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

2. 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

3. 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

4. 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 ( items)
No customisation

5. 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

6. 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

7. 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

8. 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

9. 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

10. 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

11. 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

12. 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

13. 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

14. 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

15. 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

16. 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. 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

18. 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

19. 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

20. 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

21. 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 :
Consortium

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

23. Contact Project Coordinator Dieter Holzinger Oliver Refle
Fraunhofer Institute for Manufacturing Engineering and Automation
Nobelstraße , Stuttgart Germany
Phone: +49 (0)
Dieter Holzinger
TIGER-Coatings GmbH & Co.KG
Negrellistraße 36
4600 Wels, Austria
Phone: +43 (0)