Preface	6
	Contents	7
	Acronyms	8
	1 Introduction to Miniaturisation	12
	1.1 Introduction	12
	1.2 Scaling Laws	13
	1.2.1 Geometry	14
	1.2.2 Mechanics	14
	1.2.3 Dynamics	15
	1.2.4 Micro-fluidics	16
	1.2.5 Van der Waals Force	18
	1.2.6 Electromagnetism	19
	1.2.7 Thermodynamics	20
	1.2.8 Scaling with Distances	20
	1.2.9 Scaling Exponent	22
	1.3 Materials	22
	1.3.1 Smart Materials	24
	1.3.1.1 Piezoelectric Materials	24
	1.3.1.2 Shape Memory Alloy	25
	1.3.1.3 Electroactive Polymers	26
	1.4 Micro-factories	28
	References	32
	2 Micro-injection Moulding	34
	2.1 Overview	34
	2.1.1 Technical Description	34
	2.1.2 Definition of Technology	35
	2.2 Materials	37
	2.3 Design and Simulation	38
	2.3.1 Characterisation—Micro-rheology	38
	2.3.2 Rheological Simulation	38
	2.3.3 Conclusions	39
	2.4 Process and Materials	41
	2.4.1 Principles of the Injection Moulding Process	41
	2.4.2 Key Features	44
	2.4.3 Dosage (Charge)	44
	2.4.4 Injection Speed	46
	2.4.5 Injection Pressure	46
	2.4.6 Holding Pressure	47
	2.4.7 Holding Pressure Time	47
	2.4.8 Cooling Time	48
	2.4.9 Process Temperatures in the Mould, Expansion and Balance	48
	2.4.10 Mould Venting	50
	2.5 Tools and Machines	53
	2.5.1 The Injection Machine	53
	2.5.2 Plasticising Systems	56
	2.5.3 Micro-injection System Without Plasticising	58
	2.5.4 Main Micro-injection Moulding Machines	59
	2.5.5 Micro-injection Moulds	59
	2.6 Sectors of Application	63
	2.7 Handling and Verification of Micro-parts	67
	2.7.1 Handling	67
	2.7.2 Inspection	68
	2.7.3 Morphological Analysis	69
	2.7.4 Mechanical Analysis	70
	2.8 Application Case: Micro-filter	71
	2.8.1 Description	71
	2.8.2 Micro-filter Design Analysis (FEM/CAE)	73
	2.8.3 Micro-injection Process Simulation	73
	2.8.3.1 Filling and Parameters	73
	2.8.3.2 Gate Positioning Optimisation	73
	2.8.3.3 Welding Lines and Air Traps Analysis	75
	2.8.4 Mould Design and Manufacturing	75
	2.9 Process Optimisation and Part Production	76
	Bibliography	77
	3 Micro-additive Manufacturing Technology	78
	3.1 Overview	78
	3.2 Micro-stereolithography (MSL) and Two Photon Polymerisation (2PP)	80
	3.2.1 Operating Principles	80
	3.2.2 Technology Overview and Systems	82
	3.2.3 Materials	84
	3.2.4 Applications	85
	3.3 Powder Bed Fusion Technologies	87
	3.3.1 Operating Principles	87
	3.3.2 Technology Overview and Systems	88
	3.3.3 Machines and Materials	88
	3.3.4 Applications (Table 3.3)	90
	3.4 Three Dimensional Printing via Binder Jetting	91
	3.4.1 Operating Principles	92
	3.4.2 Technology Overview and Systems	93
	3.4.3 Machines and Materials	94
	3.4.4 Applications	95
	3.5 Three Dimensional Printing via Material Jetting	95
	3.5.1 Operating Principles	95
	3.5.2 Technology Overview and Systems	96
	3.5.3 Machines and Materials	97
	3.5.4 Materials	98
	3.5.5 Applications	99
	3.6 Filament Deposition	100
	3.6.1 Operating Principles	100
	3.6.2 Technology Overview and Systems	101
	3.6.3 Machines and Materials	102
	3.6.4 Applications	105
	References	105
	4 Manufacturing Technology: Micro-machining	107
	4.1 Overview	107
	4.1.1 Why Micro-machining?	107
	4.1.2 Definitions	108
	4.1.2.1 Micro-cutting	108
	4.1.2.2 Size Effect	109
	4.1.2.3 Uncut Chip Thickness	110
	4.1.2.4 Rake Angle	110
	4.1.2.5 Shearing, Ploughing, and Rubbing	110
	4.2 Engineering Materials and Material Properties	110
	4.2.1 Elastic and Plastic Material Behaviour	110
