XGEN CONSORTIUM

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XGEN CONSORTIUM

• Partnership between organisations specialising
  in advanced technologies.
• Current members include Microbridge Services
  (Cardiff), Laser Micromachining (St. Asaph)
  Centre for NanoHealth (Swansea).
• Aim to broaden scope and commercial strengths of
  XGEN.
• Established in 2007.
• XGEN is funded by

Bringing together technology advances in Wales to
enable the development of practical, successful
and cost-effective solutions for
industry. A one-stop-shop that ensures a
streamlined service and increased manufacturing
efficiency through collaboration and innovation.
www.xgen.org.uk
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Micro Technologies in Health Care

• XGEN Next Generation Engineering
• Technium PE and Technium ST
• Applications of MNT case studies and
  development
• Micro machining technologies
• 2nd July 2009
• By Dr. Robert Hoyle
• MicroBridge Services Limited, MEC, Cardiff.

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MicroBridge Services Limited
MicroBridge Services Limited Hosted by the
Manufacturing Engineering Centre MEC, Cardiff
University Set up to exploit the commercial
potential of the micro and nano engineering and
manufacturing research activities conducted by
the MEC Services include Product design Product
development Prototyping and machining Small batch
component manufacture Micro mould tool
manufacture and moulding Metrology services
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Processes for Different Size Scales
Meso
1
100
0.01
Feature Sizes µm
Mechanical Processes

• Micro milling

• Micro turning

Energy Assisted Processes

• Micro EDM

• Laser Ablation

• Ion Beam Machining

Polymer Replication Processes

• Micro Injection Moulding, Hot Embossing

• Nano Imprinting NIL

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Micro application example

• Application of micro engineering
• BVG Airflo, Brecon, Wales
• Micro wire EDM used to manufacture extrusion
  dies.
• 0.8 mm diameter extrusion die in multi-pointed
  star shape.
• Micron tolerances on dies
• Ridge point radius of 40 microns
• Tapered die allows very controlled cross section
  of line.

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Surgical and medical devices
Key hole surgery prototype Laser milled ceramic
insulator 6mm long, 3mm wide
Micro injection moulded surgical component
prototype
Laser milled filter component for medical device
filtering unit. Overall diameter 6mm, hole
diameter 200 microns.
110 micron diameter barbed needle prototype in
stainless steel, used for piercing and holding
blood vessels
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Implant micro needle array brain sensor, Utah
University
Prosthetic limb interaction

• Brain implant inserted into the motor cortex of
  the brain.
• Detects electrical activity within the brain and
  transmitted by RF to external receiver.
• Powered by inductive coupling from external
  source.
• The patient learns how to interact with it over a
  period of weeks.
• Test have shown that patients can control
  prosthetic limbs and computer screens.

Inductive couple coil
Needle array in a cat
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Implant micro needle array brain sensor, Utah
University
Original needle array was made from deep etched
silicon but this proved too brittle for long term
use. Hence the use of tungsten.
Needle array made from tungsten by MicroBridge
Needle array, each needle is insulated in polymer
except for the point and each is electrically
isolated.
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Starbridge Systems Ltd transdermal drug delivery
Starbridge Starlet moulding and mould tool
Starbridge Starlet insulin drug pump.
Component is 7mm wide, 250 microns thick and
weighs 40 mg. Diameter of small holes is 300
microns. Material Lexan PC
Microfluidic channel component, channel width is
500 microns.
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Transdermal drug delivery polymer micro
needlesLatest research and development at
MicroBridge
Solid micro needle in polycarbonate. Base
diameter 160 microns, height 400 microns. Made by
micro injection moulding
Hollow polymer micro needles are much more
challenging. Research and development is on-going.
Hollow micro needle in polycarbonate. Base
diameter 160 microns, height 220 microns. Made by
micro hot embossing
Hollow micro needle in polycarbonate. Base
diameter 250 microns, height 180 microns. Made by
micro hot embossing
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Point of Care microfluidic devicesBlood protein
detection
Injection moulded polycarbonate microfluidic
device
Microfluidic device for protein detection in
blood samples
Courtesy of MEC SEMOFS multi partner European
funded project
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Technologies Micro-EDM Spark Erosion
EDM turned micro touch probe, 70 micron diameter
ball
Micro needles, 120 x 120 micron square
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Technologies Micro milling
Kern high speed micromilling centre. Minimum
cutter size 0.1mm diameter Minimum positive
feature size 50 microns Minimum negative feature
size 100 microns 5 axis milling capability Ideal
for micro mould tool manufacture
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Technologies Micro injection moulding
Micro injection moulding . Very precise shot
metering . Shot volume max 1 cm3 . Very good
micro feature replication . Short cycle time
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Technologies Picosecond Laser Ablation, Unique
to MicroBridge
Oxford Lasers PicoLase 1000 Pulse length 10
picoseconds
Picosecond laser, 12 axes 5 mechanical (X, Y,
Z, X rotation and Y rotation) and 7 optical (355
and 532 nm)
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Technologies PS Laser Ablation
200 micron wide and deep pocket in fused silica
90 micron slot in stainless steel
Micro mould tool in tool steel
Shark skin 3D 50 micron wide slots in tungsten
carbide
180 micron wide triangular trench
200 micron dia hole in Kapton foil
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Contact

• Thank you.
• Contact Dr. Robert Hoyle
• MicroBridge Services Limited
• c/o Manufacturing Engineering Centre MEC
• Cardiff University
• Newport Road
• Cardiff CF24 3AA
• Tel [phone]
• Fax [phone]
• Email hoylert_at_cardiff.ac.uk
• Web www.mec.cf.ac.uk