From lab to fab training for the innovation value chain
Download as PPT, PDF2 likes1,321 views
The document discusses the importance of training technicians in the innovation value chain with a focus on nanotechnology and advanced manufacturing. It emphasizes the need for a comprehensive understanding of the science, technology, engineering, and manufacturing (STEM) components to effectively support the clean energy economy. Additionally, it highlights the significance of internships and real-world experience in preparing technicians for relevant job roles.
From lab to fab training for the innovation value chain
- 1. From Lab to Fab => Training for the Innovation Value Chain Robert D. Cormia Foothill College
- 2. Overview • SETM => Innovation Value Chain • Advanced manufacturing • Extensible technicians • Start-up environments • Training for life, building to scale
- 3. SRI/Boeing Study • What do technicians do? • What do technicians know? • What don’t they know how to do? • Need relevant experience • Solve relevant problems Nanotechnology, Education and Workforce Development - AIAA Technical Conference 2007 Vivian T. Dang, Michael C. Richey, John H. Belk (Boeing), Robert Cormia (Foothill College), Nora Sabelli (SRI), Sean Stevens, Denise Drane, Tom Mason and …NCLT and Northwestern University
- 4. Nanotechnician Competencies • Measurements • Fabrication / process • Modeling / simulation • Knowledge of nanoscale • Work in teams (SETM) Deb Newberry Dakota County Technical College – University of Minnesota
- 5. Nanomaterials Engineering • Challenging applications – Novel properties – Novel structures – New processes • New structure – property relationships http://tam.mech.northwestern.edu/joswald/
- 7. PNPA Rubric • Application driven process (A) • Properties (P) • Nanostructures (N) • Fabrication (P) • Characterization (N-P) • The ‘Nanoengineering Method’ A Rubric for Post-Secondary Degree Programs in Nanoscience and Nanotechnology
- 8. PNPA Rubric as a Compass • As you work, as you learn, as you read: – What are the applications? (A) – What properties are needed? (P) – What are the (nano)structures? (N) – How do you fabricate / process it? (P) • Use characterization tools to develop structure property relationships (N-P) • Fine tune process (P) to fine tune (N-P)
- 9. PNPA / 4-D Compass Applications (A) Nanostructure (N) Properties (P) Process (P)
- 10. PNPA Rubric - Applied • In the workplace… – Think broadly about devices / applications – Visualize structures and their properties – Understand fabrication / processing – Think about characterization – constantly • Are structure-properties characterized? • Can structure-processing be improved? • Apply PNPA in every ‘working discussion’
- 11. SETM – Extensible Technicians • We don’t train for multidimensional thinking required in a workplace – Scientific knowledge – Engineering process – Technology know-how – Manufacturing competencies • Technicians need to think from all four corners of SETM – just like PNPA (rubric)
- 12. SETM / 4-D Technicians Science (S) Technology (T) Engineering (E) Manufacturing (M)
- 13. SETM => Innovation Value Chain • Scientific discovery • Engineering prototypes • Technology development • Manufacturing scale-up • From lab to fab => innovation value chain
- 14. Training for Success • Workplace effectiveness • Extensible careers • Supporting innovation • Learning platform • Nanomaterials engineering framework Bill Mansfield, a technician at the New Jersey Nanotechnology Center at Bell Labs in Murray Hill, N.J., holds a reflective 8-inch MEMS (micro-electro-mechanical system) disk in a "clean" room of the nanofabrication lab at Bell Labs.