	4.2.2 Failure of Materials	112
	4.2.2.1 Crack Propagation	113
	4.3 Design and Simulation	114
	4.3.1 Introduction	114
	4.3.2 Why Simulate Micro-cutting?	114
	4.3.2.1 Micro-machining Simulation	115
	4.3.2.2 Machining Strategies	116
	4.3.3 Micro Versus Conventional Machining	116
	4.3.4 Issues Covered by Modelling of Micro-machining	117
	4.3.5 Mechanistic Modelling of the Micro-cutting Process	118
	4.3.6 Finite Element Analysis (FEA)	119
	4.3.6.1 Established Predictive FEA Models	119
	4.3.7 Molecular Dynamics Modelling Approach	120
	4.3.7.1 Established MD Models	120
	4.3.8 Multi-scale Simulation Methods	120
	4.3.9 Indicative Costs	121
	4.4 Process, Tools and Machines	121
	4.4.1 Process	121
	4.4.1.1 Machining Scale	122
	4.4.1.2 Cutting Forces	123
	4.4.1.3 Size Effect	125
	4.4.1.4 Burr Formation	125
	4.4.2 Micro-tools	126
	4.4.2.1 Tool Size	126
	4.4.2.2 Tool Wear and Breakage	127
	4.4.2.3 Micro-tool Coatings	129
	4.4.3 Machine-Tools	129
	4.4.3.1 Micro-machining Platform Characteristics	129
	4.4.3.2 Machine-Tools Suppliers	130
	4.4.4 Measurement Systems	132
	4.4.4.1 Geometric Measurement: Pre-processing	132
	4.4.4.2 Geometric Measurement: During Processing	132
	4.4.4.3 Geometric Measurement: Post-processing	133
	4.4.4.4 Process Parameters Measurement	134
	4.5 Sectors and Applications	135
	4.5.1 Industry Sectors and Application Areas	135
	References	136
	5 Micro-waterjet Technology	138
	5.1 Introduction to Waterjet Technology	138
	5.2 High Energy Fluid Jet Generation	139
	5.2.1 High Pressure Pump	139
	5.2.2 High Pressure Circuit	140
	5.2.3 Handling System and Fixturing	141
	5.2.4 Energy Conversion	141
	5.2.5 Machining Mechanism and Cutting Heads	142
	5.2.6 Abrasive Feeding System	143
	5.2.7 Catcher	144
	5.3 AWJ Quality Assessment	144
	5.3.1 Machining Defects Description	146
	5.3.2 Defect Reduction Methods	146
	5.4 Micro-AWJ Technology	149
	5.5 Micro-AWJ Key Features	149
	5.5.1 Micro-AWJ Enabling Characteristics	150
	5.6 Micro-AWJ Case Studies	151
	5.6.1 Precision Through Defect Compensation	151
	5.6.2 Thin Layers Drilling	152
	5.6.3 Inhomogeneous Materials	153
	5.6.4 Advanced Alloys for Biomedical Applications	154
	5.6.5 Thin Details Cutting on POM	155
	5.6.6 Stainless Steel Racks Small Batch	155
	5.6.7 Deep Holes with Tight Tolerances	155
	References	157
	6 Micro-electro-Discharge Machining (Micro-EDM)	158
	6.1 Principle of Electro-Discharge Machining (EDM)	158
	6.2 Micro-EDM Process Parameters	161
	6.3 Performance of the Micro-EDM Process: Quality Indices	163
	6.3.1 Micro-EDM Milling Optimisation via Design of Experiments (DoE)	165
	6.3.2 Monitoring for Evaluating Micro-EDM Performance	166
	6.3.3 Tool Wear and Tool Path: How to Obtain Surface and Profile Accuracy in Micro-EDM Features	167
	6.3.4 High Aspect Ratio Cavities: Role of Tool Wear and Dielectric Flushing	169
	6.4 Materials and Effects on Micro-EDM Process	170
	6.5 Applications	171
	6.5.1 Straight Bevel Micro-gear	171
	6.5.2 Customised Internal Fixation Devices for Orthopaedic Surgery	173
	6.5.3 Micro-EDM Milling/Sinking Combined Approaches: Micro-filter Mould	177
	References	180
	7 Moulded Interconnect Devices	183
	7.1 Overview—Moulded Interconnect Devices	183
	7.2 Materials	185
	7.2.1 Introduction	185
	7.2.2 Requirement for Substrate Material	186
	7.2.3 Typical MID Materials	187
	7.3 Processes	188
