Christoph Baum

Simulation of dynamic effects on hydrostatic bearings and membrane restrictors

Hydrostatic bearings have an excellent static and dynamic behavior and are used for different kinds of application. Application of hydrostatic bearings is limited by friction and therewith by velocity. Typical characteristics of the hydrostatic system (load, stiffness, flow) are calculated without a velocity dependency. The geometry of the hydrostatic bearing pockets and their restrictors are optimized by using time continuous pressure distribution at the bearing pocket, laminar flow behavior as well as constant velocity of the bearing. The dynamic effects of the flow at high velocities are not considered. The paper reflects the common design and calculation methods and shows their limitations in regard to the calculation of hydrostatic bearings at high velocities. It analyzes the results of complex dynamic flow simulations of hydrostatic bearings and presents a new design and optimization concept of hydrostatic bearings. This concept analyses the oil flow at high bearing velocities and it optimizes the bearing geometry, the restrictor geometry as well as the geometry of the main mechanical components.

Dynamic long axis for ultra-precision machining of optical linear structures

Currently, fly cutting is the most popular manufacturing technology for the machining of planar groove structures. The disadvantage of this technology is the long machining time. A promising alternative technology for the machining of planar grooves is planing. The main disadvantage of planing in comparison to fly cutting is the limitation of conventional precision axes concerning a high dynamic movement. Regarding to this aspect the Fraunhofer IPT has developed a precise linear axis. It allows high dynamic movements by using an impulse decoupling system (AiF-FV-Nr.: 13,270 N). The paper describes the mechanical setup and the development and optimization of the mechanical main component. The detailed simulation of the drive system (including motor control loop and impulse decoupling system), results of static and dynamic measurements and test machining results are presented.

Comparison of roll-to-roll replication approaches for microfluidic and optical functions in lab-on-a-chip diagnostic devices

Economically advantageous microfabrication technologies for lab-on-a-chip diagnostic devices substituting commonly used glass etching or injection molding processes are one of the key enablers for the emerging market of microfluidic devices. On-site detection in fields of life sciences, point of care diagnostics and environmental analysis requires compact, disposable and highly functionalized systems. Roll-to-roll production as a high volume process has become the emerging fabrication technology for integrated, complex high technology products within recent years (e.g. fuel cells). Differently functionalized polymer films enable researchers to create a new generation of lab-on-a-chip devices by combining electronic, microfluidic and optical functions in multilayer architecture. For replication of microfluidic and optical functions via roll-to-roll production process competitive approaches are available. One of them is to imprint fluidic channels and optical structures of micro- or nanometer scale from embossing rollers into ultraviolet (UV) curable lacquers on polymer substrates. Depending on dimension, shape and quantity of those structures there are alternative manufacturing technologies for the embossing roller. Ultra-precise diamond turning, electroforming or casting polymer materials are used either for direct structuring or manufacturing of roller sleeves. Mastering methods are selected for application considering replication quality required and structure complexity. Criteria for the replication quality are surface roughness and contour accuracy. Structure complexity is evaluated by shapes producible (e.g. linear, circular) and aspect ratio. Costs for the mastering process and structure lifetime are major cost factors. The alternative replication approaches are introduced and analyzed corresponding to the criteria presented. Advantages and drawbacks of each technology are discussed and exemplary applications are presented.

Automated assembly of lens barrels with active wavefront sensor guiding

Miniaturized optics are main-components in many different areas ranging from smart devices over medical products to the area of automotive and mobility. Thus several millions if not billions of small lenses are merged into objectives. One characteristic type of objective holder is the lens barrel. The successful assembly of lenses with diameters of just a couple of millimeters into a lens barrel is an error-prone task antagonized with mass production and an optical inspection at the end of the assembly. Obviously, this process is neither time- nor cost-effective. Furthermore, the increasing imaging qualities demand for highly accurate aligned lens systems. The demand for high-quality optics in large quantities together with the small dimensions of the lenses make assembling a complex process. The Fraunhofer IPT investigates a much more elegant way inspecting the optical system during the fully automated assembly. In the assembly cell, our six-axis micromanipulator aligns the lens camera-led in the lens barrel. Next, the wavefront sensor analyses the imaging function of the lens and compares the actual status with the data from the optic model. This feedback loop between wavefront sensor and micromanipulator continues until the best position is found. We save this information as a digital twin and continue with the next lenses until the optics is completed. The observation of the optical function during the assembly process leads to high quality objectives produced in short cycle times. Moreover, our assembly cell is modular and this allows us to adopt the setup for new lens barrels easily.

