MATERIAL MATTERS

Issues in MaterialsManufacturing

In late January, the Bush administration announced that it was proposing anAdvanced Materials and Processing Program (AMPP) as a new FY93 initiative".. .to improve the manufacture and performance of materials to enhance the na-tion's quality of life, security, industrial productivity, and economic growth." Thisproposal carried with it a budget request to Congress for an additional 10% fund-ing for materials R&D. Barely one month later the President's science adviser, D.Allan Bromley, announced that a Manufacturing Initiative would undergo intensestudy and planning this fiscal year in preparation for proposed funding in FY94.

The April MRS Bulletin, with its focus on materials manufacturing, gave readerstimely technical insight into this aspect of materials science and engineering forseveral materials industries and manufacturing methodologies. As a further at-tempt to sharpen the awareness of scientists, engineers and managers, and tomore clearly identify issues inhibiting the successful application of laboratorywork, we asked representatives knowledgeable about manufacturing in severalindustries to present their views about the research-to-manufacturing process.The following comments are from Ed Bostick, who has spent a career in polymermanufacturing; from John Fan, who currently heads an advanced electronicsmaterials fabrication company; and from Peter Johnson of the Metal I'owder In-dustries Federation.

Most materials scientists are well aware that implementing their laboratorydiscoveries and developments in a manufacturing or fabrication setting is a slow,difficult process. We welcome additional comments from the materials communityas the Materials Research Society examines both the issues associated with materi-als manufacturing and the Society's possible role in improving the situation.

Gordon F.. PikeManager, Materials and Process Sciences Operations Office

Sandia National LaboratoriesChair, MRS External Affairs Committee

It's About TimeThere seems to be a ground swell of soul-

searching and self-examination by almostevery social group in the United Statesabout our productivity, especially aboutthe manufacturing process which createscapital goods. It's about time.

The science and technology communityhas an excellent record of creativity and in-novation. Tens of thousands of patents ex-ist. Our literature is active and full of newobservations that have scientific merit.Then, what is the problem?

I believe we have lost the ability to trans-late and implement this vast scientificwealth into manufactured goods for use byour world society.

As a result, science and technology havefallen into disfavor with the national forcesthat control financial resources. This situa-

tion has led to a spiral of downsizing, im-porting offshore research and develop-ment, and loss of leadership.

What should be done? Well, all scientificinstitutions in this country are part of ateam even if they don't realize it. This in-cludes academia, government, and indus-try. This team should first focus on plans tosolve implementation issues and relatethese plans to the National Academy ofSciences for real action. Does the govern-ment get involved? Of course it does, but

IMaterial Matters is a forum forexpressing personal points ofview on issues of interest to thematerials community.

not with endless parochial bureaucracyand stonewalling.

I suggest the following:1. Encourage university /government/industry/scientific relations.2. Encourage cooperative studies for grad-uate students in the manufacturing indus-try and government.3. Organize informally into groups of ad-vanced pathfinders, program technolo-gists, and trouble shooters (i.e., problemsolvers). Protect the advanced group at allcosts.4. Determine the needs of our society. Se-lect the ones that appear worthwhile andfocus on those.5. Achieve excellent basic process andproduct design, which will heighten qual-ity and simplify manufacturing.6. Reduce paperwork, useless reports, andlayers of supervision.7. Instill in our young advanced scientistsand technologists the idea that manufac-turing is interesting, challenging and excit-ing, and not beneath their dignity.8. Encourage only the advanced pathfind-ers to spend money on a scientific en-deavor if there is no perceived need orcustomer for it.9. Learn to listen and reduce the cathedralsof special interests from the scientific andtechnological environment.10. Market science and technology! Getthe order! Satisfy customers!

Edgar E. BostickPresident

Ed Bostick Technology Inc.

