Description of Foothill College Nanotechnology Program, innovation value chain, and advanced manufacturing in Silicon Valley

1. From Lab to Fab => Training
for the Innovation Value
Chain
Robert D. Cormia
Foothill College

2. Overview
• SETM => Innovation Value Chain
• Advanced manufacturing
• Extensible technicians
• Start-up environments
• Training for life, building to scale

3. SRI/Boeing Study
• What do technicians do?
• What do technicians know?
• What don’t they know how to
do?
• Need relevant experience
• Solve relevant problems
Nanotechnology, Education and Workforce
Development - AIAA Technical Conference 2007 Vivian
T. Dang, Michael C. Richey, John H. Belk (Boeing),
Robert Cormia (Foothill College), Nora Sabelli (SRI),
Sean Stevens, Denise Drane, Tom Mason and …NCLT
and Northwestern University

4. Nanotechnician
Competencies
• Measurements
• Fabrication / process
• Modeling / simulation
• Knowledge of nanoscale
• Work in teams (SETM)
Deb Newberry Dakota County Technical College – University of Minnesota

5. Nanomaterials Engineering
• Challenging
applications
– Novel properties
– Novel structures
– New processes
• New structure –
property
relationships
http://tam.mech.northwestern.edu/joswald/

7. PNPA Rubric
• Application driven
process (A)
• Properties (P)
• Nanostructures (N)
• Fabrication (P)
• Characterization (N-P)
• The ‘Nanoengineering
Method’
A Rubric for Post-Secondary Degree Programs in Nanoscience and Nanotechnology

8. PNPA Rubric as a Compass
• As you work, as you learn, as you read:
– What are the applications? (A)
– What properties are needed? (P)
– What are the (nano)structures? (N)
– How do you fabricate / process it? (P)
• Use characterization tools to develop
structure property relationships (N-P)
• Fine tune process (P) to fine tune (N-P)

9. PNPA / 4-D Compass
Applications (A)
Nanostructure (N)
Properties (P)
Process (P)

10. PNPA Rubric - Applied
• In the workplace…
– Think broadly about devices / applications
– Visualize structures and their properties
– Understand fabrication / processing
– Think about characterization – constantly
• Are structure-properties characterized?
• Can structure-processing be improved?
• Apply PNPA in every ‘working
discussion’

11. SETM – Extensible
Technicians
• We don’t train for multidimensional
thinking required in a workplace
– Scientific knowledge
– Engineering process
– Technology know-how
– Manufacturing competencies
• Technicians need to think from all four
corners of SETM – just like PNPA (rubric)

12. SETM / 4-D Technicians
Science (S)
Technology (T)
Engineering (E)
Manufacturing (M)

13. SETM => Innovation Value Chain
• Scientific discovery
• Engineering prototypes
• Technology development
• Manufacturing scale-up
• From lab to fab =>
innovation value chain

14. Training for Success
• Workplace effectiveness
• Extensible careers
• Supporting innovation
• Learning platform
• Nanomaterials
engineering framework
Bill Mansfield, a technician at the New Jersey Nanotechnology Center at Bell Labs in Murray Hill, N.J., holds a reflective 8-inch
MEMS (micro-electro-mechanical system) disk in a "clean" room of the nanofabrication lab at Bell Labs.

15. 21 Century Technicians
st
• Have bachelor’s degrees!
– many from 20 to 25 years ago
• Need specific knowledge/skills
• Support all four ‘edges’ of innovation
– Think like a scientist, act like an engineer
– Problem solve in real-time
– Support manufacturing scale-up

