
mistakes made.
265,
the graduate
didn't realise
there is also
this class
on Mondays.
So,
there is only one class.
We're going to have
a much bigger,
more comfortable room.
Tomorrow,
the class is,
where is it?
It's
in the Bren Hall,
right?
And that will be
comfortable,
that will be
a big class.
Okay?
So,
all together,
I think there's
about 58 students.
We will have to
split you
in groups
probably about 15
so that you all
physically get to
do something
in these classes
and that's why
we want to take advantage
of these Mondays.
Often,
that class will be
about preparing you
to do rapid prototyping,
for example,
or prepare you
what is CNC
machining all about.
My ultimate goal
is this.
If you apply
for a job
and you said
you know what
a clean room is
or you know what
rapid prototyping is,
you know what CNC
machining is,
I think you'll
actually score some
very good points
with many employers,
right?
Just even at that
basic level,
this should be very useful
for all of you.
It's not going to be
your usual class.
This is not a very
difficult class.
There's not too much math.
It's a lot about concepts,
all right?
And so,
for me,
grading this class
is often very difficult
because you're often
going to do group work,
right?
You're going to build,
I cannot have everyone
do CNC machining
so you're going to be
taking pictures
put a PowerPoint presentation
together about it
but you're going to do it
in a group,
right?
So in that sense,
what I praise a lot
is your activity in class
and be here,
right?
Because this kind of thing
is hands-on.
It's kind of hearing it.
It's very difficult
to get it from the web.
Many people are now
talking about classrooms
moving to the web.
Well,
this kind of a class
is one of those
that's very hard
to move to the web
although it will be on the web,
right?
Isn't it?
So,
thank you all.
