9 minute read
CO-ENGINEERING Settels differentiates itself with physics knowledge to translate prototypes into working machines
SETTELS DIFFERENTIATES ITSELF WITH PHYSICS KNOWLEDGE TO TRANSLATE PROTOTYPES INTO WORKING MACHINES
AVOIDING DEAD ENDS AND IDENTIFYING THE RIGHT WAY FORWARD
Advertisement
Customers of Settels Savenije, mostly OEMs and research institutes, are usually well aware of which processes they need but not how to translate them into machines. Machines that can repeat those processes at a particular speed within particular tolerances, for a particular maximum cost price. Building those machines is a challenge because there are numerous physical laws that need to be taken into account. Understanding those laws and how they influence the operation of the machines is the quality that sets Settels apart.
BY MARTIN VAN ZAALEN
Sven Pekelder finds it hard to describe their working method in detail: ‘Often it’s a case of seeing what works and what doesn’t, which knowledge gaps still need to be filled. Naturally we do that in a systematic manner, but it’s also a question of experience. ’ Photo: Settels
Designing a machine that does exactly what the customer wants calls for a good understanding of the interaction between the physics of the process and the physical properties of the device, and hence of the laws of physics ’ , begins Sven Pekelder. ‘Around 15 years ago, we became aware of a pattern in our working method. By understanding that interaction, we were repeatedly able to differentiate ourselves towards customers and deliver good solutions for them. Since then, we have been deliberately highlighting physics in our communication with customers ’ , explains the CTO of the Eindhoven-based solution provider.
PUSHING THE LIMITS OF PHYSICS CALLS FOR CLOSE TEAMWORK, UNDER ONE ROOF
Settels Savenije works for international high-tech clients including ASML, Teledyne, Elekta, IAI, Thermo Fisher, Kulicke & Soffa, Zeiss and Bosch Rexroth. Settels is a total solution provider of systems, modules and critical components to OEMs at the forefront of technology, located in Eindhoven, the Netherlands, with a workforce of 155 people. Half of them work in R&D, 25% in Advanced Systems and 25% in Precision Parts. Since 2020, all these people have been working under one roof in Eindhoven. A strategic choice, says Sven Pekelder. ‘As a developer and manufacturer of highly complex high-tech modules and systems, we are pushing the limits of what is feasible in terms of physics. Moreover, we are under constant pressure to meet the time-to-market – and to get it right the first time. In our philosophy, that means you need to have the design and manufacturing knowledge physically close to each other. Because by doing so you create a situation in which people automatically share knowledge; then you get the cross-pollination that ensures that the designs developed can actually be manufactured properly and efficiently. ’
•www.sttls.nl
MANIPULATION
‘Under specific physical conditions ’ , he illustrates, ‘ you can turn a material into a plasma state and get it to deposit on a surface. That technology is ideal for vapour deposition on very thin layers. But in some cases you want the plasma state without deposition. For example, in ASML’ s EUV machine the aim is to create the EUV with tin plasma and a laser source but to avoid depositing tin on the mirrors. Our strength lies in understanding all the associated physical processes and how to manipulate them inside a device, in order to get the machine to produce the desired output. ’
DIFFERENT SCALE, DIFFERENT APPROACH
Customers, he says, are often opportunistic and overly optimistic.
already have an adequate understanding of the process that needs to be industrialised. They have already demonstrated that it works on a small scale in a prototype and assume that upscaling will not be a major problem. But suppose you want to build a machine to produce TV screens. This process involves cutting multiple screens from a large glass sheet. Just because you can effectively handle
those plates at a size of 1 x 1 m doesn ’t mean to say that will be the case when you go to 3 x 3 m. In this example, the size increases by a power of two but the weight by a power of three – which has significant implications for the power required by the machine in order to achieve the same speed. At a bigger scale, the same process may call for a completely different approach. ’ In order to find the right approach, the engineers at Settels use a procedure in the initial feasibility phase which has been ‘ evolving ’ for fifteen years. ‘Because each time, we are faced with challenges that are not completely new to us but are slightly different than previous cases. So for instance, we may quickly identify that the pattern of
heat generation is the same as in a previous project but we may be far less sure about the airflow. ’
ASSESSING RISKS
The first phase, continues Pekelder, is primarily about clearly establishing where the action of physical laws in the specific context of the required process is still unknown. ‘Because that’ s where the risks lie. We can establish that by means a physical model or a digital simulation to perform a proof of principle test. This allows us to see whether we are going down an expensive cul-de-sac, which is what we want to avoid. Based on the results, we can see what knowledge we are still lacking in order to identify the right way – or ways – forward. ’ Pekelder finds it hard to describe their working method in detail: ‘Often it’ s a case of seeing what works and what doesn ’t, which knowledge gaps still need to be filled. Naturally we do that in a systematic manner, but it’ s also a question of experience. It means we can save time. Which is important, because customers are almost always in a hurry. ’
PRESENTING THE RISKS
A crucial aspect of communication with customers is that they are clearly presented with the risks that still exist at a particular moment. Again, Settels ’ engineers use physics. ‘Because it is a universal language. Concrete calculations and models based on physical laws are always convincing. We use them to tell customers about the solutions we have in mind, but also about what we don ’t know and about which undesirable outcomes are possible. Being prepared for setbacks – and the associated delays and costs – makes them far easier for customers to accept. ’
Expertise – Passion – Automation
Your Semiconductor Partner in all areas
The semiconductor industry is one of SMC’s key markets. Production in this sector requires the highest purity. SMC has been working closely with leading semicon companies for many years.
