Molecular dynamic based novel manufacturing methods for next generation of silicon wafers

There is pressing need for innovative manufacturing methods to fabricate silicon wafers. Historically, Loose abrasive slurry sawing (LSS) has remained the most popular process for producing PhotoVoltaic (PV) silicon wafers but higher productivity has pushed the usage of newly emerging technology known as fixed abrasive diamond wire sawing (DWS) to the forefront.

A typical DWS process, entails sawing large cylindrical ingots of silicon (on a preferred crystal orientation) using a series of parallel wires. The surface quality of the cut wafers attained by this method inevitably results in the formation of undesirable micro-fractures and cracks on the silicon cut surface. Currently there is limited in-depth understanding of the DWS process as the process is still in its infancy. Therefore, a significant opportunity exists in developing the DWS production process.

The project aims at developing of a scientific understanding of the DWS process will improve the yield and reduce the manufacturing costs, as it can contribute up to 20% of the wafer manufacturing costs. To understand the process, the project will take a simulation based approach involving the use of high end Finite Element Analysis (FEA). Eventually the aim of this project is to predict the material removal process as a function of the processing equipment and processing parameters.

The major beneficiaries of the research outputs from the Centre for Doctoral Training in Ultra Precision (CDT-UP) include UK manufacturing companies (especially SMEs), the University partners, including the two primary universities, and the wider UK universities engaged in Ultra Precision research, in addition to society in general. Benefits will be realised in terms of:- increased economic activity in the field of UP through spin-out companies, licensed technology outputs, and the realisation of new products made possible with the application of UP manufacturing capabilities; greater knowledge of and a wider appreciation of the technical capabilities of UP systems; the provision of highly trained PhD level personnel for UK industry to spearhead new ultra precision competencies; and the creation of new products for the market based on UP competencies and technologies, which have the potential for significant societal impacts in areas such as health-care, transport, energy generation, and communications.
The importance of ultra precision manufacturing to the UK economy and the key issues and barriers to economic success are highlighted in the main proposal which demonstrate the central role of ultra precision manufacturing technology in ensuring economic growth. Many emerging sectors and next generation products will demand ultra precise components (nanometre, and sub-micron-level tolerance). To date semiconductor systems, and microsystems (optical, mechanical, or electrical) use complex expensive process steps in their production. Such extensive process chains are needed to create even initial pre-production prototypes. This issue has become a significant barrier to SME's realising their innovative products requiring UP. We aim to develop ultra precision manufacturing technologies that will offer precision capabilities, with a reduced level of capital investment compared to traditional semiconductor fabrication routes. These include:- wide area roll-to-roll printing of electronic devices, optical films, and structured surfaces; novel micro machining technologies for the production of 3-dmensional components such as micro-mechanical elements, embossing and injection mould tools, and micro-embossing tools.; direct writing and accretion of nanoscale features of semiconductor materials for low cost prototyping of micro and nano systems.
Manufacturing success requires not only the generation of new knowledge, it also requires people with the ability to invent and innovate. The education and research training of the CDT-UP will be developed in partnership with the new EPSRC centre for Ultra Precision, a wide range of industrial collaborators, and other UK universities working in the field of UP. This leading educational centre will respond to both the industrial need of UK companies, and the educational development strategies of UK universities, in developing the people with the technical capabilities necessary to move from the inventive steps to innovation platforms, thereby increasing the potential for wealth creation in the UK. We ensure that UK manufacturing can meet the future technical and business challenges needed to compete globally. The potential of the UK's innovation capacity to create new high-end manufacturing jobs is significant. Maximising this wealth generation opportunity within the UK will however depend on successfully realising next generation innovative production systems. Without relevant production research, r&d infrastructure, and an effective technology supply chain, there will be a limit to the UK's direct employment growth from its innovation capacity, leading to a constant migration of UK wealth creation potential into overseas economies. CDT-UP will develop a significant number of highly trained manufacturing engineers who will be essential to provide the leadership necessary to drive UK high value manufacturing forward and provide the vision for future prosperity.