STTR Phase II: A Lithographic Gelcasting Process using Nanoparticulates: An Enabling Technology for Mass Production of Microdevices with Nanoscale Features

STTR 第二阶段：使用纳米颗粒的光刻凝胶铸造工艺：具有纳米级特征的微型器件大规模生产的使能技术

• 批准号: 0848712
• 负责人: Jesse Shrock
• 金额: $ 50万
• 依托单位: Advanced Powder Products, Inc.
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2009
• 资助国家: 美国
• 起止时间: 2009-01-15 至 2011-09-30
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=0848712&HistoricalAwards=false
• 关键词: STTR; Phase; II; Lithographic; Gelcasting

This Small Business Technology Transfer (STTR) Phase II project will develop and commercialize a novel Lithographic Gelcasting (LGC) manufacturing process for microdevices that is amenable for economical volume production. Molds will be made using photolithography and filled with nanoparticulate materials. The resulting parts will then be sintered and the photoresist removed. The objectives of the proposed work are to develop the nanoparticulate casting process into a robust, repeatable, and high-yield manufacturing process for mass production, through the use of statistical process models that relate the manufacturing process parameters to desired outcomes, and determine the range of process capability and design space as it relates to manufacturing and design attributes such as feature size and geometry, achievable tolerances, process yield, and manufacturing costs. This effort will be conducted on known client/partner designs so that actual components will be produced for an end application while the process is being developed. The motivating application for this work is the fabrication of microsurgical instruments, a class of devices that is quite challenging from the perspective of feature size, material, and physical properties. The proposed manufacturing method will impact many types of devices and systems that will benefit from attractive material properties and mass production capability. If successful the proposed manufacturing methods have the potential to impact surgical instruments used in procedures as disparate as laparoscopy and its endoscopic or transluminal variants, neurosurgery, robotic-assisted surgery, flexible endoscopy such as colonoscopy, ophthalmology including vitreoretinal surgery, transluminal vascular procedures, and biopsy. In 2004 surgical and medical instruments comprised an approximately $24 billion industry. Millions of minimally invasive surgical procedures are performed annually in the U.S., where individual disposable instruments typically cost $100 - $3,000. Other industries requiring three dimensional precision parts could also be impacted. Besides the commercial potential the success of this enterprise could impact the economy of the local community in Central Pennsylvania.

这个小型企业技术转移（STTR）II期项目将开发和商业化新型的光刻凝胶播种（LGC）制造工艺，可用于经济销量生产。模具将使用光刻造影制成，并充满纳米构造材料。然后，所得部分将被烧结，并去除光孔。拟议工作的目标是通过使用将制造过程参数与所需的结果相关联的统计过程模型，将纳米刻张的铸造过程开发为批量生产的强大，可重复和高收益制造过程，并确定与制造和设计相关的过程和设计的范围，并确定型号的范围，以构成型和工具，以构成和设计效率，并具有成本和成本效果，并具有成本和成本，并具有成就和成果，并且具有成就，并且具有成就，并且具有相关性。这项工作将以已知的客户/合作伙伴设计进行，以便在开发过程时为最终应用程序生产实际的组件。这项工作的激励应用是制造微型外科仪器，这是一类设备，从特征大小，材料和物理性能的角度来看，这非常具有挑战性。拟议的制造方法将影响许多类型的设备和系统，这些设备和系统将受益于有吸引力的材料特性和质量生产能力。如果成功，则提出的制造方法有可能影响腹腔镜检查中使用的手术工具及其内窥镜或易感变体，神经外科手术，机器人辅助手术，柔性内窥镜检查，例如结肠镜检查，例如眼镜检查，眼科治疗，眼科手术，包括玻璃体模术手术，玻璃体性手术，易流性血管造血，易流性血管造血和生物。 2004年，手术和医疗工具包括大约240亿美元的行业。每年在美国进行数百万个最低侵入性的手术程序，在美国，个人一次性工具通常成本为$ 100- $ 3,000。其他需要三维精度零件的行业也可能会受到影响。除了商业潜力外，该企业的成功可能会影响宾夕法尼亚州中部当地社区的经济。