From Lab to Fab => Training for the Innovation Value Chain

Robert D. Cormia

Foothill College

Overview

• SETM => Innovation Value Chain

• Advanced manufacturing

• Extensible technicians

• Start-up environments

• Training for life, building to scale

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

Nanotechnician Competencies

• Measurements

• Fabrication / process

• Modeling / simulation

• Knowledge of nanoscale

• Work in teams (SETM)

Deb Newberry Dakota County Technical College – University of Minnesota

Nanomaterials Engineering

• Challenging applications– Novel properties– Novel structures– New processes

• New structure – property relationships

http://tam.mech.northwestern.edu/joswald/

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

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)

PNPA / 4-D Compass

Properties (P)

Applications (A)

Process (P)

Nanostructure (N)

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’

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)

SETM / 4-D Technicians

Engineering (E)

Science (S)

Manufacturing (M)

Technology (T)

SETM => Innovation Value Chain

• Scientific discovery• Engineering prototypes• Technology development• Manufacturing scale-up• From lab to fab =>

innovation value chain

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.

21st Century Technicians

• 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

Nanotechnology Program Outcomes

Introduction to NanotechnologyScale and forces

o Dominate forces at all scales of distanceEmergence of properties at scale

o Melting point, plasticity, thermal and electrical conductanceSelf assembly process

o Crystals, molecular networks, biomoleculesAtom as a building block of materials

o Crystals, glasses, metals, liquid / networksSurface dominated behavior

o Surface area vs. volume, surface properties vs. bulk, surface behavior and chemistry

Role of quantum mechanicso Conduction, phonons, interaction with light

Applications of nanotechnology / deviceso Solar panels, fuel cells, semiconductors, ink,

Industries that use nanotechnologyo Semiconductor, electronics, energy, medicine, advanced materials

Characterization toolso Image (AFM/SEM), surface (AES/XPS), structure (XRD/TEM), and bulk

(XRF/EDX/WDX)

Nanomaterials and NanostructuresNanomaterials vs. ‘traditional’ materialsNanostructures and novel properties

o Nanofibers, nanoparticlesProcess => structure => properties => applications

o Designing structures for end use propertiesTypes of materials

o Glass, ceramic, metal, alloy, polymers and composites, Types of properties

o Strength, plasticity, thermal and electrical conductance, electromagnetic

Fabrication basicso Fab facilities, tools, processes, CNT

Processingo Heat treatment, quenching, alloys, composites, fibers

Modeling and designing for desired propertieso Computer modeling of structure properties relationships

Choice of materials and structureso Select for properties and applications

Characterization tools for nanostructures / nanomaterialso Image, surface, composition, structural

Nanocharacterization Instruments and characterization tools

o (AFM/SEM), surface (AES/XPS), structure (XRD/TEM), and bulk (XRF/EDX/WDX)

Types of analyseso Materials characterization, process development, failure analysis

High vacuum and high voltage basicso Vacuum t safety, vacuum awareness, high voltage and safety

Sample preparation and handlingo Cleanliness, cleaning, dust and vacuum considerations

Instrument selectiono Image, surface, composition, structure, physical properties

Data gathering, analysis, and tabulationo Instrumental techniques, data gathering , tabulation interpretation

Interpreting composition and chemistry, modeling structureo Building atomic and molecular structure from composition, chemistry,

and x-ray dataUsing a LIMS, searching spectral databases

o Knowledge management tools to aid future problem solvingReporting data, writing formal industry reportsClient management skills

NanofabricationType of fabs

o Silicon, MEMS, Waferso Clean room basics, air filtration, dust

Safety basicso Vacuum equipment, High voltage

Silicon fundamentalso Deposition, masking, etching

Virtual / physical tour of a silicon fabMEMS basics

o Silicon and polymer based MEMS Nanochemistry

o Self Assembled Monolayerso Dendrimers, Quantum Dots

Thin film depositiono Vacuum deposition, Sputtering, CVD/PECVDo Roll coating (web), Spin coat

Plasma depositiono Plasma equipment, Gas chemistry

Surface modificationo Chemical, gas, plasma

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

Advanced Materials

• Thin film coatings• Nanopowders / nanoparticles• Nanocarbon (CNT/CNSC)• Polymers and composites• Specialty metals / alloys• Advanced biofuels

Carbon Nanospheres (Onion Like Carbon) for high energy batteriesNanosphere 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

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

Advanced Manufacturing

• Clean energy– Wind, solar, fuel cells

• Advanced biofuels– 100M gallons/day 2022 target

• Biotechnology– Nanomedicine, cancer vaccines

• Electric vehicles and batteries

Synthetic and Biosynthetic FuelsBiosynthetic 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.

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.

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.

Biomass to Biofuels

Berkeley Lab Opens Advanced Biofuels Facility

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

Algal Biofuels Forecast Scenarios

Evolution of Algal Biofuels

http://www.chem.info/Articles/2010/03/Alternative-Energy-Algae-Investment-Trends-Advanced-Biofuels-Insight/

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

Building a Clean Energy Economy

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!

Demanufacturing - RemanufacturingIn 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’.

Training for R&D

• Internships matter!

• Developing ‘competency’

• Hands on learning

• Current technology

• Real-world problems

• Real-world mentors

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!