16. Nanotechnology Program Outcomes

17. Introduction to Nanotechnology Nanomaterials and Nanostructures
•Scale and forces •Nanomaterials vs. ‘traditional’ materials
o Dominate forces at all scales of distance •Nanostructures and novel properties
•Emergence of properties at scale o Nanofibers, nanoparticles
o Melting point, plasticity, thermal and electrical conductance •Process => structure => properties => applications
•Self assembly process o Designing structures for end use properties
o Crystals, molecular networks, biomolecules •Types of materials
•Atom as a building block of materials o Glass, ceramic, metal, alloy, polymers and composites,
o Crystals, glasses, metals, liquid / networks •Types of properties
•Surface dominated behavior o Strength, plasticity, thermal and electrical conductance,
o Surface area vs. volume, surface properties vs. bulk, surface behavior electromagnetic
and chemistry •Fabrication basics
•Role of quantum mechanics o Fab facilities, tools, processes, CNT
o Conduction, phonons, interaction with light •Processing
•Applications of nanotechnology / devices o Heat treatment, quenching, alloys, composites, fibers
o Solar panels, fuel cells, semiconductors, ink, •Modeling and designing for desired properties
•Industries that use nanotechnology o Computer modeling of structure properties relationships
o Semiconductor, electronics, energy, medicine, advanced materials •Choice of materials and structures
•Characterization tools o Select for properties and applications
o Image (AFM/SEM), surface (AES/XPS), structure (XRD/TEM), and bulk •Characterization tools for nanostructures / nanomaterials
(XRF/EDX/WDX) o Image, surface, composition, structural
Nanocharacterization Nanofabrication
•Instruments and characterization tools •Type of fabs
o (AFM/SEM), surface (AES/XPS), structure (XRD/TEM), and bulk o Silicon, MEMS, Wafers
(XRF/EDX/WDX) o Clean room basics, air filtration, dust
•Types of analyses •Safety basics
o Materials characterization, process development, failure analysis o Vacuum equipment, High voltage
•High vacuum and high voltage basics •Silicon fundamentals
o Vacuum t safety, vacuum awareness, high voltage and safety o Deposition, masking, etching
•Sample preparation and handling •Virtual / physical tour of a silicon fab
o Cleanliness, cleaning, dust and vacuum considerations •MEMS basics
•Instrument selection o Silicon and polymer based MEMS
o Image, surface, composition, structure, physical properties •Nanochemistry
•Data gathering, analysis, and tabulation o Self Assembled Monolayers
o Instrumental techniques, data gathering , tabulation interpretation o Dendrimers, Quantum Dots
•Interpreting composition and chemistry, modeling structure •Thin film deposition
o Building atomic and molecular structure from composition, chemistry, o Vacuum deposition, Sputtering, CVD/PECVD
and x-ray data o Roll coating (web), Spin coat
•Using a LIMS, searching spectral databases •Plasma deposition
o Knowledge management tools to aid future problem solving o Plasma equipment, Gas chemistry
•Reporting data, writing formal industry reports •Surface modification
•Client management skills o Chemical, gas, plasma

19. Advanced Manufacturing
• Not just ‘high tech’, but ‘high value’
• From advanced materials to biofuels
• All aspects of clean energy technology
• Nanomaterials to specialty alloys
• Integrating disassembly into design

20. Advanced Materials
• Thin film coatings
• Nanopowders / nanoparticles
• Nanocarbon (CNT/CNSC)
• Polymers and composites
• Specialty metals / alloys
• Advanced biofuels

22. Carbon Nanospheres
(Onion Like Carbon) for
high energy batteries
Nanosphere mixed with Poly
Vinylidene Fluoride (PVDF) are
used in high performance energy
storage, especially in transportation
solutions. The surface of fullerene
soot is electrophilic and can have
dangling bonds, however the key
feature is the crystallinity of
graphene sheets. HRTEM (High
Resolution Transmission Electron
Spectroscopy) is an important tool
in characterizing the degree of
crystallinity in heat treated
fullerenes. A collaboration between
industry, government, and
academia is researching the
process development and
advanced manufacturing of
nanocarbon sphere chains (CNSC)
for a range of applications from
energy storage to composites.
http://www.personal.psu.edu/ckg5046/research.html

23. Carbon Nanotube Batteries
Lithium ion
batteries with
carbon nanotube
electrodes
charge faster,
safer, and last
10x longer
http://news.discovery.com/tech/new-lithium-batteries-could-last-10-times-longer.html

24. Advanced Manufacturing
• Clean energy
– Wind, solar, fuel cells
• Advanced biofuels
– 100M gallons/day 2022 target
• Biotechnology
– Nanomedicine, cancer vaccines
• Electric vehicles and batteries

25. Synthetic and Biosynthetic Fuels
Biosynthetic fuels are the key to reducing and eventually eliminating dependence
on petroleum, and blending of low carbon synthetic fuels. Biotechnology and
genetically engineered organisms are central to production of novel biosynthetic
fuels including hydrogen from algae.

