Transforming Innovation into Scalable Solutions
Summary
The company was looking for a strategic partner to validate their groundbreaking ALD process. They needed a business ally who could convert their proof-of-concept laboratory tool into a reliable and reproducible electromechanical manufactured product.
Manufacturing Challenge
- Stringent Timeline - Implement efficient processes to complete the project within a limited timeframe.
- Constrained Budget - Manage project costs effectively by optimizing resource allocation to stay within budget.
- Design and Development - Create a sophisticated yet reliable process machine that ensures consistent deposition results
- High-Stakes Environment - Operate within an industrial context where reliability is critical, minimizing the risk associated with equipment failure.
Systems Assembly Process
Step 1: DFMA & Engineering Collaboration
We start with evaluating critical system characteristics and boundaries for manufacturing. Our MFE team reviews the design package to identify alternative methods or designs that enhance these characteristics.
Step 2: PFG Usage
The CNC machine shop at Innovent enables fast R&D at the project’s start and allows for design changes during assembly. Components like the process chamber, manifolds, and heater blocks are developed and made in-house.
Step 3: SWG Usage
Process chambers and gas management systems aren’t one-size-fits-all; each customer requires a tailored setup. Our batch building approach, followed by 1-2 piece customizations, helps reduce costs and lead times for our customers.
Step 4: SMG Usage
This is where the product comes to life. Our technicians bring the frame and sub-assembly kits into the build cell in our class 100K room for assembly. We finish the process with Factory Acceptance Testing (FAT), enabling drop-shipping to customers worldwide.
Step 5: Supply Chain Management
Our materials team uses a forecast approach, often buying long lead items like pumps, regulators, and custom electronics up to 52 weeks in advance. This allows us to build, test, and ship orders within 12 weeks of receiving a factory order sheet.
Step 6: User Training
There are instances where the end customer will come to the Innovent facility to be trained on how to use the tool ahead of it leaving the facility. This allows for a more streamlined startup process for the end user once the tool is in the field.
Innovent Solution
Following the completion of the business plan, our engineering team launched a Design for Manufacturability (DFM) initiative, utilizing cutting-edge design principles and precise process parameters to develop an advanced electromechanical system. By concentrating on critical factors—such as gas flow, heating, cooling, and vacuum control—we delivered a solution with superior performance, tailored specifically to meet client requirements.
The final design integrated a range of custom components, meticulously fabricated and assembled in-house, including precision-machined and welded vacuum chambers, plate heaters, and process gas lines. Additionally, we leveraged our established supply chain to efficiently procure key elements such as frame weldments, electronics enclosures, and external panels, further streamlining the manufacturing process.
As the design evolved and the Bill of Materials (BOM) expanded, we proactively engaged with new suppliers to secure top-quality commercial components and specialized parts, ensuring a robust and reliable final product.
"At Innovent, our vertical integration gives our customers a distinct advantage. We collaborate on technology concepts like the ALD platform, track component progress through machining and welding, and bring it to life in our cleanroom. This streamlined process accelerates time to market, lowers costs, and ensures our customers top-quality, high-performance systems, built to specifications." Tom MacDerment, Director of Engineering
Innovent's Capabilities Utilized
- Precision Fabrication - CNC machining of flanges, vacuum components, through post welding of chambers
- Orbital Tig Welding - Two distinct gas panels and a network of interconnecting gas lines for optimized performance
- Clean Room Assembly - This system is assembled in a Class 100K cleanroom, specifically designed for end-use applications
Business Impact
Innovent's solutions have fueled business and market growth for our client and have resulted in substantial time savings, efficiency improvements, and enhanced quality. By effectively addressing complex manufacturability challenges, they empowered their client to thrive in a competitive marketplace, reinforcing their position and driving long-term success.
This effort led to the successful scaling of a revolutionary Atomic Layer Deposition (ALD) tool, significantly impacting the nanotechnology semiconductor industry. Through their robust Design for Manufacturability (DFM) program, this product evolved into several innovative models, each incorporating cutting-edge technology and enhanced reliability.
While the client focuses on their core product development, they leave everything else up to Innovent.
Interested in learning if Innovent has a solution for you? Reach out to IES today and we'll help find a tailored solution for you.
This case study was originally posted to Innovent.