IC Hybrid Manufacturing Planning With SMT-Based Operation Sequencing
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Current hybrid-manufacturing approaches face challenges in planning cost-effective and efficient manufacturing steps for integrated circuits, often requiring additional post-processing operations when transitioning between additive and subtractive manufacturing technologies, leading to increased time-to-market and costs.
Innovation Solution
A system and method that determines a hybrid-manufacturing plan by converting manufacturing constraints into a satisfiability modulo theory (SMT) problem using a Satisfiability (SAT) modulo difference logic solver, optimizing the sequence of additive, subtractive, or modification operations based on a constraint matrix and cost analysis to minimize costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If additive and subtractive manufacturing are performed separately by different machines, then each manufacturing technology can be applied independently, but additional post-processing operations are required leading to increased time-to-market and manufacturing costs
Solution Approach 1:
The patent combines additive and subtractive manufacturing capabilities into a single hybrid manufacturing system. The system integrates material deposition (additive) and material removal (subtractive) operations in one machine, allowing seamless transitions between operations without post-processing steps. This merging eliminates the time loss associated with transferring workpieces between separate machines and performing intermediate post-processing operations.
2Ease of manufacture
If additive and subtractive manufacturing are performed separately by different machines, then each manufacturing technology can be applied independently, but additional post-processing operations are required leading to increased manufacturing costs
Solution Approach 1:
The hybrid manufacturing system merges additive and subtractive manufacturing capabilities into a single integrated platform. By combining these processes in one machine, the system eliminates the need for separate post-processing operations and multiple machine setups, thereby reducing overall manufacturing costs despite the increased complexity of the integrated system.
3Productivity
If current hybrid-manufacturing approaches complete additive manufacturing steps followed by subtractive manufacturing steps, then a systematic process can be established, but the sequencing may not be cost-effective or efficient
Solution Approach 1:
The patent implements dynamic sequencing of manufacturing operations based on real-time analysis of the workpiece geometry and process requirements. Rather than following a fixed additive-then-subtractive sequence, the system dynamically determines the optimal operation order by evaluating multiple factors including material properties, tool accessibility, and process constraints. This dynamic approach enables cost-effective and efficient manufacturing by selecting the most appropriate operation sequence for each specific workpiece.
Solution Approach 2:
The system changes the sequencing parameter of manufacturing operations based on workpiece-specific characteristics. By analyzing the geometric parameters, material properties, and process constraints of each workpiece, the system adjusts the operation sequence parameters to optimize for cost-effectiveness and efficiency. This parameter change allows the systematic process to adapt to different manufacturing scenarios rather than following a rigid sequence.
4Productivity
If current hybrid-manufacturing approaches complete additive manufacturing steps followed by subtractive manufacturing steps, then a systematic process can be established, but the sequencing may not be efficient
Solution Approach 1:
The system employs dynamic operation sequencing that adapts to each workpiece's specific requirements. By evaluating geometric complexity, material properties, and process constraints in real-time, the system determines the most efficient operation sequence. This dynamic approach reduces manufacturing time by avoiding unnecessary intermediate steps and optimizing the transition between additive and subtractive operations based on the actual workpiece characteristics rather than following a fixed sequence.
Data Source
AI summary
One embodiment of the present disclosure provides a system for determining a hybrid-manufacturing plan for manufacturing an integrated circuit (IC). During operation, the system can obtain a set of hybrid-manufacturing constraints for manufacturing the IC. The set of hybrid-manufacturing constraints can include a set of primitives, a set of atoms, and an atom end-state vector. An atom can correspond to a unit of spatial volume of the IC. A primitive can represent an additive, subtractive, or a mixed manufacturing process corresponding to one or more atoms of the IC. Next, the system can determine a plurality of feasible hybrid-manufacturing plans based on the set of manufacturing constraints. Each feasible hybrid-manufacturing plan can represent an ordering of the set of primitives that satisfies the atom end-state vector. The system can then determine costs for manufacturing the IC using the plurality feasible hybrid-manufacturing plans. The system can determine, based on the costs, an optimized hybrid-manufacturing plan for manufacturing the IC.