SBIR Phase II: Novel Manufacturing Method for Precision Optical Encoders

SBIR 第二阶段：精密光学编码器的新型制造方法

• 批准号: 2322184
• 负责人: Sergey Zakharov
• 金额: $ 100万
• 依托单位: ZS SYSTEMS LLC
• 依托单位国家: 美国
• 项目类别: Cooperative Agreement
• 财政年份: 2023
• 资助国家: 美国
• 起止时间: 2023-10-01 至 2025-09-30
• 项目状态: 未结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=2322184&HistoricalAwards=false
• 关键词: SBIR; Phase; II; Novel; Manufacturing

This Small Business Innovation Research (SBIR) Phase II project aims to develop a novel manufacturing method to produce high-accuracy, optical encoders. Encoders are sensors that measure position, either linear or angular, and convert it into an electronic signal. Modern automation and robotics systems heavily rely on encoders for precision positioning and motion control. The global encoder market is projected to reach $4.4 billion by 2028, growing from $2.4 billion in 2022. Increasingly accurate encoders are needed to further innovate and enable the manufacturing of complex next-generation products, such as advanced microchips, implantable medical devices, and precision weapon systems. As design specifications become more stringent, the need to meet the demand for high-precision encoders becomes paramount. Successful completion of the project will establish a pilot capability to cost-effectively produce encoders with over an order of magnitude finer fundamental resolution.The intellectual merit of this project is focused on developing a technology that has the potential to revolutionize the manufacturing of optical encoders. Traditional encoder production involves using contact photolithography to replicate a pattern from a master photomask. However, this process requires a full-size photomask, introduces defects and errors into the device, and limits the achievable accuracy and resolution. To address these drawbacks, a novel, high-resolution, projection lithography system is being developed to drive an additive micro-fabrication technique. The new approach offers numerous advantages, including economically viable production of precision encoders with sub-nanometer resolution, improved manufacturing yield, and shorter lead times. The Phase II research activities encompass the development of a full-size hardware prototype with performance traceable to NIST (National Institute of Standards and Technology) standards, as well as the establishment of the necessary infrastructure to support the newly developed technology.This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

这个小型企业创新研究（SBIR）第二阶段项目旨在开发一种新的制造方法，以生产高精度的光学编码器。编码器是测量线性或角度位置的传感器，并将其转换为电子信号。现代自动化和机器人系统严重依赖编码器进行精确定位和运动控制。预计到2028年，全球编码器市场将从2022年的24亿美元增长到44亿美元。需要越来越精确的编码器来进一步创新和实现复杂的下一代产品的制造，例如先进的微芯片，植入式医疗设备和精密武器系统。随着设计规格变得越来越严格，满足高精度编码器的需求变得至关重要。该项目的成功完成将建立一个试点能力，以经济有效地生产编码器超过一个数量级更精细的基本分辨率。该项目的智力价值集中在开发一种技术，有可能彻底改变光学编码器的制造。传统的编码器生产涉及使用接触光刻法从主光掩模复制图案。然而，该工艺需要全尺寸的光掩模，将缺陷和误差引入到器件中，并且限制了可实现的精度和分辨率。为了解决这些缺点，正在开发一种新颖的高分辨率投影光刻系统以驱动增材微制造技术。这种新方法具有许多优点，包括经济上可行的亚纳米分辨率精密编码器生产，提高制造产量，缩短交货时间。第二阶段的研究活动包括开发一个性能可追溯到NIST（美国国家标准与技术研究所）标准的全尺寸硬件原型，以及建立必要的基础设施来支持新开发的技术。该奖项反映了NSF的法定使命，并通过使用基金会的知识价值和更广泛的影响审查标准进行评估，被认为值得支持。