Smart modular reconfigurable fully-digital manufacturing system with a knowledge-based framework: example of a fabrication of microfluidic chips

This paper presents an innovative approach to the development of a smart fully-digital manufacturing system based on a modular and reconfigurable production concept. In particular, multiple “plug and play” manufacturing modules, i.e. functional printing, laser processing and welding, in addition to a positioning control unit and quality inspection system, are exploited in an agile manufacturing platform combined with a knowledge-based framework, termed “3D-I”. This enables the production of tailored laminated parts, made up of stacks of functionalised layers of polymer films, with intricate 3D micro features. However, since no tool or mask making is needed, a medium to small lot-size and even one-off parts can be produced in a cost-effective manner. For the evaluation of the “3D-I” approach, a case study of micro-fluidic chips, exemplifying functional parts, are fabricated. The results prove the feasibility of the developed smart system to produce micro-devices with pre-defined specifications. In addition, the knowledge-based manufacturing system demonstrates its potential to offer profitable production scenarios of microdevices, with high flexibility and scalability, outside the area of mass production.