- 15. 21 Century Technicians st • Have bachelor’s degrees! – many from 20 to 25 years ago • Need specific knowledge/skills • Support all four ‘edges’ of innovation – Think like a scientist, act like an engineer – Problem solve in real-time – Support manufacturing scale-up
- 17. Introduction to Nanotechnology Nanomaterials and Nanostructures •Scale and forces •Nanomaterials vs. ‘traditional’ materials o Dominate forces at all scales of distance •Nanostructures and novel properties •Emergence of properties at scale o Nanofibers, nanoparticles o Melting point, plasticity, thermal and electrical conductance •Process => structure => properties => applications •Self assembly process o Designing structures for end use properties o Crystals, molecular networks, biomolecules •Types of materials •Atom as a building block of materials o Glass, ceramic, metal, alloy, polymers and composites, o Crystals, glasses, metals, liquid / networks •Types of properties •Surface dominated behavior o Strength, plasticity, thermal and electrical conductance, o Surface area vs. volume, surface properties vs. bulk, surface behavior electromagnetic and chemistry •Fabrication basics •Role of quantum mechanics o Fab facilities, tools, processes, CNT o Conduction, phonons, interaction with light •Processing •Applications of nanotechnology / devices o Heat treatment, quenching, alloys, composites, fibers o Solar panels, fuel cells, semiconductors, ink, •Modeling and designing for desired properties •Industries that use nanotechnology o Computer modeling of structure properties relationships o Semiconductor, electronics, energy, medicine, advanced materials •Choice of materials and structures •Characterization tools o Select for properties and applications o Image (AFM/SEM), surface (AES/XPS), structure (XRD/TEM), and bulk •Characterization tools for nanostructures / nanomaterials (XRF/EDX/WDX) o Image, surface, composition, structural Nanocharacterization Nanofabrication •Instruments and characterization tools •Type of fabs o (AFM/SEM), surface (AES/XPS), structure (XRD/TEM), and bulk o Silicon, MEMS, Wafers (XRF/EDX/WDX) o Clean room basics, air filtration, dust •Types of analyses •Safety basics o Materials characterization, process development, failure analysis o Vacuum equipment, High voltage •High vacuum and high voltage basics •Silicon fundamentals o Vacuum t safety, vacuum awareness, high voltage and safety o Deposition, masking, etching •Sample preparation and handling •Virtual / physical tour of a silicon fab o Cleanliness, cleaning, dust and vacuum considerations •MEMS basics •Instrument selection o Silicon and polymer based MEMS o Image, surface, composition, structure, physical properties •Nanochemistry •Data gathering, analysis, and tabulation o Self Assembled Monolayers o Instrumental techniques, data gathering , tabulation interpretation o Dendrimers, Quantum Dots •Interpreting composition and chemistry, modeling structure •Thin film deposition o Building atomic and molecular structure from composition, chemistry, o Vacuum deposition, Sputtering, CVD/PECVD and x-ray data o Roll coating (web), Spin coat •Using a LIMS, searching spectral databases •Plasma deposition o Knowledge management tools to aid future problem solving o Plasma equipment, Gas chemistry •Reporting data, writing formal industry reports •Surface modification •Client management skills o Chemical, gas, plasma
- 19. Advanced Manufacturing • Not just ‘high tech’, but ‘high value’ • From advanced materials to biofuels • All aspects of clean energy technology • Nanomaterials to specialty alloys • Integrating disassembly into design
- 20. Advanced Materials • Thin film coatings • Nanopowders / nanoparticles • Nanocarbon (CNT/CNSC) • Polymers and composites • Specialty metals / alloys • Advanced biofuels
- 22. Carbon Nanospheres (Onion Like Carbon) for high energy batteries Nanosphere mixed with Poly Vinylidene Fluoride (PVDF) are used in high performance energy storage, especially in transportation solutions. The surface of fullerene soot is electrophilic and can have dangling bonds, however the key feature is the crystallinity of graphene sheets. HRTEM (High Resolution Transmission Electron Spectroscopy) is an important tool in characterizing the degree of crystallinity in heat treated fullerenes. A collaboration between industry, government, and academia is researching the process development and advanced manufacturing of nanocarbon sphere chains (CNSC) for a range of applications from energy storage to composites. http://www.personal.psu.edu/ckg5046/research.html
- 23. Carbon Nanotube Batteries Lithium ion batteries with carbon nanotube electrodes charge faster, safer, and last 10x longer http://news.discovery.com/tech/new-lithium-batteries-could-last-10-times-longer.html
- 24. Advanced Manufacturing • Clean energy – Wind, solar, fuel cells • Advanced biofuels – 100M gallons/day 2022 target • Biotechnology – Nanomedicine, cancer vaccines • Electric vehicles and batteries
- 25. Synthetic and Biosynthetic Fuels Biosynthetic fuels are the key to reducing and eventually eliminating dependence on petroleum, and blending of low carbon synthetic fuels. Biotechnology and genetically engineered organisms are central to production of novel biosynthetic fuels including hydrogen from algae.
