cooperation projects
Collux ZIM project funding
By the end of 2020 we will have together with the Chair for technical chemistry at the University of Duisburg-Essen and the Company CryLas GmbH from Berlin carried out a collaborative project.
This project was Central Innovation Program for SMEs (ZIM) promoted. The ZIM is a nationwide funding program that is open to all technologies and sectors, with the aim of sustainably strengthening the innovative power and thus the competitiveness of medium-sized companies. The technological innovation content and good market opportunities of the funded R&D projects are essential for approval (https://www.zim.de/ZIM/Redaktion/DE/Article/ueber-zim.html).
Division of work areas
The company CryLaS GmbH was involved in the selection of a suitable laser system and the development of the electrical system, while the University of Duisburg-Essen was entrusted with the process engineering basics and the overall integration of the machine.
Our scope of duties included product/design development, device ergonomics, housing construction and industrialization of the prototype as well as presentation creation.
The specification
project flow
In the first phase of work, it was necessary to precisely define the general conditions of the project. The outer dimensions of the device housing, which were adapted to the circumstances of the environment, were relatively clear. Compactness has been defined as one of the primary goals of product development, as space on laboratory workbenches is limited and multiple devices often have to be placed side by side. This resulted in maximum dimensions in depth and height. A width has not been set for the time being. Basically, however, it was important to keep the footprint of the device as small as possible.
At the same time, the team from the university and the company CryLaS developed a first possible technology package, consisting of optics and electronic components, which defined the minimum dimensions of the housing. For the construction of the machine, the following applied: the more compact the housing, the more cost-effective and easy to integrate the device is in production and in use.
It was determined that the nanocolloids should be produced with the highest possible purity. The starting materials should be three precious metals (gold, silver and platinum) and a colloid medium (fluid).
So we needed both an exchangeable material cartridge and three liquid containers, because in addition to the fluid we also needed a container for the liquid to flush the system and a stabilizer solution.
In addition, a release quantity was defined as a measure for the intended collection vessel.
While the University of Duisburg-Essen and CryLas were conducting various series of tests to determine the prerequisites for optimal productivity of the ablation (process of colloid creation), we created the first ergonomic and topology concepts based on the key data known at the time.
For this purpose, the questions had to be answered beforehand as to which functions the machine has and which requirements must be met in the area of conflict between users, environment and technology.
The following subject areas could be defined by the schematic drawing of the nano-automatic machine:
- fluid delivery
- Target
- UI
- collection vessel
- inner workings
- housing construction.
In this way, it was possible to determine which factors were set and for which sub-areas new concepts were required.
To support this, we created a process matrix. With the help of the plan, we were not only able to simulate a detailed course of action for the user, but also to disclose weak points and potential risks in the process.
In order to ensure good device ergonomics, a particular focus was on investigating the interaction points between humans and the device. As a result, we were able to define areas of action. These include operation via the digital interface, filling and replacing the fluid tanks, inserting or replacing the target housing and removing the finished precious metal colloid.
In order to check ergonomics and function, we made mockups of three favorite construction variants. At this early stage of the process and in the development of these ergonomic concepts, the "design" in the sense of an aesthetic, external design did not play a role. It is important that the functionality of a device is guaranteed first, so that the aesthetics can then be matched to the function.
Our workshop infrastructure also proved to be necessary and helpful in this project. We developed a removable material cassette, which we produced in our in-house 3D laboratory using 3D printing. We made these available to the university so that the function and tightness of the cassette could be tested in the test series and tested in connection with the ejection mechanism, which we also developed.
"How can we imagine the case?"
In the next step we started with the design and technical implementation of the machine housing. An important step, because up until now we only had a concept and, thanks to the prototypes, an idea of how the structure would be. The project partners initially found it difficult to imagine how the black cardboard boxes would become a real device. What we needed was a suitable visualization. In addition to the many skills, the designer's ability to turn ideas into real products is the decisive factor.
We developed a design for the machine that was aesthetic, based on ergonomic knowledge, met all safety requirements and was easy to implement according to the production method.
The small series of 20-500 pieces required production methods without expensive mold or jig construction. Here it became clear once again that no compromises in design are necessary, even with major restrictions in terms of manufacturing options. Since we have already worked successfully on projects with similar issues in the past, we were able to draw on our experience in the field of design with bent sheet metal and folded parts.
Taking the requirements catalog into account, two design variants were created. One variant impressed with its minimal footprint, while the other variant was based on frontal operation as a central feature of the design.
These were presented and discussed at a project meeting. The main difference is the location of the two fluid containers. The "easy front access" variant convinced all project partners unanimously in terms of handling and design potential.
Iteration loops are part of our everyday life
Since the laser system used up to that point did not achieve the desired performance and the device would not have been sufficiently competitive on the market in this configuration, a more powerful laser beam source had to be used and tested again. The alternative laser system finally provided the desired productivity. As a result, the device topology had to be revised and the design and CAD had to be adapted to the new, larger installation space of the technology.
Correction loops are part of the development process and are valuable in early phases, since there is still the opportunity to implement them without great expense. These types of adjustments and optimizations are also part of our day-to-day business in other projects.
In particular, the aspect of possible scaling, which was already discussed when evaluating the two design variants, now turned out to be a great advantage.
In this way, the adaptation could be implemented without changing the character and the original design ideas of the machine.
prototyping
Our final work package consisted of putting the developed design in our prototype workshop implement. During planning and construction, care was taken to ensure that the housing can be built back to 100% in the prototype stage so that any changes can be made afterwards. For example, instead of permanent welded joints, the housing parts were initially screwed together. Later, in series production, various screw connections can be replaced by welds, which further reduces assembly work and production costs. After receiving the externally manufactured housing parts, which we had previously designed in CAD, we were able to start assembling the functional prototype. Made of bent sheet metal and folded parts, milled parts , screws and 3D printed parts , through painting, assembly and pasting with product graphics, the first two nano fully automatic machines were created step by step.
The conclusion of the project was the insertion of the mounting plate with the laser system and the connection of the housing and the technical unit.
The result is two functional prototypes that, as planned, can be used to present the project idea at trade fairs or similar events and for initial field tests.
The result
Wir erachten den Transfer von Wissen und innovativen Forschungsergebnissen aus den akademischen Bereichen in die Industrie als besonders wichtig. Deshalb sind wir stolz, Teil der Kooperation sein zu können und als Innovationstreiber und umsetzungsorientierte Partner, Ideen wirtschaftlich in den Markt zu bringen. Wir halfen nicht nur bei der Formfindung des Automatengehäuses und dessen Ergonomie, sondern leisteten auch bei der Prozessoptimierung zur Erstellung des Kolloides unseren Beitrag. Das erklärte Ziel der Ausgründung ist für das Jahr 2022 geplant. Hierfür wünschen wir viel Erfolg und freuen uns, dass wir das junge Start-Up auch weiterhin als Design- und Entwicklungspartner begleiten werden.
