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Options for additive rapid prototyping methods (3D printing) in MEMS technology

Victor A. Lifton (Pingtronics Corp, Bridgewater, New Jersey, USA)
Gregory Lifton (Rensselaer Polytechnic Institute, Troy, New York, USA)
Steve Simon (Pingtronics Corp, Bridgewater, New Jersey, USA)

Rapid Prototyping Journal

ISSN: 1355-2546

Article publication date: 12 August 2014

3537

Abstract

Purpose

This study aims to investigate the options for additive rapid prototyping methods in microelectromechanical systems (MEMS) technology. Additive rapid prototyping technologies, such as stereolithography (SLA), fused deposition modeling (FDM) and selective laser sintering (SLS), all commonly known as three-dimensional (3D) printing methods, are reviewed and compared with the resolution requirements of the traditional MEMS fabrication methods.

Design/methodology/approach

In the 3D print approach, the entire assembly, parts and prototypes are built using various plastic and metal materials directly from the software file input, completely bypassing any additional processing steps. The review highlights their potential place in the overall process flow to reduce the complexity of traditional microfabrication and long processing cycles needed to test multiple prototypes before the final design is set.

Findings

Additive manufacturing (AM) is a promising manufacturing technique in micro-device technology.

Practical implications

In the current state of 3D printing, microfluidic and lab-on-a-chip devices for fluid handling and manipulation appear to be the most compatible with the 3D print methods, given their fairly coarse minimum feature size of 50-500 μm. Future directions in the 3D materials and method development are identified, such as adhesion and material compatibility studies of the 3D print materials, wafer-level printing and conductive materials development. One of the most important goals should be the drive toward finer resolution and layer thickness (1-10 μm) to stimulate the use of the 3D printing in a wider array of MEMS devices.

Originality/value

The review combines two discrete disciplines, microfabrication and AM, and shows how microfabrication and micro-device commercialization may benefit from employing methods developed by the AM community.

Keywords

Citation

A. Lifton, V., Lifton, G. and Simon, S. (2014), "Options for additive rapid prototyping methods (3D printing) in MEMS technology", Rapid Prototyping Journal, Vol. 20 No. 5, pp. 403-412. https://doi.org/10.1108/RPJ-04-2013-0038

Publisher

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Emerald Group Publishing Limited

Copyright © 2014, Emerald Group Publishing Limited

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