Andreas Dietzel

Capillary Self-Alignment of Mesoscopic Foil Components for Sensor-Systems-in-Foil

This paper reports on the effective use of capillary self-alignment for low-cost and time-efficient assembly of heterogeneous foil components into a smart electronic identification label. Particularly, we demonstrate the accurate (better than 50 μm) alignment of cm-sized functional foil dies. We investigated the role played by the assembly liquid, by the size and the weight of assembling dies and by their initial offsets in the self-alignment performance. It was shown that there is a definite range of initial offsets allowing dies to align with high accuracy and within approximately the same time window, irrespective of their initial offset.

Dynamics of capillary self-alignment for mesoscopic foil devices

We report experimental evidence for three sequential, distinct dynamic regimes in the capillary self-alignment of centimeter-sized foil dies released at large uniaxial offsets from equilibrium. We show that the initial transient wetting regime, along with inertia and wetting properties of the dies, significantly affect the alignment dynamics including the subsequent constant acceleration and damped oscillatory regimes. An analytical force model is proposed that accounts for die wetting and matches quasi-static numerical simulations. Discrepancies with experimental data point to the need for a comprehensive dynamical model to capture the full system dynamics.

Foil-to-Foil System Integration Through Capillary Self-Alignment Directed by Laser Patterning

This paper introduces a new integration technology for cost-effective high-precision mechanical and electrical integration of mesoscopic functional foil components onto foil substrates. The foil-to-foil assembly process is based on topological surface structuring via laser patterning that enables accurate capillarity-driven self-alignment of foil dies. The concurrent establishment of high-yield electrical interconnections is obtained through conductive adhesives. The foil surface energy controls the acceptance window of initial offsets for optimal self-alignment performance. The proposed topological patterning and system design enable alignment accuracies for centimeter-sized foil dies as high as 15 μm, barely influenced by the evaporation of the assembly liquid and curing of the conductive paste. Full foil-to-foil system integration is demonstrated through the electrically functional assembly of an array of Au-sputtered capacitive humidity sensors onto a patterned base foil circuitry.

Capillary Gripping and Self-Alignment: A Route Toward Autonomous Heterogeneous Assembly

We present a pick-and-place approach driven by capillarity for highly precise and cost-effective assembly of mesoscopic components onto structured substrates. Based on competing liquid bridges, the technology seamlessly combines programmable capillary grasping, handling, and passive releasing with capillary self-alignment of components onto prepatterned assembly sites. The performance of the capillary gripper is illustrated by comparing the measured lifting capillary forces with those predicted by a hydrostatic model of the liquid meniscus. Two component release strategies, based on either axial or shear capillary forces, are discussed and experimentally validated. The release-and-assembly process developed for a continuously moving assembly substrate provides a roll-to-roll-compatible technology for high-resolution and high-throughput component assembly.

Characterization of oxygen transfer in vertical microbubble columns for aerobic biotechnological processes

This paper presents the applicability of a microtechnologically fabricated microbubble column as a screening tool for submerged aerobic cultivation. Bubbles in the range of a few hundred micrometers in diameter were generated at the bottom of an upright‐positioned microdevice. The rising bubbles induced the circulation of the liquid and thus enhanced mixing by reducing the diffusion distances and preventing cells from sedimentation. Two differently sized nozzles (21 × 40 µm2 and 53 × 40 µm2 in cross‐section) were tested. The gas flow rates were adjustable, and the resulting bubble sizes and gas holdups were investigated by image analysis. The microdevice features sensor elements for the real‐time online monitoring of optical density and dissolved oxygen. The active aeration of the microdevice allowed for a flexible oxygen supply with mass transfer rates of up to 0.14 s−1. Slightly higher oxygen mass transfer rates and a better degassing were found for the microbubble column equipped with the smaller nozzle. To validate the applicability of the microbubble column for aerobic submerged cultivation processes, batch cultivations of the model organism Saccharomyces cerevisiae were performed, and the specific growth rate, oxygen uptake rate, and yield coefficient were investigated. Biotechnol. Bioeng. 2014;111: 1809–1819.

Surface-Passive Pressure Sensor by Femtosecond Laser Glass Structuring for Flip-Chip-in-Foil Integration

To allow for smaller sizes, smoothness and robustness of exposed surface, and for integration in flexible sensor arrays, an innovative piezoresistive pressure sensor design has been developed. In contrast to known concepts, the sensing elements and the conducting tracks are positioned within the pressure reference chamber and, thus, protected against environmental influences such as water or particles. Sensing elements are electrically accessible from the backside by vias, thus enabling a fully flat surface totally free of electrical elements as desired for flow experiments. The sensor comprises a thin silicon sensing membrane and a body made from glass holding the reference chamber and the vias. The structuring of the sensor body is performed by femtosecond laser ablation. Steep ablation edges are realized, leading to small sensor dimensions. The sensing membrane is fabricated using potassium hydroxide (KOH) wet etching. The glass body and the silicon membrane can be connected with different techniques; hitherto, adhesive bonding by an epoxy resin layer was successfully tested. A sensitivity of 10 mV/V/bar and stable operation up to 7 bar absolute pressure could already be demonstrated. The new concept simplifies micromanufacture and allows for flip-chip-assembly in foil-based flexible systems that can be used in liquids and harsh environments.

