... DRAFTWorkingPapersVersion040510a systems approachthatinvolvesfundingofmultipleactivitiesfrombasic research toprototypedevelopment,inanintegratedfashionisbest.DOE’sARPA‐Eprogramisonesuchprogramthathas the flexibilitytosponsorR&Dthatspansmultiplestages,frombasic research tocommercialization, and inareasthatareotherwisetoocross‐cuttingormulti‐disciplinarytofitinto the currentS&Tfundingsystem.123456789101112131415161718192021222324252627282930313233343536373839404142Createregulations and standardsettingin the areaof advanced manufacturing isanotherappropriaterole for S&Torientedagencies.ExpertsatNISTstatethatwhilehundredsofstandardsexist for ICs,almostnonedone for MEMs and othertechnologiesrelevant for advanced manufacturing. MEMS and evolvingnanotechnologyproductstendtobespecialized,customproducts; and lackofstandardscankeepcosts for newapplicationshigh, and hurtU.S.competitivenessbothindomestic and internationalmarkets(NISTMEL).16Depending on howtheyarestructured,regulations and standardsmayaddtocostofproduction,butcanalsospurinnovation.Thereareseveralexamplesin the environment domainwhereregulationstriggered the discovery and introductionofcleanertechnologies and environmental improvements.Build the physicalinfrastructure.AsGregTasseynotes,“whileproductscommercializedbased on newtechnologiesareprivategoods, the underlyingtechnologyplatforms(“generictechnologies”) and supporting“infratechnologies”arederivedfromacombinationofpublic and privateassets.”17Thisobservationisimportant for tworeasons.First,thatinfrastructureis the foundationthatcommercializedtechnologiesarebuiltupon and enablestheirdesign,development, and production, and, second,that the governmentcan and shouldplayaroleinfosteringearlyinvestmentinunder‐supported manufacturing infrastructureR&D,supplychainintegration, manufacturing systems integration, and technologymaturitylifecyclemanagement.Emergingfirmsthatlackdesignsupport,tools,matureprocesses, and technical and businessknow‐howmustdemonstratesomeplanorabilitytodeveloptheseinordertoattract the requisiteinvestmentcapitaltogetoff the ground.Existingfirmsmustconstantlyrefine and renew the technologyplatform and manufacturing processesthattheyemployinordertokeepupwithcompetitors,letalonecapturecompetitiveadvantage.Therefore, manufacturing infrastructureinnovationisseenasessentialtobothnew and existingfirms and wouldbenefitfromagovernmentcommitmenttoprovidingaccesstoworld‐bestR&D,processes, and technologies.Skill‐Building for Advanced Manufacturing Akeyfactorinrespondingquicklytocustomerneeds and developingnewprocesses and productsmorerapidly(twoimportantattributesof advanced manufacturing) isaworkforcethatisready for thesechallenges.Severalexperts,especiallyfrom the manufacturing industry,lamented the lackofappropriatelytrainedworkersfromU.S.institutions.Thisdearth(amongotherreasonstobesure)leadsthemtomanufactureelsewhere,especiallyAsia.Whenaskedifhiscompanywasbeingheldbackbyweakscience and matheducationinAmerica’sK‐12schools,PaulOtellini, the CEOofIntelcommented,“Asacitizen,Ihateit.Asaglobalemployer,Ihave the luxuryofhiring the bestengineersanywhere on earth.IfIcan’tgetthemoutofMIT,I’llgetthemoutofTsinghua.”Expertswithwhomwespokeindicatedthattoaid the UnitedStatesingrowingits advanced manufacturing economy and toovercometechnologicalchallenges,workersneedtobe better and moredifferentlyeducated. For example,inarecentreport,JamesDuderstadtof the UniversityofMichiganproposedthatundergraduateengineeringshouldbereconfiguredasanacademicdiscipline,similartootherliberalartsdisciplinesin the sciences,arts, and humanities,allowingstudentstobenefitfrom the broadereducationalopportunities for alifetimeoffurtherlearningratherthanprofessionalpractice.Simultaneously,engineering(or,perhapsmorebroadly,technology)shouldbeincludedin the liberalartscanonundergirdingatwenty‐first–centuryundergraduateeducation for allstudents.18 The governmentmayneedtoconsiderarangeofnewideassuchasthistorevampeducation for manufacturing relatedjobs.16NISTMELhomepagehttp://www.nist.gov/mel/,accessedJanuary29,2010.17GregTassey,“Rationales and mechanisms for revitalizingUS manufacturing