Automated assembly of microfluidic "lab-on-a-disc"

Point-of-care (POC) testing attracts more and more attention in the medical health sector because of their specific property to perform the diagnostic close to the patient. The fast diagnosis right at the hospital or the doctor’s office improves the medical reaction time and the chances for a successful healing process. One of this POC test systems is a “Lab-on-a-Disc” (LoaD) which looks like a compact disc crisscrossed with microfluidic tubes and cavities. The fluid to be analysed is placed in the LoaD and an external device then rotates the LoaD. The cavities inside the LoaD and the centrifugal force ensure a clearly defined sequence of the analysis. Furthermore, we aim for an inexpensive manufacture of the medical product without neglecting its quality and functionality. Therefore, the Fraunhofer IPT works on an assembly cell to implement dissoluble films concisely into the disc. This dissoluble film demonstrates its successful usage as a gate for the fluid, which opens after a predefined moment in the cycle. Furthermore, we investigate to integrate a laser welding process into our gantry system and demonstrate its efficiency with the welding of polymer discs. This procedure is clinically safe because no further laser absorption material is needed in the sealing process, which might pollute the LoaD. Moreover, this process allows the alignment of several discs before the welding and therefore leads to precisely manufactured LoaDs in large quantities. All these methods together enable a fast, costefficient and reliable mass production to bring POC testing among the people.

Characterization of individualized assembly for BFL-compensated FAC on bottom tab modules (Conference Presentation)

Uncertain glue gaps lead to challenging assembly tasks in respect to shrinkage control. With decreasing back-focal lengths (BFL) in collimators, the tolerance window for correct alignments decreases as well and forces manufactures to find novel approaches to realize the bonding process. We present performance characteristics of an automated assembly cell for individualized FAC on bottom tab modules. BFL-compensated collimators allow minimizing the critical adhesive gap between substrate and diode laser. This provides optimal control over shrinkage, as well as thermal aspects of the bonding properties. We will focus on the active alignment, which provides the individual focus distance, as well as the relative image processing necessary to assemble both components with ±1 µm precision. Our machine concept and measurement equipment is suitable as stand-alone process for optic manufacturers, as well as integrated part in the final application assembly. In last year’s publication (SPIE 10086), we presented the general concept and can now support our approach with more details from our operating data. With minimized adhesive gaps, the robustness of the proposed concept and a precise characterization of its process window is key, as minimal variations lead to rejects and cause high costs during the final application assembly. Besides classic properties, many more characteristics, e.g. smile behavior of the optic module, are potential optimization factors to increase beam quality. Characterization data from both optic and laser allow applying tolerance matching, where alignment is physically constraint. Performance wise, we will discuss the repeatability, achievable precision and the implications on process time.

Individualized FAC on bottom tab subassemblies to minimize adhesive gap between emitter and optics II (Conference Presentation)

The quality of High Power Diode Laser (HPDL) systems highly depends on the assembly precision. Nowadays, neither the precision of the manipulation tools (step resolution < 10 nm) nor the measurement systems utilized in active alignment algorithms (alignment precision of ~50 nm) are the quality limiting factors but the bonding process is. This is due to the volumetric shrinkage of fast curing UV-adhesives in the curing process. The objective of this work is to minimize the absolute volumetric shrinkage of the UV curing adhesives between edge emitter and bottom tab so no significant misalignment while curing is expected. The approach was first described in the paper [SPIE 10086-28] and aims for minimizing the glue gap and therefore the amount of adhesive through combining active alignment of fast axis collimators (FAC) to edge emitter with a tolerance compensated individualized FAC on bottom tab subassembly in a fully automated production process. With less adhesive the absolute volumetric shrinkage is reduced. The expected benefits are the reduction of the misalignment through volumetric shrinkage and a 100% quality assessment without additional costs. Lens quality data such as smile, residual divergence and optical surface imperfections can be characterized. A permanent data collection provides feedback for all previous and following production systems and allows the improvement of the quality for the whole HPDL production chain. This paper presents the results gathered by implementing the individualized FAC on bottom tab process in an industrial production environment and compares it to the expected benefits to conventional HPDL production.

