1. Title - Investigations into microfeatures formation in non-conductive materials by ultrasonic micromachining

Speaker - Harsh Pandey

Brief Abstract -

The demand for precise microfabrication in materials like glass and alumina is growing due to their exceptional properties, including electrical insulation and optical transparency. However, their hiardness and brittleness make machining complex microfeatures challenging. My research investigates ultrasonic micromachining (USM) as an effective alternative for processing these materials. The study includes the design of a 6×6 multi-tip tool assembly and a tapered horn using finite element analysis to ensure uniform vibration and minimize stress. A dynamic numerical model predicts material removal and cross-sectional profiles with high accuracy (±5%). Parametric studies revealed the influence of ultrasonic power, tool feed rates, and abrasive sizes, achieving high aspect ratios (>5) and etch rates (8 µm/s for glass, 2 µm/s for alumina). Tool wear analysis showed significant wear (up to 21%) at high power and larger abrasives, while cyclic impacts reduced tool surface roughness. This research establishes a framework for using USM in non-conductive materials, showcasing its precision and potential for advanced microelectronic applications like Through-Glass Vias (TGVs) and Redistribution lines (RDLs).

Bio -

Harsh is currently pursuing a Ph.D. in Mechanical Engineering at IIT Bombay, focusing on ultrasonic micromachining (USM) for microsystem packaging applications. His research involves numerical and experimental analysis of microfeature formation in non-conductive substrates like glass and alumina. He has designed a 6×6 multi-tip tool assembly and developed models for material removal and via profile prediction with high accuracy. His work highlights USM's capabilities in fabricating high aspect ratio microholes, microchannels and enhancing surface adhesion. He completed M.Tech. in Mechanical Engineering from IIT Roorkee, where he designed a bobbin Friction Stir Welding (FSW) tool to improve joint performance. He hold a B.Tech. in Mechanical Engineering from AKTU. Through his research journey, he has  gained expertise in advanced manufacturing techniques and material characterization, focusing on applications in microelectronics and packaging technologies.

2. Title - Screw-Extruded Polymer Additive Manufacturing Using Cable Robots

Speaker - Dr. Yash Mittal

Abstract & Bio are attached here Research Talk Series-Yash-Jan2025.pdf