R&Dstrategies,”op.cit.18JamesDuderstadt,“Engineering for aChangingWorld:ARoadmapto the FutureofEngineeringPractice, Research and Education,” The MillenniumProject,UniversityofMichigan,2008. ... DRAFTWorkingPapersVersion040510123456789101112131415161718192021222324252627282930313233343536373839404142434445464748 The industrysees the waytoovercomethiscost and complexityhurdleisthroughphotonicintegration.Assuch,threeclassesofdevicesrepresent the integrationin the photonicsworld. The planarlightwavecircuit(PLC)consistsonlyofpassivedevicesfabricatedfromtransparentmaterialsusingplanartechnology.Itisessentiallyopticalwiring and canperformsomesignalprocessingbutdoesnotalter the signal.TypicallyPLCmaterialsaresilica on silicon,polymers, and silicon on isolator(SOI). The industryhasusedthistechnologywidely for the last10years. The photonicintegratedcircuit(PIC)is the sameasaPLCbutalsoincludes on chipgeneration,modulation,alteration, and detection.Ithasbothpassive and activephotonicdevices(InPorGaAs‐based) and transparent and opaquesemiconductormaterialswithdifferentbandstructures and doping.Semiconductorwaferprocessingtechnologiesfabricate the opticalwaveguidedevices.PICscanbemonolithic,whereallof the devicesresideinonedie,orhybrid,wherecertaindevicesarephysicallyattachedtogetherontoacommonplatformtofunctionasoneunit.Thistechnologyrepresents the currentstate‐of the art, and whereindustryR&Disfocused. The optoelectronicintegratedcircuit(OEIC)is the sameasaPICbutincludes on chipelectronicstodrive the activeelements and provideelectricaloutputs.Itconsistsofphotonic and electronicdevicescombinedontoonechip and fabricatedusingsemiconductorprocessingtechnologies.Thisfuturetechnologyisone the industryhopestoachieve.Becauseof the largeexistinginfrastructure,siliconwouldbe the idealcandidate for photonicintegration.Althoughresearchershavefabricatedmostof the requiredactive and passiveopticalfunctionsinsilicon(Si), the fundamentalchallengehasbeenthatsilicondoesnotsupportalaser,anessentialcomponentin the opticalworld.Academic and industrialresearchershavedevisedcleverapproachestomitigatethisshortcomingofsilicon. For the mostpart,theyhaverelied on the indiumphosphide(InP)materialssystem for the laser. The problemwithInPistwofold—immatureproduction environment and concomitantly the lackofasharedcommonproductionapproach.First, the material and fabricationinfrastructureisimmature.TypicalwafersizesofInPare3inches,withleadingedgeat6inches.Siliconfabrication, on the otherhand,typicallyuses8‐or12‐inchwafers.Six‐inchtechnology for Siismanygenerationsold.Because the market for InPdevicesisrelativelysmall, the toolinfrastructurehasnotbenefitedfromahighlevelofinvestment.Second,InPdeviceshaveevolvedina manufacturing environment where the intellectualpropertyisembeddedin the process,ratherthan the design.Asaresult,onecannottakeadevicefabricatedinonefacility and replicateitusing the processesofanotherfabricationfacility(fab).Again,inthisrespectphotonicintegrationisat the levelofmaturityofsiliconin the 1960s,beforeCMOSbecame the technologyofchoice.Notwithstanding the difficultiesofmonolithicintegration on the InPplatform,somecompanies,suchasJDSU and Infinera,havesuccessfullybroughtproductsbased on monolithicInPintegrationtomarket.Oclerobelievesitiswell‐positioned for thismarketsegmentbecauseofitsInPfabinCaswellUK. The secondapproachtoPICsistointegrateasmanypassive and activecomponents on asiliconsubstrateaspossible, and thenattach and couplecriticalnon‐Sicomponentsto the platform.Oneof the advantagesofSiasaplatformisthatSiO2makes for anexcellentwaveguidematerial, and the processescanbefullycompatiblewith the existingCMOSinfrastructure. The challengeisin the mismatchof the thermalconductivitiesofInP and Si.Astemperaturechanges, the componentsmayshiftslightly,impacting the alignmentof the opticalpath.CompaniesthatfollowthisapproachincludeKotura,Luxtera, and NeoPhotonics.Potentialroadblocksaheadincludedensitylimits,both on and offchip.With the massiveamountofwirebondingrequired for theseintegratedphotonicdevices, and withall the