ASME CRTD Research Committee on Nanomanufacturing Technology

Nanomanufacturing Survey Results December 2012

Background
ASMEs nanomanufacturing activities include the Center for Research & Technology Development (CRTD) NanoManufacturing Research Committee and the ASME NanoEngineering Interdisciplinary Council. ASME is considering developing a workshop to provide a better understanding and assessment of the state of nanomanufacturing and the most pressing needs in nanomanufacturing research, education, and training. It needs to identify the challenges that industry and organizations in the nanotechnology and nanomanufacturing areas currently face. To accomplish this an online survey was conducted in June, 2012. The survey was sent to 6,522 individuals who had either purchased Nano-related products from ASME or participated in Nano-related activities (conferences, etc.). 334 started the survey and 139 completed the survey.

Key Findings
Most of the respondents take part in the commercialization of nanotechnology.
About half are involved in the commercializing of nanotechnology or currently enhance existing products or processes by incorporating nanotechnology. About three-quarters say they desire to enhance existing products or processes by incorporating nanotechnology.

Respondents play a variety of different roles in commercializing nanotechnology. In many instances the number of individuals involved in commercializing nanotechnology is small (<20 individuals). The most frequently mentioned products incorporating nanotechnology in the process of commercialization include:
Coatings, paints, and thin-films Nanoparticles and nano powders Semiconductors, nanowires, lithography, and print products 3

Key Findings (2)

Finding appropriate personnel, networking with others in the field, and learning about commercialization strategies were judged as the more pressing needs. The key challenge areas of greatest concern include:
Insufficient capital investment Long path to commercialization High cost of processing Process scalability

It appears the foreign competition, regulatory concerns, environmental safety and health, and unattractive market potential are viewed as key challenges of low concern consistent with the evaluations of different areas of need. There are specific products for which certain key challenge areas are of greater concern and other products for which certain key challenge areas are of lesser concern.
4

Key Findings (3)

Academic journals are the most utilized ways of stay abreast of advances in nanotechnology. However, development from industry and industrial needs are more often communicated through magazines and newsletters. A little more than one-third currently support professional or trade associations in the nanotechnology area. A little more than two-fifths (43%) of the organizations receive funding from the federal government for nanotechnology research and development.
This funding has led to a commercialized product(s) for 15% of the organizations receiving this funding; another 57% claim they have products currently in development.

Roles in Nanotechnology Commercialization

Play Role in Commercializing Nanotechnology Yes 44% Currently Enhance Existing Products or Processes by Incorporating Nanotechnology No 47%

No 56%

Yes 53%

Desire to Enhance Existing Products or Processes by Incorporating Nanotechnology No 25% Yes 75% 6

Roles in commercializing nanotechnology

Consulting 6% Materials Supplier Intermediate 4% Processor 5% Equipment Manufacturer 4% Component of Subsystem Supplier 4% Academic Lab/Organization 49%

Manufacturer/ Integrator/ Assembler 12% Energy, capital equipment 1% Contract or nonprofit R & D org 11% Government Lab/Agency 2%

What specific role does your organization play in commercializing nanotechnology?

Number of personnel involved in nanotechnology commercialization

More than 100 12%

51 - 100 7%

21 - 50 13%

Less than 10 52%

11 -20 16%

How many personnel are directly involved in your organizations nanotechnology commercialization activities?

Types of products incorporating nanotechnology being commercialized

Coatings, Paints and Thin-Films Nanoparticles and Nanopowders Semiconductors, Nanowires, Lithography & Print Products Nanofluidics and Filtration Products Electronic Devices, Displays & Optoelectronics Catalysis, Battery, Fuel Cells & Energetics Drug Delivery, Diagnostic Systems & Medical Implants Nano-Bio &Tissue Engineering Products Environmental Sensing & Remediation Products Computing, Design & Software Tools Nano-manipulation, Imaging & Visualization Tools Defense, Security, & Protective Gear

52 44

38
27 26 22 22 21 19 18 18

15
15 14 12 8 6 0 10 20 30 40 50 60

Biomarkers and Q-Dots

Transportation & Structural Products Personal Care, Nanofluids & Colloids Other Convergence Products

What types of products incorporating nanotechnology have been commercialized and/or are being developed?