Materials ManufacturingShould Be a Practical,Acceptable Goal

As most of us are aware, advanced mate-rials, ranging from semiconductors, super-conductors, ceramics, etc., are the buildingblocks for whole generations of new de-vices and components. In many aspects,they will form the enabling parts of manysystems. There is no lack of scientificknowledge and discoveries of advancedmaterials in this county; however, there is astrong need for manufacturing know-howfor these materials. There are, of course,entrepreneurial companies which focus onpioneering the commercialization of ad-vanced materials. Successful adoption ofthese manufactured materials, which ad-mittedly are in the beginning of the chain,requires many enabling elements otherthan scientific know-how. Large capital in-vestments are needed, especially in devel-oping production machines, which areusually custom designed and constructedfor advanced materials. Because several

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MATERIAL MATTERS

machine generations are usually needed, astable, cohesive scientific and engineeringteam, coupled with a long-time commit-ment by the top management, are re-quired. All these attributes are usuallylacking in small start-up companies. LargeU.S. corporations, on the other hand, havea strong aversion to getting into materialmanufacturing areas since such invest-ments frequently do not satisfy their near-term financial returns.

As this dilemma continues, investmentsdry up, infrastructures weaken, and ad-vanced materials (or materials in general)are manufactured abroad. The wealth ofscientific and engineering talent in the U.S.academic institutions will have limited ca-reer opportunities, and the governmentalagencies will begin to question the useful-ness of all their funding if no serious com-mercialization in new materials results. Ibelieve this chain of events is already hap-pening. We must reverse this trend, or ourcompetitiveness in materials, and hencedevices and systems, will be greatly under-mined.

It is essential that we begin a serious dis-cussion on how to make materials manu-facturing a practical, acceptable goal. Thisrequires the coordinated efforts of smalland large companies, government agen-

cies, academic institutions, and profes-sional societies. The issues involved aremultiple, and the time to put our handsaround them is now.

John C.C. FanChairman & CEO

Kopin Corporation

Powder Metallurgy Struggleswith Lengthy Lead-Times

As a manufacturing technology for preci-sion metal components, the powder metal-lurgy field has struggled with lengthylead-times for turning R&D and pilot-plantideas into commercial products.

One industry expert told me it can take10-20 years to develop a new material into acommercially acceptable, viable product.Besides the staying power needed to de-velop new technology, people are some-times reluctant to change. Engineers feelcomfortable with the parameters of a triedand tested material, and are slow to changeto new ones. Many companies are alsoconstrained by management guidelinesthat call for quick payback times for an in-vestment. It is tough to get visionaries ontoboards of directors who will back a newidea for a long period of time.

The metal injection molding sector of the

powder metallurgy industry has beenaround for at least 15 years. Much R&Deffort has gone into this technology in rawmaterials and process equipment. But onlyin the last few years has metal injectionmolding reached the commercial stage ofsupplying products in critical applicationsin aerospace, defense, computers, fire-arms, and biomedical products. Today,about 60-70% of the orthodontic clips weuse are metal injection molding products.

The forging of powder metallurgy per-forms is another case in point. This tech-nology took quite a long time to develop,but soon all "Big Three" car companies willbe using powder metallurgy hot-forgedconnecting rods in their engines. Ford wasfirst, taking the plunge in the 1.9 liter en-gine for the 1987 Escort and Lynx models.

Better communication among research-ers, development engineers, and produc-tion people is needed to speed up theprocess from the lab to the productionfloor. Management also needs to bebrought into the loop. And of course,every new technology needs its "champi-ons" who persevere despite all odds.

Peter K. JohnsonDirector, Marketing and Public Relations

Metal Powder Industries Federation

1 9 9 2 MRS FALL MEETING ABSTRACT DEADLINE:JULY 1 , 1 9 9 2

Abstracts of contributed papers (one original) must be received at MRSHeadquarters no later than July 1, 1 9 9 2 . Abstract size is 5 in. (12.7 cm) wideby 5 in. (12.7) cm long. Be sure to indicate the appropriate symposium and alsoyour full name, mailing address, phone and fax numbers.

Mail abstracts to:

Materials Research SocietyATTENTION: ABSTRACT ENCLOSED9800 McKnight RoadPittsburgh, PA 15237

A number of symposia from this meeting will publish proceedings in the MRSSymposium Proceedings series. Camera-ready manuscripts for these proceedingswill be refereed at the meeting. Further information will be provided after theabstract deadline.

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