Curing-in-the-loop strategy for multidimensional-shrinkage compensation in active alignment FAC assembly (Conference Presentation)

Tight tolerances for the final position and orientation of optical components are best controlled in automated and high volume production with statistical process control. Semi-automated and low-volume scenarios on the other hand are in need for a suitable approach, capable to react resiliently on remaining uncertainties of the bonding process. Active alignment has proven to lower the tolerances for finding the optimal position regarding the overall performance. We will present a novel shrinkage-compensation strategy, which extends the active control loop to integrate the curing process. We will discuss the adhesive properties necessary for the realization of our strategy and our measurement equipment used for the characterization of such properties. Besides a predicable shrinkage curve, the critical cross-linking level, until no further manipulation is possible, is a key factor. Furthermore, the machine concept, the curing capabilities and the active evaluation needs to follow special requirements. Since the shrinkage-behavior is highly sensitive to the amount of UV, the effective power on the adhesive needs to be controlled by optimizing the orientation of the light source. We integrated the UV-light in our micromanipulator in order to always ensure an optimal illumination In order to apply regression analysis for a multidimensional shrinkage model, misalignments in the selected degrees of freedom must be observable with sufficient precision. As validation of our strategy, we examine the collimation of a diode laser bar.

Continuous-flow, microfluidic, qRT-PCR system for RNA virus detection

AbstractOne of the main challenges in the diagnosis of infectious diseases is the need for rapid and accurate detection of the causative pathogen in any setting. Rapid diagnosis is key to avoiding the spread of the disease, to allow proper clinical decisions to be made in terms of patient treatment, and to mitigate the rise of drug-resistant pathogens. In the last decade, significant interest has been devoted to the development of point-of-care reverse transcription polymerase chain reaction (PCR) platforms for the detection of RNA-based viral pathogens. We present the development of a microfluidic, real-time, fluorescence-based, continuous-flow reverse transcription PCR system. The system incorporates a disposable microfluidic chip designed to be produced industrially with cost-effective roll-to-roll embossing methods. The chip has a long microfluidic channel that directs the PCR solution through areas heated to different temperatures. The solution first travels through a reverse transcription zone where RNA is converted to complementary DNA, which is later amplified and detected in real time as it travels through the thermal cycling area. As a proof of concept, the system was tested for Ebola virus detection. Two different master mixes were tested, and the limit of detection of the system was determined, as was the maximum speed at which amplification occurred. Our results and the versatility of our system suggest its promise for the detection of other RNA-based viruses such as Zika virus or chikungunya virus, which constitute global health threats worldwide. Graphical abstractPhotograph of the RT-PCR thermoplastic chip

Individualized FAC on bottom tab subassemblies to minimize adhesive gap between emitter and optics

High Power Diode Laser (HPDL) systems with short focal length fast-axis collimators (FAC) require submicron assembly precision. Conventional FAC-Lens assembly processes require adhesive gaps of 50 microns or more in order to compensate for component tolerances (e.g. deviation of back focal length) and previous assembly steps. In order to control volumetric shrinkage of fast-curing UV-adhesives shrinkage compensation is mandatory. The novel approach described in this paper aims to minimize the impact of volumetric shrinkage due to the adhesive gap between HPDL edge emitters and FAC-Lens. Firstly, the FAC is actively aligned to the edge emitter without adhesives or bottom tab. The relative position and orientation of FAC to emitter are measured and stored. Consecutively, an individual subassembly of FAC and bottom tab is assembled on Fraunhofer IPT’s mounting station with a precision of ±1 micron. Translational and lateral offsets can be compensated, so that a narrow and uniform glue gap for the consecutive bonding process of bottom tab to heatsink applies (Figure 4). Accordingly, FAC and bottom tab are mounted to the heatsink without major shrinkage compensation. Fraunhofer IPT’s department assembly of optical systems and automation has made several publications regarding active alignment of FAC lenses [SPIE LASE 8241-12], volumetric shrinkage compensation [SPIE LASE 9730-28] and FAC on bottom tab assembly [SPIE LASE 9727-31] in automated production environments. The approach described in this paper combines these and is the logical continuation of that work towards higher quality of HPDLs.