We carry everything, from thermo chillers, high quality components which meet strict requirements – such as nonleakage, clean specification and corrosion resistance – to high vacuum components.
In Eindhoven the SMC Technology Center is close to its customers, offering customized subassemblies, also in ISO 6 validated cleanroom, and chiller services.
As your partner we accept every challenge. Get the decisive edge with SMC.
www.smc.nl
NEDINSCO WANTS TO GROW ACROSS THE BOARD IN THE COMING YEARS APPLYING INNOVATION TO MULTIPLE MARKETS
Venlo-based company Nedinsco is active in sectors including semiconductors and defense and has made a name for itself as a specialist in optical systems for lithographic machines, such as beam delivery systems and optical alignment tools. Nedinsco also specializes in applications for military vehicles and vessels such as day and night vision equipment, optical sensor platforms and back-up sight systems. Demand for the optical solutions which the firm has developed for the defense and semiconductor sector is now also extending to other markets, such as safety & security. An important USP for Nedinsco is that the firm is able to combine knowledge of mechatronics with optical expertise. ‘On top of that, we have all the capabilities in house to deliver complete systems for our customers.’
Going forward, Nedinsco wants to introduce its knowledge and expertise to other markets besides defense. The company has been active in the semicon industry for a long time and is now turning its focus to sectors such as transport, safety & security, oil & gas and mining. ‘These sectors also need optical solutions that will always work, something we are very good at, partly thanks to our experience in defense. There is a great deal of potential in these new markets’, says Vossen, who has overseen the semicon and industrial market as sales manager for Nedinsco since January 1st. The semicon industry continues to account for a substantial proportion of turnover and headlines Nedinsco's long-term strategical focus. For instance, the firm previously worked for ASML and is fully geared to serving customers in this sector. With its own cleanroom for assembly and an optical assembly department with flow cabinets and other facilities in order to enable ESD-safe production, Nedinsco is ready for the future. ‘All operations take place under one roof here: from turning and milling raw materials to surface treatment and specialized assembly of opt mechatronic modules.’
VALUABLE KNOWLEDGE
With regard to the field of semiconductors, the firm supplies products including opt mechatronic modules, such as a beam delivery system that creates the light source in an extreme UV machine for chip manufacturing. When it comes to safety & security, on the other hand, pan & tilt systems are worth noting. ‘This application can be seen in coastguard vessels and tanks, but now also in high-end camera security systems that are able to track movement and temperature. Over the years, we have acquired a lot of valuable knowledge in this area and of course these systems meet the high requirements of the defense industry. Naturally, the application requirements for other markets are not as extreme as e.g. having an optical system mounted beside the barrel of a tank, but there are definitely overlaps in terms of shock resistance, weather resistance and stabilization of the optical systems.’
TOUGH REQUIREMENTS
Yet another application involves data capture systems on the roads: a 360° camera system on cars in order to identify all kinds of objects, from overhanging branches near high-voltage cables to the condition of roads and litter detection. ‘In systems like this, its important that they are ruggedized, that they can cope with the elements’, says Vossen. As such, quality is an important core value at Nedinsco. ‘We extend the quality requirements we have to meet for defense to our products and solutions for other markets. Our quality department makes sure only the very best products leave the factory and that our systems are qualified. That makes us a strong, reliable partner in our market.’
FURTHER DEVELOPMENT
Another important development coming in the near future concerns Nedinsco's own 360-degree optical system. Vossen expects to launch it this year. As elsewhere, software and electronics will play a key role. ‘In the coming years, we plan to further develop this area in order to be able to continue to compete at a high level. This will mean applying our innovations from defense and semicon more widely in other markets and vice versa.’ Vossen concludes with an invitation. ‘Customers are always welcome to contact us with an idea or challenge; together, we will look for the best vision solutions in even the most difficult circumstances.’
Nedinsco Jan van Riebeeckweg 5 5928 LG Venlo T +31 (0)77 355 87 77 E info@nedinsco.com I www.nedinsco.com
