Manufacturing Frontiers

National Science FoundationDirectorate for Engineering

Adnan Akay

Manufacturing Contribution to US GDP

Source: National Association of Manufacturers, U.S. Department of Commerce

Wholesaletrade, 11%

Services 14%

Retail, 14%

Finance, Real Estate, and

Insurance, 22%

Software, 6%

Manufacturing, 22%

Transportation and Utilities, 10%

Other,1+%

Manufacturing Contribution to US GDP and Employment

0%

5%

10%

15%

20%

25%

30%

35%

1950 1955 1960 1965 1970 1975 1980 1985 1990 1995 2000

Mfg Share of US Employment Mfg Share of US GDP

Data Source: US Dept of Labor, NAM GDP calculations using 1982 constant-weighted price index

Issues & Drivers

Competition – emerging economies Enabling technologies Environment, sustainability, resource issues Socio-economics Regulations

EU ManufutureEU Manufuture

Response

New products and service with high added values

New business models Emerging manufacturing sciences and

engineering

EU ManufutureEU Manufuture

Manufacturing Research: Example Directions

Improving decision making (tolerancing, fixturing, tool path optimization)

New processes (nanomanufacturing, lithography, solid freeform fabrication)

Metrology and process monitoring (nanometrology)

Predictive modeling (incorporation of uncertainty)

(J. Lee-Ohio State U) (S. Girshik-U. Minnesota)

(P.Gouma-SUNY SB)

Challenge: Manufacturing Across Scales

Manufacturing Miniaturization Trends

MacroMesoMicroNano-Manufacturing

Nanomanufacturing

* Focus on manufacturing scale-up issues for industrial mass production: producibility, predictability, productivity

* Emphasis on 3-D systems up-scaling integration across dimensional scales: nano-structures functional devices system architectures products & services

* Multi-functionality across energetic domains: mechanical, electromagnetic, biological etc.

* Intelligence/information value added at nanoscale: materials, processes, equipment

* Theory, modeling simulation and controls

* Physical and human infrastructure, impact to education, society, economy and environment

Manufacturing Materials: Composites, Coatings, Biomaterials

* Synthetic Gecko adhesives (R. Fearing- UC Berkeley)

* Shape memory polymer nanocomposites for MEMS (K. Gall - U. of Colorado)

* Biodegradable green composites for automotive applications (L. Drzal – Michigan State)

* Nanoreactor processes for oriented materials (S. Kim- PSU)

* Nano-turf and nano-pebbles: Nanoengineered low flow friction surfaces (C.J. Kim - UCLA)

Manufacturing Processes:Surface / Volume Structuring

* Staggered probes for integrating nanomachining and metrology (R. Vallance, Univ. of Kentucky)

* Novel low-cost nanolithography technique using nanometric high- transmission optical antenna (X. Xu, Purdue Univ.)

* NanoXerography: the use of electrostatic forces to pattern nanoparticles

(H. Jacobs, Univ. of Minnesota)

* Development of novel 3D nanolithography (X. Zhang, UCLA)

Manufacturing Equipment: Sensors, Actuators, Controls

* Motion control platform for accurate measurement and manufacturing of nanostructures (S. Smith, UNC)

* Creating the nanogate for experimental verification and development of flow and particle behavior in submicron channels (A. Slocum - MIT)

* Torque spectroscopy for nanosystem fabrication (D. Cole, Duke Univ.)

* Kinesin-powered nanochemomechanical (NCMS) systems (R. Stewart - Univ. of Utah)

Macro-Manufacturing: Technologies for 3D Construction and Transportation

* Umeda Sky City – Osaka, Japan (Hiroshi Hara)

* Space Elevator (NASA)

* Reusable Launch Vehicles-X-34, PathFinder (NASA)

* Buildings, towers, bridges, pipelines, grids* Aircraft, spacecraft, ships, submarines* Cyberinfrastructure, ground communications

Manufacturing Technologies for Energy

* Photocatalytic water electrolysis (B. Parkinson, Colo State Univ)

* Photocatalytic syngas pro- duction (S. Barnett, NWU)

*Artificial Photosynthesis(R. Fearing-UC Berkeley)

* Polymer photovoltaics with semiconductor nanorods (P. Alivisatos, UCB/NanoSys)

Bio-Manufacturing:Synergy with Nature

•Learning from Nature -Biomimetic system/machine design -Bioinspired manufacturing processes

•Working with Nature -Hybrid bio/abiotic structures -Biological processing by design

•Assisting Nature -Environmentally benign manufacturing -Recycle/Reuse/Remediation processes

(A. Belcher, MIT)

(S. Williams, HP) (J. Jacobson, MIT)

CMMI ProgramsDirectly Related to Manufacturing

Materials Design and Surface Engineering Materials Processing and Manufacturing Nanomanufacturing Manufacturing Machines and Equipment Manufacturing Enterprise Systems Operations Research Service Enterprise Engineering Sensor Innovation and Systems

Studies and WorkshopsManufacturing in the 21st Century

WTEC Study on Micro-Manufacturing Grand Challenge on Instrumentation and Metrology for

Nanotechnology Design, Modeling, Fabrication and Characterization of

Nanotube-Reinforced Composite Materials for Multifunctional Applications

Nanotechnology: Concept to Product Multi-functional Structures for Energy Harvesting and Storage

Technologies Exchanging Cyberinfrastructure Themes in Engineering

Design Opportunities for Innovative, Multidisciplinary Research in

Manufacturing Machines and Processes, WTEC study on Carbon Nanotube Production Technologies