David Alan Dornfeld

• PhD Mechanical Engineering
• Managing Director at University of California, Berkeley

Comparison of the experimentally measured electrochemical corrosion rate and the physical material removal rate (MRR) revealed that during copper chemical mechanical planarization (CMP) most of the copper was removed mechanically by interaction with sliding abrasive particles. The mechanism for mechanical removal of copper was explained by consider...

This paper proposes a classification scheme for performance metrics for smart manufacturing systems. The discussion focuses on three such metrics: agility, asset utilization, and sustainability. For each of these metrics, we discuss classification themes, which we then use to develop a generalized classification scheme. In addition to the themes, w...

InDeaTe is a Design Tool that aids the designer by empowering ideation through a methodical process of design. This paper presents the evaluation of the tool through a case study on a manufacturing system design problem conducted in University of California, Berkeley. The problem given was to design a ‘smart’ manufacturing line for a lawnmower shaf...

Manufacturing affects all three dimensions of sustainability: economy, environment, and society. This paper addresses the last of these dimensions. It explores social impacts identified by national level social indicators, frameworks, and principles. The effects of manufacturing on social performance are framed for different stakeholder groups with...

Increasing awareness of energy consumption and its environmental impacts has prompted a need to better predict the energy consumption of various industrial processes, including manufacturing. Modeling can allow manufacturers to optimize the efficiency of their manufacturing processes. Highly accurate, data-driven models of energy consumption of CNC...

Improved data quality and availability, along with lower computation costs, have generated interest in sensor-based tool condition monitoring technologies. In this study, an integrated vibration and acoustic sensor is used for tool condition monitoring, particularly for chatter detection and tool condition classification. Based on feature extractio...

While additive manufacturing and 3D printing achieved notoriety for their abilities to manufacture complex three-dimensional parts, the state of the art is not truly three-dimensional. Rather, the process plans for the majority of these machines rely on a stack of discretized, two- dimensional layers, which results in parts with stair-stepped sur...

Recent interest in improving pedagogical approaches in science, technology, engineering, and mathematics (STEM) fields has stimulated research at many universities. Several educational methodologies are reviewed in the context of manufacturing and through the lens of sustainability. It is found that there is a need to identify and understand the ST...

Modern enterprises of all sizes operate in global manufacturing networks and complex global supply chains. Because sustainability is now a major concern, global manufacturing enterprises must optimize their global supply chain over multiple objectives including sustainability. It is important for such enterprises to analyze their global supply chai...

An assessment framework was developed to evaluate and characterize material recovery facilities within the U.S. that process e-waste. The framework consists of five key categories including, facility overview, operating model and process flows, product flows, collection methods, and facility resource use. The results were used to conduct a material...

The green cleaning industry continues to pursue products that reduce or eliminate impacts on human health and the environment; however, these impacts over the life cycle are not well understood. This study assessed environmental impacts of four green cleaning products from Method Products, PBC (all-purpose cleaner, hand wash, dish soap) and Ecover...

In the current age of big data and sustainability, accuracy and effectiveness of life-cycle assessment (LCA) are becoming more important for strategic decision-making. This paper describes a data-intensive approach to life-cycle assessment, with the use phase of a lithium-ion mobile phone battery as a case study. LCA datasets involving a temporal d...

Increasing connectivity, use of digital computation, and off-site data storage provide potential for dramatic improvements in manufacturing productivity, quality, and cost. However, there are also risks associated with the increased volume and pervasiveness of data that are generated and potentially accessible to competitors or adversaries. Enterpr...

This paper describes a real-time data collection framework and an adaptive machining learning method for constructing a real-time energy prediction model for a machine tool. To effectively establish the energy consumption pattern of a machine tool over time, the energy prediction model is continuously updated with new measurement data to account fo...

Using a machine learning approach, this study investigates the effects of machining parameters on the energy consumption of a milling machine tool, which would allow selection of optimal operational strategies to machine a part with minimum energy. Data-driven prediction models, built upon a nonlinear regression approach, can be used to gain an und...

Advanced manufacturing depends on the timely acquisition, distribution, and utilization of information from machines and processes across spatial boundaries. These activities can improve accuracy and reliability in predicting resource needs and allocation, maintenance scheduling, and remaining service life of equipment. As an emerging infrastructur...

Additive manufacturing offers completely new possibilities for the manufacturing of parts. The advantages of flexibility and convenience of additive manufacturing have had a significant impact on many industries, and optimizing part quality is crucial for expanding its utilization. This research aims to determine the sources of imprecision in fused...

