Micro product design, development and production

• Identify and derive detailed technical specifications of a micro mechanical component based on functional requirements
• Propose various technical solutions and criteria to select the best one
• Apply the design for manufacturing (DFM) approach for various design proposals and select the right materials
• Conduct design FMEA (Failure Mode Effect Analysis)
• Rank and choose different designs based on criteria such as functionality, manufacturability and sustainability
• Evaluate selected micro manufacturing processes using experimental approaches
• Produce CAD drawings (both 2D and 3D) for the developed micro mechanical systems and related production equipment
• Produce and evaluate functional prototypes by digital manufacturing techniques (e.g. 3D printing)
• Present decisions and results in terms of reports and presentations

In the course students will work on design and production of a specific micro mechanical device. The device will be based on polymers and/or metal materials. The corresponding manufacturing technologies include micro injection moulding, hot embossing of micro structures, CNC milling, micro electrical discharge machining, electroforming, additive manufacturing, joining, and assembly at micro scale. The starting point is a set of functional requirements for the device. The students have to transform these requirements into technical specifications, technical drawings and working prototypes. The realization of the prototypes involves hand-on work with selected micro manufacturing processes suitable for Industry 4.0.

Technical drawing 41000 (or equivalent).
Production technology 41714/41781/41787/41788.
Materials technology 41650, 41659.
Micro technology 41742.

Project work in the 3-weeks period.
The students will be grouped into teams of “experts” that will have to work together to fulfil the project goals.

The course content will partly be linked to the activities at CAMM – Centre for Acoustic-Mechanical Micro Systems (www.camm.elektro.dtu.dk)

Minimum: 8, Maximum: 24.

Please be aware that this course has a minimum requirement for the number of participants needed, in order for it to be held. If these requirements are not met, then the course will not be held. Furthermore, there is a limited number of seats available. If there are too many applicants, a pool will be created for the remainder of the qualified applicants, and they will be selected at random. You will be informed 8 days before the start of the course, whether you have been allocated a spot.