Open Competition 3 - Chemistry and Materials

Development of Micro- and Meso-Scale Machine Tool Technology

Sponsor: Ingersoll Machine Tools, Inc.

• Project Performance Period: 8/1/2004 - 4/30/2007
• Total project (est.): $2,809,854.00
• Requested ATP funds: $2,000,000.00

Miniaturization technology, innovatively applied to machine tool development, holds an important key to the new manufacturing challenges created by the exploding world of micro/meso scale technology. Such innovative technology would enable the development of mechanical components with manufactured features measuring in the hundreds of microns or less. These components are needed in optics, electronics, medicine, biotechnology, communications, avionics, and other fields. The range of specific product applications is very broad and includes such diverse products as microscale fuel cells, micropumps and valves, microfluidic controls, microholes for fiber optics, medical implants, micronozzles for high temperature jets and micromolds for microforming of components. Ingersoll Machine Tools believes that micro- and meso-scale components are best manufactured using miniaturized machine tools. Based upon requests from a large diverse group of micro/meso component manufacturers, Ingersoll will develop the technologies required to produce commercially viable miniature machine tools for these applications. Ingersoll envisions its meso machine tools (mMT) will not exceed 250 by 250 by 250mm in size and will cost between $10,000 and $25,000. The smallest ultraprecise machine tools currently available cost well over $250,000. Ingersoll mMTs will be capable of machining three-dimensional surfaces to very high accuracy, well beyond today's commercially available equipment. Upon completion of this three-year project, Ingersoll will demonstrate its proof of concept mMT prototype machines. Significant technical challenges, mathematical model,s and a new understanding of key processes relevant to micromachining will be pursued. The Department of Mechanical and Industrial Engineering at the University of Illinois (Urbana, Ill.) and the Department of Mechanical Engineering at Northwestern University (Evanston, Ill.) will be subcontracted to participate in all aspects of this projects. Work at the universities will include spindle-bearing fabrication and sealing technologies, tool holding, part holding, and construction of an mMT that achieves ultrahigh accuracies with surface finishes at submicron levels. Ingersoll needs ATP support to fully fund this ambitious and potentially very significant project. When successfully developed, this technology has the potential to be used in a wide range of industrial applications. Considering the broad impact microscale technologies are expected to have on the U.S. economy, the development of micro/meso machine technology is critical to regaining U.S. leadership in machine tool technology.

For project information:

John Osborn, (815) 987-6039
joo@ingersoll.com

ATP Project Manager

Richard Bartholomew, (301) 975-4786
richard.bartholomew@nist.gov