Recent advances in machine automation and sensing technology offer new opportunities for continuous condition monitoring of an operating machine. This paper describes an intelligent machine monitoring framework that integrates and utilizes data collection, management, and analytics to derive an adaptive predictive model for the energy usage of a mi...

To achieve knowledge of the effects of broaching to the component and the influence on subsequent process steps such as heat treatment and hard machining, broaching experiments were performed on plates made of normalized case hardening steel SAE 5120 in [1]. To investigate the effect of heat treatment, five broaching variants of [1] were chosen and...

In this paper we will explores techniques for fabricating optical components for use in an artificial photosynthesis prototype. Specifically, methods were developed for creating rapid tooling to injection mold optics. Three mold fabrication methods were compared: CNC machining of plastic, CNC machining of aluminum, and 3D printing of plastic. For t...

Increasing energy demands coupled with decreasing resources and increased concerns about the long-term impacts of energy production are driving the development and full-scale implementation of new energy production systems. In general, several considerations must be addressed to move technology from the prototype phase to complete deployment, while...

Chemical mechanical planarization (CMP) is a highly complex process where material removal may vary between wafers and within a wafer surface. Optimal performance and high yields in CMP require process monitoring, particularly endpoint detection, which aims to determine the exact polish time needed to avoid defects created by overpolishing. This pa...

Recent advances in machine automation and sensing technology offer new opportunities for continuous condition monitoring of an operating machine. This paper describes an intelligent machine monitoring framework that integrates and utilizes data collection, management, and analytics to derive an adaptive predictive model for the energy usage of a mi...

Recent advances in manufacturing techniques have opened up new interest in rapid prototyping at the microscale. Traditionally microscale devices are fabricated using photolithography, however this process can be time consuming, challenging, and expensive. This paper focuses on three promising rapid prototyping techniques: laser ablation, micromilli...

Recent developments in microfluidics have opened up new interest in rapid prototyping with features on the microscale. Microfluidic devices are traditionally fabricated using photolithography, however this process can be time consuming and challenging. Laser ablation has emerged as the preferred solution for rapid prototyping of these devices. This...

A drilling burr-control chart (DBCC), based on experimental results, is a tool for the prediction and control of drilling burrs for a large range of drilling parameters. A micro-drilling burr-control chart (M-DBCC) was developed for a standard double-sided copper-clad laminated (CCL) printed circuit board (PCB) with laminated fiber-reinforced plast...

The pressing needs of energy, water and other resource conservation worldwide is a major engineering challenge. In manufacturing, developing green technologies (from process and tooling to the entire enterprise) is one way to insure that future manufacturing systems are sustainable. To do this, innovation in advanced manufacturing is needed. The ba...

Chemical mechanical planarization (CMP) is an essential manufacturing process in semiconductor fabrication. Chipmakers continue to adopt CMP for device planarization or surface finishing of substrate materials. Evaluating the environmental impact of the CMP process may contribute to the greening of the semiconductor process. In this paper, we propo...

Manufacturing is a resource-intensive and costly endeavor, yet the impacts of implementing a combination of lean and green practices in a manufacturing facility can hardly be forecasted and have typically been simulated, optimized, and valuated independently. This paper identifies an approach for incorporating both lean and green strategies into a...

Market pressures on manufacturing enterprises incentivize minimum resource consumption while maintaining part quality. Facilities with advanced manufacturing tools often utilize rapid prototyping for production of complicated or specialty parts. Additive manufacturing offers an alternative to traditional production methods which are often time and...

As environmental and social awareness in production engineering rises, sustainability in discrete manufacturing processes has to be controlled better and enhanced. Sustainability indicators offer a simple and affordable solution for quickly assessing sustainability; however, they have been employed rarely on the process level. This study selects si...

Developing sustainable products and processes is growing in importance due to increasing regulation, consumer interest, access to information, and competitive forces. In order to adequately evaluate the sustainability of products and processes, there is a need to consider the impacts from all three pillars of sustainability – society, environment,...

This chapter has as its objective a basic introduction to the topic to set the stage for the rest of the book. It introduces first the importance of this topic now and then the motivation, basics, and definitions associated with green manufacturing and sustainability. It describes some of the drivers that are causing governments and industry to tak...