	7.3.1 Overview	188
	7.3.2 Two-Shot Injection Moulding	188
	7.3.3 Laser Direct Structuring (LDS)	191
	7.3.4 Hot Embossing	194
	7.3.5 Aerosol-Jet Printing	195
	7.3.6 Advantages and Challenges of Each Technology	197
	7.4 MID Assembly	199
	7.4.1 Mounting Techniques	199
	7.4.2 Positioning	199
	7.4.3 Challenges	200
	7.5 Sectors and Applications	201
	7.6 Application Case	202
	References	203
	8 Micro-scale Geometry Measurement	205
	8.1 Introduction	205
	8.2 Contact Techniques	206
	8.2.1 Stylus Instruments	206
	8.2.2 Micro Coordinate Measuring Machines	207
	8.2.2.1 Introduction to Coordinate Measuring Machines	207
	8.2.2.2 Capability of Commercial Micro-CMMs	208
	8.2.2.3 Micro-probing Systems	208
	8.2.2.4 Sources of Error on CMMs	211
	8.3 Non-contact Techniques	212
	8.3.1 Focus Variation Microscopy	212
	8.3.2 Coherence Scanning Interferometry	213
	8.3.3 Confocal Microscopy	215
	8.3.4 Laser Triangulation	217
	8.3.5 Micro-fringe Projection	219
	8.4 Tomographic Methods	220
	8.4.1 Optical Coherence Tomography	220
	8.4.2 X-ray Computed Tomography	223
	References	224
	9 Micro-assembly	230
	9.1 Introduction	230
	9.2 Hybrid Micro-systems Production	231
	9.3 Micro-assembly Definition	231
	9.4 Micro-assembly Methods	233
	9.4.1 Classification	233
	9.4.2 Robotic Micro-assembly	236
	9.4.3 Self-assembly	237
	9.4.4 Robotic Micro-assembly and Self-assembly Compared	237
	9.4.5 Hybrid Micro-assembly	238
	9.5 Robots for Micro-assembly	239
	9.5.1 Definition	239
	9.5.2 Classification	240
	9.5.3 Design Considerations	241
	9.5.4 Example of Robots for Micro-assembly	242
	9.6 Micro-manipulation Systems	245
	9.6.1 Issues in Micro-manipulation	245
	9.6.2 Micro-manipulation Strategies	246
	9.6.2.1 Contact Manipulation	246
	9.6.2.2 Contact-Free Handling	249
	9.6.3 Release Strategies	250
	9.6.3.1 Active Techniques	250
	9.6.3.2 Passive Techniques	251
	9.7 Sensors and Control Methods for Micro-assembly	251
	9.7.1 Vision	251
	9.7.2 Force Sensing	255
	9.7.3 Environmental Conditioning in Micro-assembly	256
	9.8 A Case Study: The ITIA Micro-assembly Work-Cell	258
	References	261
	10 Market Analysis, Technological Foresight, and Business Models for Micro-manufacturing	267
	10.1 Introduction	267
	10.2 Micro-manufacturing Market Analysis	268
	10.2.1 Business Drivers and Market Demands	268
	10.2.2 Main Sectors of Application	269
	10.2.2.1 Healthcare	271
	10.2.2.2 Energy	271
	10.2.2.3 Aerospace	272
	10.2.3 Key Stakeholders	273
	10.2.4 Strengths, Weaknesses, Opportunities, Threats	274
	10.3 Future of Micro-manufacturing Market and Technological Foresighting	276
	10.3.1 Market Trends	276
	10.3.2 Future Sectors	277
	10.3.3 Future Applications and Technologies	278
	10.3.3.1 Future of Micro-parts	279
	10.3.3.2 Future of Micro-manufacturing Technologies	281
	10.4 Business Models for Micro-manufacturing	282
	10.4.1 What Is a Business Model?	282
	10.4.1.1 Business Model Elements	283
	10.4.2 Innovative Business Models	286
	10.4.3 Current Business Models for Micro-manufacturing	287
	10.4.3.1 Traditional Machinery Selling	287
	10.4.3.2 Production Service	288
	10.4.4 Innovative Business Models for Micro-manufacturing	290
	10.4.4.1 Personalised Manufacturing for Healthcare with Closed Integration with Hospitals	290
	10.4.4.2 Micro-factory	292
	10.4.4.3 Micro-machinery Producers	293
	References	296
	Index	298