Needs in Nano Manufacturing

Finding appropriate personnel to employ 51

Networking with others in the field Learning about commercialization strategies Interacting between your organization and federal agencies Protecting your intellectual property in the nanotechnology sphere Understanding the regulatory "maze" 0 35 10 20 30 40 Percent top-two box

47

47

44

41

50

60

To what degree do you have a need for the following. Please use a fivepoint scale where five indicates an extreme needs and one no need at all.

10

Key Challenges
Insufficient Capital Investment Long path to commericialization High cost of Processing Process Scalability Manufacturing resources not keeping pace with developments Multi-discplinary aspects impose complex resource needs Lack of development tools Material/product variability Shortage of qualified technical manpower Availability of raw materials Societal benefits not recognized Developing sustainable alliances/supply-chains Intellectual Property Issues Lack of qualified management/business skills Foreign Competition Regulatory Concerns Environmental Safety and Health Concerns Unattractive Market Potential 0 10 36 49 47 39

28 26 24 21 20 19 18 18 17 17 16 16 16 15
20 30 40 50 60

Percent Key Challenge

11

Key challenge areas for different products

Key Challenge Area 1. Insufficient investment capital Products Strongly Challenged Nano fluidics & Filtration Products Defense, security, & protective gear Nano-bio tissue engineering products Personal care, Nano fluids and colloids Convergence products Defense, security, & protective gear Semiconductors, Nanowires Convergence products Drug Delivery, Diagnostic Systems, & Medical Implants Products Less Challenged Transportation and Structural Products Computing, Design, and Software Tools Convergence Products

2. Long path of commercialization

3. High cost of processing

4. Process Scalability

Nano-bio Engineering Products Nano Manipulation, Imaging & Visualizations Tools Computer Design and Software Tools Personal care, Nano fluids and colloids Defense, security, & protective gear Electronic devices, displays & optoelectronics displays Biomarkers & Q-dots Convergence products

5. Manufacturing Resources not in pace with developments

12

Key Challenge Area

6. Multi-disciplinary aspects impose complex resource needs 7. Lack of development tools

Products Strongly Challenged

Electronic devices, displays & optoelectronics display Convergence products Personal care, Nano fluids and colloids Semiconductors, Nanowires Drug Delivery, Diagnostic Systems, & Medical Implants Defense, security, & protective gear

Products Less Challenged

Catalysis, battery, fuel, and energetics Semiconductors, Nanowires Electronic devices, displays & optoelectronics displays

8. Material/product variability

Defense, security, & protective gear Convergence products

Biomarkers & Q-dots Nanoparticulates & nanopowders

9. Shortage of qualified technical manpower

Personal care, Nano fluids and colloids Convergence products

Nanoparticulates & nanopowders Biomarkers & Q-dots

10. Availability of raw materials 11. Developing sustainable alliances/supply-chains 12. Societal benefits of nanotechnology are not recognized Defense, security, & protective gear Convergence products Electronic devices, displays & optoelectronics display Nano-bio Engineering Products Nano Manipulation, Imaging & Visualizations Tools Biomarkers & Q-dots

13

Key Research Challenges Faced

Absence of high-fidelity modeling and simulation tools, lack of knowledge on "physics of failure" of micro/Nano components and devices Acquiring research support for university research. Partnering with companies willing to aid in commercialization. Affordable development resources, patent trolls, All type of resources and IPR Allocating resources for research Best scalable way to produce nanoparticles Bonding of various materials Centralized execution, low flexibility in research proposals Complex manufacturing process leads to long cycles in development Consistency of processes and funding Control and Characterization; Computational Limitations Developing sustainable and reliable supply chains for processing the nanopolymer during each process Developing the right tools Doing good science Durable optical coatings on glass to tailor solar spectrum handling Getting buy-in from management to research nanomaterials. Hard to find materials or research related to materials Having facilities to scale up from research to commercial products Hiring good graduate students and making sure to have the necessary infrastructure How to scale up

What are the key research challenges that you face in your work on micro/nano manufacturing?