26. Why we need biofuels at scale
• We can reduce and/or eliminate petroleum
– Reduce petrol from 400 M to 100 M gallons/day
• Step 1: increase fuel efficiency to 50 mpg
– Reduces liquid fuels to 200 M gallons day
• Step 2: increase biofuels to 100 M gal/day
– Reduces ‘petroleum’ to 100 M gallons/day
• Step 3: replace petroleum with ???
– Hydrocarbon engineering, other biofuels, etc.

27. Biofuel’s high hurdle
Today the US produces about 37
million gallons a day (mgd) of
ethanol, an amount that needs to
increase to about 100 mgd by 2022.
This goal is important for two
reasons. First, for resource depletion
(peak conventional oil production)
and second for GHG emissions.
Consider a scenario where vehicle
efficiency increases by a factor of 2
(from 22-25 mpg to 44-50 mpg). We
use ~400 mgd of gasoline a day
(10% ethanol). Our total ‘gasoline’
demand would drop to about 200
mgd from 400 mgd. Having 100 mgd
of advanced biofuels would provide
50% of out 200 mgd liquid
transportation needs, reducing our
reliance on hydrocarbon based
petroleum by 75% (50% from
efficiency and 50% from advanced
biofuels) providing both price stability
and significantly reduced GHGs.

28. Biomass to Biofuels
Berkeley Lab Opens Advanced Biofuels Facility

29. SETM => Advanced Biofuels
• Laboratory Research (S)
– Bioscience
– Bioengineering
• Pilot facility (E)
– Prototype 1,000 gal a day
• Demonstration facility (T)
– 10,000 gallons a day
• Commercial facility (M)
– 1M gallons a day / $1B yr

30. Algal Biofuels Forecast Scenarios

31. Evolution of Algal Biofuels
http://www.chem.info/Articles/2010/03/Alternative-Energy-Algae-Investment-Trends-Advanced-Biofuels-Insight/

32. Clean Energy – What is it Worth?
• Wind => $500 billion to offset coal by 50%
• PV => $500 billion to offset natural gas
• Biofuels => $150 billion a year in US fuels
• Electric Vehicles (EV) => $1 trillion
– 15% of current US fleet (30 million cars, ~ CA)
• Energy storage => $100 B grid storage, $1
trillion if 50% of cars were PHEV/EV (2020)
• Smart energy => $1 trillion for a modern grid

33. Building a Clean Energy Economy

35. Hydrogen Fuel Cells
Push conversion efficiency from
50 to 60 %, and ultimately to 75%
Develop a low carbon source of hydrogen
for fuel – and this is a real game changer!

37. Demanufacturing -
Remanufacturing
In a high technology economy where
some raw materials are both precious
and scarce, products will require
demanufacturing to recover
components and materials for
reprocessing, and remanufacturing.
Electric motor and battery technology
may be such an industry. Technicians
trained in complex disassembly,
materials safety, and advanced
manufacturing (problem solving skills).
These jobs will range in skills, and
may be very good training /
therapeutic for returning veterans with
Traumatic Brain Injury (TBI). These
are extremely important jobs and
competencies in an emerging
‘sustainable manufacturing economy’.

38. Training for R&D
• Internships matter!
• Developing ‘competency’
• Hands on learning
• Current technology
• Real-world problems
• Real-world mentors

40. Summary
• Innovation matters, scale
matters more!
• US needs to ‘reclaim’ advanced
manufacturing, esp. clean energy
• Technicians support SETM model
• Training needs to support SETM
• Internships are essential to a
SETM technician’s academics!