Semiconductor manufacturing, one of the fields of manufacturing in which the USA has played a dominant role for decades, is seen as a major consumer of resources and a source of environmental impact. The objective of this chapter is to introduce the basics of semiconductor manufacturing and, then, look at a detailed analysis of the energy and globa...

The purpose of this chapter is to illuminate some of the basic principles of green manufacturing. That is, establish a framework of principles against which relevant examples can then be mapped to determine how green a system or solution is and find areas for potential improvements. This forms the structure of the discussion in following chapters w...

Green Manufacturing: Fundamentals and Applications introduces the basic definitions and issues surrounding green manufacturing at the process,machine and system (including supply chain) levels. It also shows, by way of several examples from different industry sectors, the potential for substantial improvement and the paths to achieve the improvemen...

This chapter first looks at the principal developments in manufacturing over the last several hundred years and where this is leading in the future. The role of sustainable manufacturing, and requirements to actually enable this, is discussed. Then, some discussion of “what is manufacturing’s role” relative to the life cycle impact and resource con...

Sustainable manufacturing requires simultaneous consideration of economic, environmental, and social implications associated with the production and delivery of goods. Fundamentally, sustainable manufacturing relies on descriptive metrics, advanced decision-making, and public policy for implementation, evaluation, and feedback. In this paper, recen...

Copper chemical mechanical planarization (CMP) depends for its efficacy on many parameters, including the need for the solution to passivate the surface of copper. The influence of copper ions on the formation of such protective layers in an acidic solution containing BTA and glycine was investigated using potential-step chronoamperometry using two...

A novel semi-empirical model was developed for predicting the material removal rate (MRR) during chemical mechanical polishing (CMP) based on the following assumptions: plastic contact at the wafer–particle interface, elastic contact at the pad–particle interface, a particle size distribution, and a randomly distributed surface roughness of the pol...

This paper presents a semi-empirical model for determining the energy consumption of an injection molding machine based on the energy profile of the injection molding process. The model utilizes empirical data to the idle or baseline energy consumption of the machine tool, which is non-negligible. A theoretical analysis is used to determine the pro...

To face increasing concerns about energy and environmental impact in product manufacturing, effective estimation of the processes’ impact is necessary as a way of improvement. In this paper, software support is suggested for the mold making process. We analyzed energy consumption in two major operations in mold making, computer numerically controll...

Green machining strategies can affect several aspects of a manufacturing system including part quality, which must remain sufficient to ensure the product's value. Improved part quality can also reduce life cycle environmental impacts through increased resource efficiency, which adds a further consideration. This paper quantifies the impact of thes...

Sustainable manufacturing has received enormous attention in recent years as an effective solution to support the continuous growth and expansion of manufacturing industry. In this paper, we present a three dimensional system approach for sustainable manufacturing from environmental perspective. This method attempts to address the sustainability is...

This paper aims to provide a systematic overview of the state of the art in energy and resource efficiency increasing methods and techniques in the domain of discrete part manufacturing, with attention for the effectiveness of the available options. For this purpose a structured approach, distinguishing different system scale levels, is applied: st...

Since machining is a prevalent process in product manufacture this study reviews the accuracy of a specific energy characterization model to predict the electrical energy consumed by a 3-axis milling machine tool during processing. The energy characterization model had an accuracy of 97.4% for the part manufactured under varied material removal rat...

It has become increasingly important for manufacturers to implement sustainability into tool and process design. Existing models that evaluate the sustainability of abrasive processes focus mostly on case studies of selected energy and resource streams and rarely contain holistic process models. This study uses basic principles of axiomatic design...

What is resilience? How does it relate to manufacturing and, in particular, green and sustainable manufacturing?

Today producers are becoming more responsible for their products, not only because of legal requirements but also to gain a competitive edge, as consumers are increasingly considering the broader impacts of their purchases. As a result, companies are beginning to address the ecological impacts of products and manufacturing processes in addition to...

Production engineering faces the challenge to satisfy the increasing industrial demand for higher productivity and high requirements on workpiece quality at the same time. Furthermore, the rising environmental awareness adds additional constraints. Especially grinding processes have high relevance for industrial applications because they generate h...

Manufacturers have pursued green machining strategies, such as process time reduction, to address the demand for environmental impact reduction. These strategies, though, increase the stresses on the manufacturing system, which can affect availability, service life, achieved part quality, and cost. This study presents a total cost analysis of proce...

