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