Smart tools: laser macro/micro fabrication strategies for embedding fiber optic sensors within heterogeneous metallic structures

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Inspired by the fact that optics and photonics have been declared as key technologies for the 21st century by both the American Research Council and the European Union, the Engineering Directorate of the US National Science Foundation (NSF) has identified the integration of optical devices with engineering systems as one of the strategic research areas in its visionary plans. To address this challenging area of interest, this project aims to realize a new area in the manufacturing community called "Smart Tools", through the development of an embedding process to integrate optical sensors within metallic structures of a variety of manufacturing devices such as dies and cutting tools. The need to obtain in-situ information on the performance and lifetime of production tools is of prime importance to many manufacturing and oil industries. This requirement can be addressed through the use of embedded sensors, which will enable the monitoring of physical parameters at locations inaccessible by regular sensing systems. The use of smart metal tools will improve the overall efficiency and accuracy of the manufacturing process, which will, in turn, increase productivity.