14

Key Research Challenges Faced (2)

I am working on thermal fluid behavior of Nanofluids experimentally and also numerically. Actually, there are not available all size of nanoparticles in the market. There are the lacks of different nanoparticles material in the market as well. The size which they indicate is not proper size as well. There is not any data base for stabilizing material for different Nano fluids. On the other hand regarding the safety issues, using the nanoparticles which already dispersed in the base fluid could be important which they are not in the market for all nanoparticles and also all size as well. Identifying the process steps needed to fabricate the device and then locating user fab that can support the process steps. Device verification is complex and expensive. It would be nice to have a user test lab along with a user fab (pay equipment use by the hour). Insufficient equipment for nanofabrication Insufficient funding Insufficient investment capital Interdisciplinary nature of the field require communication between professionals across the disciplines Irreproducibility at nano-scale It s application in the oil & gas industry. Keeping abreast or ahead of the curve in the development of commercial products and how they need to be evaluated. Lack of experienced staff for practical/industrial attractive applications with projection [even for the near future] Lack of industry funding. Lack of knowledge databases that connect commercial and research resources Lack of resources Lack of theoretical exposure

What are the key research challenges that you face in your work on micro/nano manufacturing?

15

Key Research Challenges Faced (3)

Large scaling consistent product Lead Free Solders Long path to commercialization (2) Manpower (2) Manufacturing sample of different structure Material availablities Measuring what you manufacture. Moving from nanofabrication to nanomanufacturing. Understanding which technologies are most likely to go to market first. Microfabrication Much of the leader in nanotech base a significant part of the research in non-reality. I was heavily in involved in nanotech in in the 1990s but moved on to other things when I found people like those at the foresight institute more interested in things like freezing your head when you die or working backwards from the future as their main goals instead of furthering nanotech in any real way. Multi-disciplinary aspects Nanomanufacturing still needs transition from the lab to the fab, this could only be done by development and not at research labs or academia Nanoparticles Obtaining federal funding. Prioritization of tip-based nano manufacturing as an important and viable technology Particles and contamination Process scalability Rapid identification of promising new product designs Reproducibility of properties on a large scale Reproducibility of results

What are the key research challenges that you face in your work on micro/nano manufacturing?

16

Key Research Challenges Faced (4)

Resolution, compatibility Rheology and processability of nano-particle laden melts and interfacial effects in multicomponent melts. Scale up Scale up to large production size/volume Scaling up, another major challenge is maintaining customer specs. Nano specs are difficult to get exact but customers demand specifics Screening / sourcing nanomaterials for incorporation in industrial scale equipment Shortage of qualified technical manpower Synthasis and characterizing of nanoparticles Testing/prove of concept The durability of products incorporating nanotechnology is called into question. Materials which rely on implanted or adsorbed nanoparticles are subject to failure. The seems to be a disconnect between the pure, fundamental science of nanotechnology and the broad implementation of such technology, especially at the societal level. Turn-about time Understanding nanoparticle dispersion behavior during wetting of solid substrates Understanding of the nucleation and first particle growth Validation and metrology of nanostrucutres is a key challenge We are into engineering consultancy We are trying to improve our Insulation Materials

What are the key research challenges that you face in your work on micro/nano manufacturing?

