SBIR Phase II: Novel Manufacturing Method for Precision Optical Encoders

这个小企业创新研究（SBIR）第二阶段项目旨在开发一种新的制造方法来生产高精度光学编码器。编码器是测量位置的传感器，无论是线性的还是角度的，并将其转换成电子信号。现代自动化和机器人系统严重依赖于编码器的精确定位和运动控制。全球编码器市场预计将从2022年的24亿美元增长到2028年的44亿美元。为了进一步创新和制造复杂的下一代产品，如先进的微芯片、植入式医疗设备和精确的武器系统，需要越来越精确的编码器。随着设计规范变得越来越严格，满足高精度编码器需求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，以经济有效地生产具有超过一个数量级精细基本分辨率的编码器。这个项目的智力价值集中在开发一种有可能彻底改变光学编码器制造的技术。传统的编码器生产包括使用接触光刻技术复制主掩模的图案。然而，这个过程需要一个全尺寸的光掩模，在设备中引入缺陷和错误，并限制了可实现的精度和分辨率。为了解决这些缺点，一种新型的高分辨率投影光刻系统正在开发中，以驱动增材微加工技术。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的生产，提高了制造成品率，缩短了交货时间。第二阶段的研究活动包括全尺寸硬件原型的开发，其性能可追溯到NIST（国家标准与技术研究所）标准，以及建立必要的基础设施来支持新开发的技术。该奖项反映了美国国家科学基金会的法定使命，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。

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.