Buy a Laser Micromachining System, or have it contract-manufactured?
Micro Parts Production Strategy: In-house production, or outsource to contract manufacturer?
A product development company will not want to start manufacturing a million widgets on a production run without first trying out different micromachining processes and materials. Remember, its just not laser micromachining that’s available. What about mechanical and FIB micromachining for prototypes, and then look at the possibility of using these as replication bases (molds).
Similar to writing wih a pen, laser micromachining in most respects is a serial process- one where each feature on a device is made one at a time. Exceptions do exist- like big excimers that can machine entire devices using a step-and-repeat process similar to silicon bulk/surface micromachinig.
Although parallel/batch processes can be expensive to begin with, some microdevices might be more amenable to mass production using parallel processes that culminate in replication using molding and/or electroplating. In fact, many of the commercially available microfluidic devices have been designed, prototyped and produced using silicon micromachined (MEMS) molds combined with polymer (PDMS is very common) or metal replication.
Once you settle on the 1) Design, 2) Material and, 3) Process, it is time to decide on your production strategy. Do you want to buy a micromachining system so that you have full control of not only the manufacturing process, but also time-schedules? Or, instead of in-house fabrication, outsource the manufacturing to the company that helped develop the process, like a Laser Micromachining service provider?
Service Providers vs. Product Developers
A contract-fabrication order that leads to a laser Micromachining System sale is the goal of many companies. It can be a profitable proposition when a customer decides to buy a laser micromachining system for in-house micorfabrication. However, for some other service providers, it is contract manufacturing that can be a honey pot. So, if you are a customer, what would you do?
Sour Deals
Often, the choice seems obvious, but neither sides consider the long-term scenario. When a deal turns sour, whether it be after a system sale, or during an outsourced contract manufacturing arrangement, both sides think the other is the devil incarnate. In reality, neither parties might be at fault- it could have been a cascading effect, with a vicious circle of ever-growing finger-pointing.
Advantages of a System sale: Seller’s Perspecive
Who doesn’t like a system sale? Same job shop set-up, just put in a nice enclosure, stencil your company’s name on it, prepare a user’s manual, and we are on our way! But it is not that simple… Integrating a laser, motion system, optics etc into one system is easy- provided the micromachining system is being operated by the service provider at their facility. It will not be the same as the one that is delivered to the customer. The system on which trial parts were made is run by experienced operators, with engineers on-hand to fix any issues and technicians who know how to adjust the tiny screws of mirror and lens mounts.
A customer-system needs to be idiot-proof: Enclosures, interlocks, sensors, rugged last mile beam delivery components, taco-proof the loading zone- lest your night-shift operator eating his dinner while loading parts doesn’t spill shreds of cheese onto the work surface.
Note to interns: De-ionized water out of a medical grade squirt bottle should not be used as the drink of choice with your to-go dinner. I don’t care if you get out of whack with your electrolyte balance, all I ask is that you don’t fall unconscious during your shift- we are already late on the last batch.
To conform with local/state/federal rules, the system needs to be transformed into a “safe for kids” model, unless you want to hear from your friendly government enforcer after an accident that was actually thought to be impossible until now. All this costs money in manpower and materials. However, companies have to make a profit, and they do this by marking-up the system. This markup is usually quite high because of the expertise and effort that goes into building these systems, and not because of material cost.
…and a Bonus
Another revenue area in a Laser System sale is the AMC. It might appear that the company is trying to scare the living daylights out of the customer by project the doomsday scenario and having them buy an AMC. In reality, it is often a good insurance policy, unless the customer is technically inclined and competent. However, remember that standard exclusions apply (but are not disclosed): Signing on the dotted line usually provides only a “best-effort” service policy. Its the same when you buy a car or a camera.
In an other article, we will look at the advantages of contract manufacturing from a manufacturer’s perspecive, as well as look at on-site fabrication versus outsourcing from a purchaser’s perpective.