17

Key Tool and Infrastructure Challenges

Access to manufacturing and metrology toolsets is expensive Acquiring equipment grants. Adequate for prototyping and low volume demonstrators Availability (2) Capital Commercial instruments are highly specific and not usually customizable. As a result, working on nanomnufacturing often requires the development of custom instruments to help understand processes. This is expensive, time consuming, and forces the researcher to narrow scope to a specific process type (e.g., nano print lithography) which may or may not be the next big thing. Cost Cost and {tools + infrastructure} limited only to some big companies and renown Labs and universities Cost is too high Cost of electronic microscopes Cost, accessibility Developing special fixtures Developing the right tools Environmental safety and health concerns. Facilities Finding competent/knowledgeable commercial 3rd-party sources. We can always find academic sources, but those just can't produce to time/cost goals. Have a good chemistry to make samples High capital cost of tools, access to tools at universities is limited, tools are down a lot High investment and running cost, lack of exposure to available infrastructure High price

What are the key challenges that you face regarding the tools and infrastructure you use to work on micro/nano manufacturing?

18

Key Tool and Infrastructure Challenges (2)

I can't get myself hired by the people who need me Imaging Improve realization of nanoparticles Instruments, measuring Insufficient capital. Insufficient federal funding. Insufficient human resources who have an extensive background and solid expertise in nanotechnology Insufficient tools Knowing the government standards and how best to analyze products for "nano" related short-comings. Lack of R&D sponsored to solve specific industry problems Lack of screening tools Lack of tools/reference instruments supporting consistent results for verification Large profit margins of manufacturers due to limited sales Lighting (LED vs. laser) Long lead times for vacuum coating and processing equipment Losing objective decisions. Hydrophobia surfaces depend on a science that is objective from user to user Low processing temperature and higher re-melting temperatures maintenance issue of infrastructure Making friends in R&D Labs on challenging areas Making sure the SEM, EM, AFMs, and other characterization tools run properly Modeling and layout tools are very expensive for a small business. Must rely on open source software and general purpose tools. The takes longer and is more error prone. User fabs are great for R&D but are not good for small scale production.

What are the key challenges that you face regarding the tools and infrastructure you use to work on micro/nano manufacturing?

19

Key Tool and Infrastructure Challenges (3)

Most of the fabrication tools need to be retrofitted with in-house solutions to make them compatible to nonmanufacturing Old or unreliable R&D scale equipment Precise control over the dimension of the structures Rapid nondestructive nanoscale characterization Reliability. Reliable, robust, "affordable" methods of implementing nanotechnology are needed. Sanction Scale and automation Scale-up of lab processes Scaling dimensions Searching the application in medicine Shortage of qualified technical manpower Stability and reproducibility The nanoparticle size is not exact. The shape of particles is not the same as well. The conventional thermal conductivity meters cannot work well for Nano fluids. The tools means development that are typically done during prototyping and not at research labs The tools required are not commercially available because the need has not been previously realized We don't do microfiber so there is no interest in pursuing anything we can't farm out. We invented smart blending machinery that is scalable. However, more work is needed to improve uniformity in resulting materials. Workforce training and understanding

What are the key challenges that you face regarding the tools and infrastructure you use to work on micro/nano manufacturing?

20

Safety Challenges Faced

A better understanding is needed of how nano-particles migrate from matrix materials to the environment and on biodegradation. Air quality is greatly affected by the nanoparticles. We spend a great deal of effort and money into implementing safety measures. Breathing, air quality, toxicity research variances EHS of nanomaterials is a key issue in commercialization Evolving regulations Government policy issues Insufficient knowledge regarding proper safety protocols for handling nanoparticle powders and dispersions It is generally unknown how the human body will respond to nanoparticles and nano machines etc. and there is a fair amount of indication that these could pose significant health problems. Lack of central data repository that is freely accessible Lack of long term exposure data for many nano materials Laser Lasers and high voltages Looking out for our insured customers so that they don't have an issue; and we lose face. Many unknowns concerning health impacts of nanomaterials Most people follow the rule safety first and this is proper Nanoparticle inhalation. Process chemicals and byproducts are often toxic. Poor quality of available nanoparticles Potentially, touch handling of coated surfaces or rework/grinding of coated surfaces could be a vector for human exposure in skin/eyes, lungs

What specific challenges do you face regarding the safety of your work?