- 26. Why we need biofuels at scale • We can reduce and/or eliminate petroleum – Reduce petrol from 400 M to 100 M gallons/day • Step 1: increase fuel efficiency to 50 mpg – Reduces liquid fuels to 200 M gallons day • Step 2: increase biofuels to 100 M gal/day – Reduces ‘petroleum’ to 100 M gallons/day • Step 3: replace petroleum with ??? – Hydrocarbon engineering, other biofuels, etc.
- 27. Biofuel’s high hurdle Today the US produces about 37 million gallons a day (mgd) of ethanol, an amount that needs to increase to about 100 mgd by 2022. This goal is important for two reasons. First, for resource depletion (peak conventional oil production) and second for GHG emissions. Consider a scenario where vehicle efficiency increases by a factor of 2 (from 22-25 mpg to 44-50 mpg). We use ~400 mgd of gasoline a day (10% ethanol). Our total ‘gasoline’ demand would drop to about 200 mgd from 400 mgd. Having 100 mgd of advanced biofuels would provide 50% of out 200 mgd liquid transportation needs, reducing our reliance on hydrocarbon based petroleum by 75% (50% from efficiency and 50% from advanced biofuels) providing both price stability and significantly reduced GHGs.
- 28. Biomass to Biofuels Berkeley Lab Opens Advanced Biofuels Facility
- 29. SETM => Advanced Biofuels • Laboratory Research (S) – Bioscience – Bioengineering • Pilot facility (E) – Prototype 1,000 gal a day • Demonstration facility (T) – 10,000 gallons a day • Commercial facility (M) – 1M gallons a day / $1B yr
- 30. Algal Biofuels Forecast Scenarios
- 31. Evolution of Algal Biofuels http://www.chem.info/Articles/2010/03/Alternative-Energy-Algae-Investment-Trends-Advanced-Biofuels-Insight/
- 32. Clean Energy – What is it Worth? • Wind => $500 billion to offset coal by 50% • PV => $500 billion to offset natural gas • Biofuels => $150 billion a year in US fuels • Electric Vehicles (EV) => $1 trillion – 15% of current US fleet (30 million cars, ~ CA) • Energy storage => $100 B grid storage, $1 trillion if 50% of cars were PHEV/EV (2020) • Smart energy => $1 trillion for a modern grid
- 33. Building a Clean Energy Economy
- 35. Hydrogen Fuel Cells Push conversion efficiency from 50 to 60 %, and ultimately to 75% Develop a low carbon source of hydrogen for fuel – and this is a real game changer!
- 37. Demanufacturing - Remanufacturing In a high technology economy where some raw materials are both precious and scarce, products will require demanufacturing to recover components and materials for reprocessing, and remanufacturing. Electric motor and battery technology may be such an industry. Technicians trained in complex disassembly, materials safety, and advanced manufacturing (problem solving skills). These jobs will range in skills, and may be very good training / therapeutic for returning veterans with Traumatic Brain Injury (TBI). These are extremely important jobs and competencies in an emerging ‘sustainable manufacturing economy’.
- 38. Training for R&D • Internships matter! • Developing ‘competency’ • Hands on learning • Current technology • Real-world problems • Real-world mentors
- 40. Summary • Innovation matters, scale matters more! • US needs to ‘reclaim’ advanced manufacturing, esp. clean energy • Technicians support SETM model • Training needs to support SETM • Internships are essential to a SETM technician’s academics!