Dipl.-Ing. Oliver Refle, Fraunhofer IPA & Dieter Holzinger, Tiger Coatings

3D Printing & Assembly of Smart Products in Package (SPiP) (Mechatronic Micro-Systems) Customised and down-scaled electrical components Personalised complex 3D electronic packaging Highly-miniaturised and integrated sensor systems New generation of biochips & data loggers Innovating wearable medicals Integrating PV modules into windows and facades 17.09.2018

A multitude of (printed) applications & novel products 3D Printing & Assembly of Smart Products in Package (SPiP) (Mechatronic Micro-Systems) A multitude of (printed) applications & novel products in high-value / fast growing markets demanding for: customization fast prototyping increased complexity 17.09.2018

Bottlenecks of today’s manufacturing Today’s globalised production chain: Thousands of km transport, numerous production stages, time-consuming Product Component/ Chip-production Packaging Final Assembly Very time-consuming process Adapted to huge lot sizes (+ 100.000 items) No customisation 17.09.2018

The NextFactory Solution One-stop-shop: Production in one place All-in-one: All production stages in one machine User-centric: Customised designs, small to large lots Service-centric: One supplier, one contact 17.09.2018

The NextFactory Solution A hybrid manufacturing approach including… … Inkjet-based 3D-printing … Microdispensing … Assembly … Measurement & Inspection 3D printing (Packaging) Functional/Smart materials in 3D printing Functional components (Sensors systems etc.) 3D Assembly Inspection & testing 17.09.2018

The NextFactory Solution Transferring the principles of AM to a hybrid process chain Utilizing the degrees of freedom known from conventional AM For manufacturing functional micro-mechatronic systems 3D printing (Packaging) Functional/Smart materials in 3D printing Functional components (Sensors systems etc.) 3D Assembly Inspection & testing 17.09.2018

NextFactory: All in one machine solution Conducting Materials Customised Micro-Systems of all kinds on the spot in < 1 day based on your design 3D Printing 3D-Assembly Inspection Support Materials Smart Materials Insulating Materials Functional components 17.09.2018

Manufacturing System 3D freeform printing technologies High-precision 3D micro-assembly technologies Quality management methods and sub-systems Manufacturing System Modelling, simulation and optimisation tools Smart and functional materials for the additive manufacturing process 17.09.2018

3D freeform printing technologies Additive Manufacturing on the basis of several printing technologies, including piezo-inkjet micro deposition technologies Enable free-form designed packages and complex internal material arrangements Integration of functional and conductive materials 3D freeform printing technologies High-precision 3D micro-assembly technologies Quality management methods and sub-systems Manufacturing System Modelling, simulation and optimisation tools Smart and functional materials for the additive manufacturing process 17.09.2018

High-precision 3D micro-assembly technologies Integration of discrete / functional components directly in the course of the additive building process Micro placement on complex 3D-surfaces Using flexible / interchangeable gripping technologies for a wide range of components 3D freeform printing technologies High-precision 3D micro-assembly technologies Quality management methods and sub-systems Manufacturing System Modelling, simulation and optimisation tools Smart and functional materials for the additive manufacturing process 17.09.2018

Modelling, simulation and optimisation tools Multi-Physics Process Model and Condition- based Health Monitoring Software Online Process Monitoring Quality prediction Process Optimization 3D freeform printing technologies High-precision 3D micro-assembly technologies Quality management methods and sub-systems Manufacturing System Modelling, simulation and optimisation tools Smart and functional materials for the additive manufacturing process 17.09.2018

Quality management methods and sub-systems Inline process monitoring based on multi- sensor measurement systems Reliable quality statement for each part Closed-loop process control for stable interaction between 3D-printing & micro- assembly 3D freeform printing technologies High-precision 3D micro-assembly technologies Quality management methods and sub-systems Manufacturing System Modelling, simulation and optimisation tools Smart and functional materials for the additive manufacturing process 17.09.2018

Nextfactory Manufacturing System Continous interaction between 3D-printing, microassembly and measurement instead of purely linear combination Modular machine- & process setup to allow extendability scalability Integration of all necessary processes into one machine 3D freeform printing technologies High-precision 3D micro-assembly technologies Quality management methods and sub-systems Manufacturing System Modelling, simulation and optimisation tools Smart and functional materials for the additive manufacturing process 17.09.2018

Nextfactory Manufacturing System Internal setup of current machine design 3D freeform printing technologies High-precision 3D micro-assembly technologies Quality management methods and sub-systems Manufacturing System Modelling, simulation and optimisation tools Smart and functional materials for the additive manufacturing process Finalization of machine planned middle of 2016 2015-10-22

A closer look on materials… 3D freeform printing technologies High-precision 3D micro-assembly technologies Quality management methods and sub-systems Manufacturing System Modelling, simulation and optimisation tools Smart and functional materials for the additive manufacturing process 17.09.2018

NextFactory: Type of materials Insulating Material: Inkjet printable building material based on acrylates High thermal stability High chemical stability Support Material: Inkjet printable acrylate based ink Easy removable in water an supersonic bath Conductive Material: Solvent based Silver ink Inkjet printable or dispensable Cured by photonic sintering Functional Material: Allows application with direct skin and salvia contact To be applied on top of 3D-printed parts Dispensable 17.09.2018

Nextfactory – Insulating & Support Material Requirements: Low shrinkage during curing Shrinkage would lead to tension within the building block Different shrinkage values between insulating & support material would lead to defects High thermal stability 10 minutes at 200 °C must be survived without softening and geometrical distortion No cracks are allowed Wetting behaviour Insulating ink and support ink have to wet each other but must not mix 17.09.2018

Nextfactory – Conductive Material Requirements: Good wetting of insulating ink Similar thermal expansion as insulating ink; otherwise cracks High conductivity Thermal sintering & laser sintering applicable Inkjet-printable and dispensable 17.09.2018

The NextFactory Use Cases UC1 Sunplugged All-in-one manufacturing of micro junction boxes on solar panels UC2 cellasys All-in-one manufacturing of sensor systems for autonomous monitoring in food UC3 Microsemi Embedded Die Technology 17.09.2018

Would you like to know more about the project? Are you a micro-system manufacturer or using micro-systems in your production processes? Are you a technology provider for micro-system manufacturing? Register to stay informed about NextFactory demonstration events Register here : www.nextfactory-project.eu Consortium 17.09.2018

Questions? Stand A35, Hall A6, (Tiger Coatings) We are happy to answer at Stand A35, Hall A6, (Tiger Coatings) 17.09.2018

Contact Project Coordinator Dieter Holzinger Oliver Refle Fraunhofer Institute for Manufacturing Engineering and Automation Nobelstraße 12 70569, Stuttgart Germany Oliver.Refle@ipa.fraunhofer.de Phone: +49 (0)711-970-1867 www.ipa.fraunhofer.de nextfactory-project-office@eurtd.com Dieter Holzinger TIGER-Coatings GmbH & Co.KG Negrellistraße 36 4600 Wels, Austria Dieter.Holzinger@tiger-coatings.com Phone: +43 (0)664-60400571 www.tiger-coatings.com 29.10.2015