wiresrunning10or40GHzsignalsthoughthem,theyactlikeaphaseantenna,bringingupseriousissuesofelectromagneticinterference.AnotherkeyimpedimenttoPICdevelopmentis the lackofaneconomicallyviablefoundrybase. The economicrealityisthatmanyIII‐Vfoundriesarestrugglingwithexcesscapacity and no“killerapplication”insightthatwoulddrivevolume.Companiestrytolockinwhatlittlecustomerbasetheyhavethroughproprietaryprocessesthatarenotportablefromfoundrytofoundry. On the technicalside, the lackofarobustmarket,haslimited the developmentofcomprehensivemodelingsoftware and otherinfrastructureelements.Researchersinterestedinbuildingphotonicintegratedcircuitshaveto ... DRAFTWorkingPapersVersion040510MassCustomization12345678910111213141516171819202122232425262728293031323334Oneof the definitionsof advanced manufacturing references the need for new manufacturing platformstobeflexibletorespondtocustomerdemands.Anemerging advanced manufacturing conceptsuggestedindiscussionswithexpertsis the abilitytoachievecost‐effective“masscustomization”ofaproduct.Throughadvancesincomplexproductrealization and single‐unit manufacturing, asdescribedpreviously,masscustomizationisbecomingamoreplausiblereality. Advanced manufacturing techniques,suchassolidfree‐formfabrication(oftencalled“additive manufacturing ) and laserprocessing,cancreatecomplex,customproducts and replacementpartsthatarerequiredtobeproducedquicklyinlowvolumes.5Suchadvancesin manufacturing couldleadtonewwaysofapproachingpersonalizedmedicine and biomanufacturingofpharmaceuticals.Somedefinepersonalizedmedicineas“aformofmedicinethatusesinformationaboutaperson’sgenes,proteins, and environment toprevent,diagnose, and treatdisease.”6Givenlimitations and reducedefficacyofconventionalmedicinesacrossbroadpatientpopulations,manyresearchersarelookingtowardspersonalizedhealthcarestrategies and cell‐basedtherapiesto better targetdiseases.However, manufacturing technologies for targetedtherapiesthatmeet the regulatory and economicrequirements for successfulcommercializationarestillinembryonicstages.Anotherexampleofmasscustomizationthatemergedfromdiscussionswithindustryexpertsis the manufacturing ofcustomizableprescriptioneyelenseswithuniquefeatures. The technology,developedbyLuxottica,allows for specialfeaturessuchascoatings and progressivelensestobemademorepreciselythroughnewlayeringtechnologies.Advancesin manufacturing processestocreatedesktopmachineshaveenabled the companytoautomatelens manufacturing for improvedqualityatalowercost.OpenInnovation Manufacturing Anotheremergingconceptleverages the powerofcollectiveintelligence and informationtechnologytocollectnewdesign and manufacturing strategies for productdevelopment.ArecentarticledescribesaBoston‐basedCompany,LocalMotorsInc.,as the firstopen‐sourceautomotivecompany.7LocalMotorsaimstobuildanoff‐road,butstreet‐legal,vehicletobereleasedinJune2010.ThroughaCreativeCommonslicense,8notonlydesignideasbutalsodevelopment and manufacturing solutions(mostofwhichwereoff the shelfcomponents)weresolicitedfrom the public.Throughwell‐managedcommunityinputaswellastechnologiessuchas3‐Ddesignsoftware and photorealisticrenderingtechnology,enthusiasts and LocalMotorsemployeesworkedtogethertodesign and buildacarthat,accordingto the article,“putsDetroittoshame.”Network‐Centric Manufacturing Arecentreport,Rationales and Mechanisms for RevitalizingU.S.R&D Manufacturing Strategies,arguesthatamajorrequirement for competitivenessin manufacturing isagreateruseofinformationtechnologytomoreeffectivelyintegrateallbusinessoperationsin manufacturing supplychains.Onemethodofachievingthisgoalisthroughnetwork‐Centric manufacturing (NCM),definedas:95GregTassey,“Rationales and mechanisms for revitalizingUS manufacturing R&Dstrategies,”JournalofTechnologyTransfer,publishedonline29Jan2010,availableathttp://www.springerlink.com/content/e70574777627wmg4/fulltext.pdf.6SeeNationalCancerInstitute,“DefinitionofTerms,”availableathttp://www.cancer.gov/templates/db_alpha.aspx?CdrID=561717.7ChrisAnderson,“In the NextIndustrialRevolution,AtomsAre the NewBits,”WiredMagazine,January25,2010.8CreativeCommonsisanonprofitorganizationthatworkstoincrease the amountofcreativity(cultural,educational, and scientificcontent)in“the...