Published Article / This paper investigates the challenges of employing Van der Waals forces in micro-material handling since these forces are dominant in micro-material handling systems. The problems include the creation of a dust-free environment, accurate measurement of the micro-force, and the efficient picking and placing of micro-work pieces. The use of vacuum suction, micro-gripper's surface roughness, geometrical configuration and material type are presented as alternatives to overcome the challenges. An atomic force microscope is proposed for the accurate measurement of the Van der Waals force between the gripper and the micro-work piece.

Published Article / This paper explores the manipulation of Van der Waals' forces by geometrical parameters in a micro-material handling system. It was observed that the flat-flat interactive surfaces exerted the highest intensity of Van der Waals' forces followed by cone-flat, cylinder-flat, sphere-flat and sphere-sphere interactive surfaces, respectively. A conical micro-gripper proved to be versatile in manipulating the Van der Waals' forces efficiently in a 'picking up' and 'releasing' mechanism of micro-work parts. It was deduced that the pick-up position should be rough and spherical, and the placement position should be smooth and flat for an effective 'pick-and-place' cycle to be realised.

Thesis (PhD)--Stellenbosch University, 2012. / This doctoral dissertation focuses on the application of Van-der-Waals’ forces in micromaterial handling. A micro-material handling system consists of four main elements, which include: the micro-gripper, the micro-workpart, the picking up position and the placement position. The scientific theoretical frameworks of Van-der-Waals’ forces, presented by Van der Waals, Hamaker, London, Lifshitz, Israelachvilli, Parsegian, Rumpf and Rabinovich, are employed in exploring the extent to which these forces could be applied in a micromanufacturing situation. Engineering theoretical frameworks presented by Fearing, Bohringer, Sitti, Feddema, Arai and Fukuda, are employed in order to provide an in-depth synthesis of the application of Van-der-Waals’ forces in micro-material handling. An empirical or pragmatic methodology was adopted in the research. The Electron Beam Evaporation (e-beam) method was used in generating interactive surfaces of uniform surface roughness values. E-beam depositions of copper, aluminum and silver on silicon substrates were developed. The deposition rates were in the range of 0.6 – 1.2 Angstrom/s, at an average vacuum pressure of 2 x 10-6 mbar. The topographies were analysed and characterised using an Atomic Force Microscope and the corresponding rms surface roughness values were obtained. The Rumpf-Rabinovich equation, which gives the relationship of the exerted Van-der-Waals’ forces and the rms surface roughness values, is used to numerically model the results. In the final synthesis it is observed that the e-beam depositions of copper are generally suited for the pick-up position. Aluminum is suited for the micro-gripper and silver is suited for the placement position in an optimised micro-material handling system. Another Atomic Force Microscope was used in order to validate the numerically modelled results of the exerted Van- der-Waals’ forces. The aim was to measure the magnitude of Vander- Waals’ forces exerted by the e-beam depositions and to evaluate their applicability in micro-material handling operations. The measurements proved that Van-der-Waals’ forces exerted by the samples could be used for micro-material handling purposes on condition that they exceeded the weight of the micro-part being handled. Three fundamental parameters, ie: material type, geometrical configuration and surface topography were used to develop strategies of manipulation of micro-materials by Van-der- Waals’ forces. The first strategy was based on the material type variation of the interactive surfaces in a micro-material handling operation. This strategy hinged on the fact that materials have different Hamaker coefficients, which resulted in them experiencing a specific Van-der- Waals’ forces’ intensity during handling. The second strategy utilised variation in the geometrical configuration of the interacting surfaces. The guiding principle in this case was that, the larger the contact area was, the greater the exerted Van-der-Waals’ forces would be In the analytical modelling of Van-der-Waals’ forces with reference to geometrical configuration, a flat surface was found to exert more force than other configurations. The application of the design, for purposes of manufacturing and assembling (DFMA) criteria, also proved that flat interactive surfaces have high design efficiency. The third strategy was based on surface roughness. The rougher the topography of a given surface was, the lesser the Van-der-Waals’ forces exerted were. It was synthesised that in order for a pick-transfer-place cycle to be realised, the root-mean-square (rms) interactive surface roughness values of the micro-part (including the picking position, the micro-gripper, and the placement position) should decrease successively. Hybrid strategies were also identified in this research in order to deal with some complex cases. The hybrids combined at least two of the aforementioned strategies.

Thesis (MScEng)--Stellenbosch University, 2013. / ENGLISH ABSTRACT: There is a need for a coarse-to-fine positioning system as per a case study presented by the project collaboration partner, the Technical University of Chemnitz. The case study involves the picking and placing of piezo-ceramic micro parts into milled micro cavities. The focus of the project is the creation and development of a systematic approach for the design and the implementation of a coarse-to-fine positioning system for micro material handling. A second focus is to determine the applicability of the system for highly accurate and repeatable micro drilling and micro-milling. A systematic approach entails combining innovation management (assists in overall project structure), systems engineering (assists in specific design steps and tools) and research questions. Micro-milling was achieved, however the system proved unsuitable for highly accurate and repeatable micro drilling. The coarse-to-fine positioning system was successfully designed, built, and tested for accurate micro material handling. / AFRIKAANSE OPSOMMING: Daar bestaan ’n behoefte aan ’n grof-tot-fyn-posisioneringstelsel - soos blyk uit die gevallestudie uiteengesit deur die samewerkende projekvennoot, die Tegniese Universiteit van Chemnitz. Die gevallestudie behels die uitsoek en plasing van piezo-keramiek partikels in gefreesde mikroholtes. Hierdie projek het gefokus op die skepping en ontwikkeling van ’n stelselmatige benadering tot die ontwerp en implementering van ’n grof-tot-fyn-posisioneringstelsel vir mikromateriaalhantering en mikromasjienering. ’n Stelselmatige benadering behels dat innovasiebestuur (hulp met die algehele projekstruktuur), stelselingenieurswese (hulp met spesifieke ontwerpstappe en -hulpmiddels) en navorsingsdoelwitte gekombineer word. Die geïmplementeerde stelsel is eksperimenteel getoets en daar is bevind dat dit aan die spesifikasies en vereistes voldoen.