A manufacturing system for discrete part production under flexible process routings is studied for the reduction of cost and energy. Focus is centered on the process planning stage for product manufacture, i.e. machine tool selection. Machine tool scheduling was implemented in a discrete-event simulation environment for the evaluation of several sc...

Prior efforts have focused on environmental assessment coupled with manufacturing cost analysis; however, few have attempted integrated sustainability assessment for manufacturing. An approach is developed for sustainable manufacturing decision making and demonstrated for a machining work cell. Assessment results are obtained and discussed for thre...

This paper examines one aspect of automobile manufacturing, sheet metal joining, and endorses techniques that minimize environmental impact and cost while meeting performance standards. A methodology has been developed for evaluating kinematically constrained joining techniques based on two parameters: environmental impact and cost. The model evalu...

Energy is a necessary input for most manufacturing processes and is increasingly the focus of industry to reduce its consumption. There are many processes that use energy both directly and indirectly. Heating, ventilation, and airconditioning (HVAC) systems that precisely control indoor climate are driven both by direct and indirect process require...

The evaluation and reduction of the environmental impact of manufacturing processes have become a crucial issue in the last few years, addressing the interest of industrial and academic research towards greener solutions and technologies. Reducing input materials and energy requirements has become an imperative action in the industrial practice. As...

In this work, we propose a roll-to-roll multi-station flexographic printing process for large-scale energy storage fabrication. By leveraging a previously developed solid-state zinc-based battery technology, we have scaled it to a potentially cost-effective and environmentally friendly manufacturing method. Due to the differences in flexographic pr...

Lightweight materials have become an important strategy in the automotive industry to enable vehicle weight reduction and reduce fuel consumption. However, when developing specific strategies, the overall benefits of any material should be analyzed throughout its life cycle to comprehend energy/environmental differences that arise during its proces...

The present research analyses the environmental implications on the manufacturing, production and shipping of similar physical goods to the California market. In terms of corporate social responsibility, we address the implications of designing sustainable supply chains. The project is focused on single crystalline and poly crystalline silicon base...

The environmental impact of most consumer products is dominated by their use phase. However, these impacts tend to be driven by the manufacture of the product's components since components fabricated with higher precision typically allow the product to operate at higher efficiencies. This paper investigates the relationship between precision and li...

Precise tool length measurement and work coordinate setup have been challenging tasks in ultra-precision machining. An acoustic emission (AE) sensor can be used to do both tasks at the same time based on AE generated on contact. First, a parametric study was conducted to identify the relationship between damage on the workpiece and key parameters....

Increasing systemic error during copper CMP (Chemical Mechanical Planarization) is due to the uneven surface topography generated during the process. A mechanistic model based on a fundamental understanding of the process constituents was proposed to predict material removal rates and the post CMP topography. Two synergistic mechanisms were propose...

Currently available life cycle assessment (LCA) tools provide only a rough estimation of the environmental impact of different manufacturing operations (e.g. energy consumption). To address this limitation, a web-based and application programming interface (API) based process analysis software tools were developed to estimate the energy consumption...

The exponential growth of the semiconductor industry raises serious environmental concerns. Accurate life-cycle data are critical for both appropriate product eco-design and life-cycle analysis (LCA) of new electronic applications. Previous semiconductor LCA efforts were based on generic studies dealing with an average component description such as...

The growing demand to reduce environmental impacts has encouraged manufacturers to pursue various green manufacturing technologies and strategies. These solutions, though, may have a direct impact on several productivity metrics including availability, quality, service life, and cost. This study presents an approach to evaluate the trade-offs betwe...

Manufacturing offers many opportunities for reducing environmental impact, utilizing resources more efficiently and, overall, greening the technology of production. These opportunities are most often related to process, machine or system improvements that impact only the operation of the process, machine or system. But, there is more potential in m...

Since machine tools are used extensively throughout their functional life and consequently consuming valuable natural resources and emitting harmful pollutants during this time, this study reviews strategies for characterizing and reducing the energy consumption of milling machine tools during their use. The power demanded by a micromachining cente...

Solid state drives (SSDs) show potential for environmental benefits over magnetic data storage due to their lower power consumption. To investigate this possibility, a life-cycle assessment (LCA) of NAND flash over five technology generations (150 nm, 120 nm, 90 nm, 65 nm, and 45 nm) is presented to quantify environmental impacts occurring in flash...

