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Updated 07/27/2022
3

Magnetic PDMS micro-pillars

Inventive principles #
Contradiction:
If
we mange to create PDMS molds outside of the clean room
Then
it will reduce the need for clean room
But
it might lower the device quality
Improving parameter
Description of what is improving:
time, cost and make the process more simple
Selected improving parameter:
Device complexity
Worsening parameter
Description of what is worsening:
because it never been done we cant be sure if it will work and what the quality of the device will be
Selected worsening parameter:
Reliability
Matching principles:
  • 1
    Segmentation
  • 13
    The Other way around
  • 35
    Parameter changes
  • Jun 11 2022 9:03:29 am
    5 Whys #
    Causes Chain
    Root Cause Analysis

    creating one device takes long time

    Why?

    create copies from a working device and not from scratch

    creating one mold takes long time in the clean room

    Why?

    new process without the need of clean room

    the lithography process is to long

    Why?

    we need to improve the process or find a way to skip it

    we need to expose a lot of area to create the holes

    This is the fundamental reason for the problem (FRP).

    we need to change the pattern to make the process faster

    Jun 11 2022 9:51:17 am
    Cause and Effect Chain #

    we can't create multiple devices at the same time to reduce time

    we need to create from one mold multiple molds to do it we can create silicon mold of pillars and then to create multiple holes molds from PDMS instead of silicon.

    by creating silicon pillars instead of holes - the time in the clean room is reduced significantly because the exposure area is a lot smaller

    Jun 11 2022 10:08:22 am
    Effective Brainstorming #

    New process for PDMS micropillars fabrication


    ImplementationEasyValidationEasy
    fabricate in the clean room pillars mold instead of holes mold
    Jun 22 2022 11:53:59 am
    use pillars mold to fabricate outside the clean room multiple holes mold as needed
    Jun 22 2022 11:54:39 am
    ImplementationNot EasyValidationEasy
    creating PDMS mold instead of silicon
    2
    Jun 22 2022 12:00:28 pm
    Fabricate the device from PDMS mold
    1
    Jun 22 2022 11:57:09 am
    make multiple molds in the clean room at the same time
    0
    Jun 22 2022 11:58:31 am
    Jun 22 2022 11:50:56 am
    Functional Modeling #

    lithography and PDMS casting

    Functional rank
    Problematic rank
    optical review
    10
    pill the PDMS from the mold
    8.8
    Silicon mold
    5.6
    SEM review
    5.6
    Etching
    3.8
    bake the PDMS
    3.8
    Resist development
    3.1
    cast PDMS
    3.1
    UV exposure
    2.5
    apply nano magnetic particles
    2.5
    Lithography mask
    1.9
    apply anti adhesive coat
    1.9
    Apply photoresist
    1.3
    lithography process
    0.6
    skilled operator
    10

    we depend to much on the skilled operator, by reducing the process that requires the skilled operator we can make the process a lot more simple

    Jun 22 2022 12:30:59 pm

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