21

Safety Challenges Faced

Proper ventilation Safety is not an issue, however, insufficient data on the particle properties of different materials e.g. toxicity etc. Shortage of qualified technical manpower Standardization Standards The influence of nanoparticles There are still lingering concerns about the consequences of the proliferation of nanomaterials into daily use. There is the lack of exact standard for each nanoparticles regarding environmental issues and also in the case of accident in the laboratory. How much particle can be exposure in the environment, and how we can sense it? There is not enough research available regarding the contact of different nanoparticle with different part of human body (skin, lung, eyes). Time and effort required of students to ensure compliance. Toxic chemicals that we have to use fabricate micro/nano-scale devices Toxic chemicals to be handled Toxicity of most nanomaterials Unknown behavior of active nanomaterial in animals and human bodies User fab safety is very good and rely on this. Once device is fabricated safety issues not significant. Keeping the device clean and uncontaminated for packaging more of a concern. Very small, airborne properties

What specific challenges do you face regarding the safety of your work?

22

Ways of keeping up with advances in nanotechnology and innovations from industry in nanotechnology
Innovations from industry and industrials needs related to nanotechnology Advances in nanotechnology

Academic Journals Magazines Read newletters Network with colleagues Attend Workshops Books Webinars Professional or trade association Attend continuing education courses Participate in list serves Websites Other 0
4 4 4 8 9 13 13 17 22 29 25 27 35 34 39

43
45 42 48

64

39 40

23 22

10

20

30

40

50

60

70

How do you keep up with . . . ? (check all that apply)

23

Funding from federal government resulting in commercialized products

No, do not 57% Yes received funding from federal goverment for nanotechnolo gy research and development 43%

Funding resulted in commercialized product(s)?

Yes 15%

Has your organization received funding from the federal government from nanotechnology research and development?

Product(s) currently in development 57%

No 28%

Did this funding result in a commercialized product(s)?

24

Professional or Trade Associations in the Nanotechnology Area

Support Professional or Trade Association in the Nanotechnology Area

Yes 37%

No 63%

25

Jobs in Nano Manufacturing

A program or project leader engineers involved with micro/nano manufacturing

23

A design engineer involved with mico/nano manufacturing

20

Owner, CEO, or Senior Engineer

12

A plant floor engineer involved with micro/nano manufacturing

Other

43

10

20

30

40

50

26

Years of Experience

Less than 2 years

2 -5 years

16

6 - 10 years

24

11 - 20 years

19

More than 20 years

20

Not employed as an engineer (other type of professional)

0 5

12

10

15

20

25

30

Q. I have been a practicing engineer . . . .

27

Key Findings
Most of the respondents take part in the commercialization of nanotechnology.
About half are involved in the commercializing of nanotechnology or currently enhance existing products or processes by incorporating nanotechnology. About three-quarters say they desire to enhance existing products or processes by incorporating nanotechnology.

Respondents play a variety of different roles in commercializing nanotechnology. In many instances the number of individuals involved in commercializing nanotechnology is small (<20 individuals). The most frequently mentioned products incorporating nanotechnology in the process of commercialization include:
Coatings, paints, and thin-films Nanoparticles and nano powders Semiconductors, nanowires, lithography, and print products 28

Key Findings (2)

Finding appropriate personnel, networking with others in the field, and learning about commercialization strategies were judged as the more pressing needs. The key challenge areas of greatest concern include:
Insufficient capital investment Long path to commercialization High cost of processing Process scalability

It appears the foreign competition, regulatory concerns, environmental safety and health, and unattractive market potential are viewed as key challenges of low concern consistent with the evaluations of different areas of need. There are specific products for which certain key challenge areas are of greater concern and other products for which certain key challenge areas are of lesser concern.
29

Key Findings (3)

Academic journals are the most utilized ways of stay abreast of advances in nanotechnology. However, development from industry and industrial needs are more often communicated through magazines and newsletters. A little more than one-third currently support professional or trade associations in the nanotechnology area. A little more than two-fifths (43%) of the organizations receive funding from the federal government for nanotechnology research and development.
This funding has led to a commercialized product(s) for 15% of the organizations receiving this funding; another 57% claim they have products currently in development.

30