Passive Micromixers with Interlocking Semi-Circle and Omega-Shaped Modules: Experiments and Simulations

This study presents experiments and computational simulations of single-layer passive micromixer designs. The proposed designs consist of chains of interlocking semicircles and omega-shaped mixing modules. The performance of the new designs is compared with the concentric spiral channel configuration. The micromixers are intended to be integrated into a lab on chip (LOC) micro-system that operates under continuous flow conditions. The purpose behind the multi-curvature in these designs is the introduction of Dean vortices in addition to molecular diffusion in order to enhance the mixing performance. The micromixers were fabricated in PDMS (Polydimethylsiloxane) and bonded to a glass substrate. A three-dimensional computational model of micromixers was carried out using Fluent ANSYS. In experiments, the mixing of a 1 g/L fluorescein isothiocyanate diluted in distilled water was observed and photographed using a charge-coupled device (CCD) microscopic camera. The obtained images were processed to determine the mixing intensity at different Reynolds numbers. The standard deviation (σ) of the fluorescence indicates the mixing completeness, which was calculated along the width of the channel at various locations downstream from the channel inlet. The value of σ = 0.5 indicates unmixed streams and 0 is for complete mixing. It is found that the two new designs have a standard deviation of nearly 0.05. Additionally, complete mixing was observed at the channel outlet as demonstrated by the fluorescence images and the numerical results. However, the location of complete mixing at different positions depends on the Reynolds number, which varies between 0.01 and 50. Good agreement was found between the experiment and the numerical results. A correlation to predict the length scale where complete mixing can be achieved is given in terms of the radius of curvature, the mixing module, and the Reynolds number.

Integration of a silicon-based microprobe into a gear measuring instrument for accurate measurement of micro gears

The integration of silicon micro probing systems into conventional gear measuring instruments (GMIs) allows fully automated measurements of external involute micro spur gears of normal modules smaller than 1 mm. This system, based on a silicon microprobe, has been developed and manufactured at the Institute for Microtechnology of the Technische Universitat Braunschweig. The microprobe consists of a silicon sensor element and a stylus which is oriented perpendicularly to the sensor. The sensor is fabricated by means of silicon bulk micromachining. Its small dimensions of 6.5 mm × 6.5 mm allow compact mounting in a cartridge to facilitate the integration into a GMI. In this way, tactile measurements of 3D microstructures can be realized. To enable three-dimensional measurements with marginal forces, four Wheatstone bridges are built with diffused piezoresistors on the membrane of the sensor. On the reverse of the membrane, the stylus is glued perpendicularly to the sensor on a boss to transmit the probing forces to the sensor element during measurements. Sphere diameters smaller than 300 µm and shaft lengths of 5 mm as well as measurement forces from 10 µN enable the measurements of 3D microstructures. Such micro probing systems can be integrated into universal coordinate measuring machines and also into GMIs to extend their field of application. Practical measurements were carried out at the Physikalisch-Technische Bundesanstalt by qualifying the microprobes on a calibrated reference sphere to determine their sensitivity and their physical dimensions in volume. Following that, profile and helix measurements were carried out on a gear measurement standard with a module of 1 mm. The comparison of the measurements shows good agreement between the measurement values and the calibrated values. This result is a promising basis for the realization of smaller probe diameters for the tactile measurement of micro gears with smaller modules.

Novel strategies for the formulation and processing of poorly water-soluble drugs

Graphical abstract Figure. No Caption available. ABSTRACT Low aqueous solubility of active pharmaceutical ingredients presents a serious challenge in the development process of new drug products. This article provides an overview on some of the current approaches for the formulation of poorly water‐soluble drugs with a special focus on strategies pursued at the Center of Pharmaceutical Engineering of the TU Braunschweig. These comprise formulation in lipid‐based colloidal drug delivery systems and experimental as well as computational approaches towards the efficient identification of the most suitable carrier systems. For less lipophilic substances the preparation of drug nanoparticles by milling and precipitation is investigated for instance by means of microsystem‐based manufacturing techniques and with special regard to the preparation of individualized dosage forms. Another option to overcome issues with poor drug solubility is the incorporation into nanospun fibers.

Design, Fabrication, and Characterization of a Continuous Flow Micropump System

This paper presents the design, fabrication, and characterization of a continuous flow micropump system. The system comprises two single pneumatic micropumps connected in parallel and a fluidic capacitor. It has been made of polydimethylsiloxane (PDMS). Each of the pneumatic pumps features a pump chamber, a flexible membrane, and an air chamber. The fluidic capacitor equals a single micropump without air chamber. A maximum flow rate of 496 μL/min is obtained. The influence of the fluidic capacitor is investigated at frequencies of 1 Hz and 3 Hz. The flow rate is considerably smoothened with a smoothing factor of about 0.6.