Sustainable manufacturing has been defined by the U.S. Department of Commerce as the creation of manufactured products using processes that minimize negative environmental impacts, conserve energy and natural resources, are safe for employees, communities, and consumers, and are economically sound. Thus, it requires simultaneous consideration of ec...

Copper CMP is a corrosion-wear process, in which mechanical and chemical-electrochemical phenomena interact synergistically. Existing models generally treat copper CMP as a corrosion enhanced wear process. However, the underlying mechanisms suggest that copper CMP would be better modeled as a wear enhanced corrosion process, where intermittent aspe...

During copper CMP, abrasives and asperities interact with the copper at the nano-scale, partially removing protective films. The local Cu oxidation rate increases, then decays with time as the protective film reforms. In order to estimate the copper removal rate and other Cu-CMP output parameters with a mechanistic model, the passivation kinetics o...

Today the requirements for reducing the impact of our manufacturing activities are increasing as the world awakes to and addresses the environmental impacts of our society. Energy consumption, greenhouse gas emissions, materials availability and use, environmental impact levels, etc. are all topics of interest. Semiconductor manufacturing in genera...

Low-k dielectric material removal rate, which is significantly affected by process factors such as polishing load, wafer carrier rotation, platen rotation speed and pad age, is one of the critical issues in CMP planarization of a dielectric film when concerning productivity, throughputs and stabilization of the process, especially when trying to ac...

CIRP has had a long history of research and publication on the development and implementation of sensor monitoring of machining operations including tool condition monitoring, unmanned machining, process control and, more recently, advanced topics in machining monitoring, innovative signal processing, sensor fusion and related applications. This ke...

Reducing the energy consumption of machine tools can significantly improve the environmental performance of manufacturing systems. To achieve this, monitoring of energy consumption patterns in the systems is required. It is vital in these studies to correlate energy usage with the operations being performed in the manufacturing system. However, thi...

In this study, we performed a specific precision grinding process in an attempt to improve the mirror-quality finish and tribological characteristics of titanium nitride based coating films (TiN, TiCN, and TiAIN). The ground surfaces were highly smooth with no evidence of cracking, chipping, or peeling, demonstrating that the hard coating films wer...

This paper follows on earlier studies demonstrating the importance of transportation to the total greenhouse gas (GHG) footprint of wine and discusses the variability of transportation emissions depending on the specific type of transportation utilized. Variations in freight transportation emissions by truck, ship, train, and airplane are discussed...

The presence of solid particle contaminant chips in high performance and complex automotive components like cylinder heads of internal combustion engines is a source of major concern for the automotive industry. Current industrial cleaning technologies, simply relying on the fluid transport energy of high pressure or intermittent high impulse jets...

Toxic chemicals used in product design and manufacturing are grave concerns due to their toxic impact on human health. Implementing sustainable material selection strategies on toxic chemicals can substantially improve the sustainability ofproducts in both design and manufacturing processes. In this paper, a schematic method is presented for charac...

A special coolant system called `Ion-shot coolant system' which consists of an electrolytic liquid and a nano carbon additive was developed. A series of experimental studies had been conducted to understand the effects of the coolant in micro cutting of two steel materials with different carbon content, a high carbon chromium steel (SUJ-2) and a pr...

Environmental assessment of photovoltaic systems is a rich field, with representations of many technologies, regions and methodologies. This paper discusses some of the factors that strongly affect the outcomes of studies, encourages detailed reporting of normalization parameters and scope, and discusses a cradle to grave framework for benchmarking...

A life-cycle energy consumption analysis of a Bridgeport manual mill and a Mori Seiki DuraVertical 5060 has been conducted. The use phase incorporated three manufacturing environments: a community shop, a job shop, and a commercial facility. The CO₂-equivalent emissions were presented per machined part. While the use phase comprised the...

Atomic layer deposition (ALD) is a promising nanotechnology for wide applications in microelectronics manufacturing due to its ability to control layer growth at atomic scale. Sustainability of ALD technology needs to be quantitatively investigated in this early development stage to improve its economic and environmental performance. In this paper,...

Motion control in high-speed micromilling processes requires fast, accurate following of a specified curvilinear path. The accuracy with which the path can be followed is determined by the speed at which individual trajectories can be generated and sent to the control system. The time required to generate the trajectory is dependent on the represen...

One of the major concerns in deburring technology is centered on how to predict the size and shape of burrs to insure uniform removal and, if this is possible, how to design the process or product in advance to minimize or control the burr size. This paper reviews some of the research done over the past several years on this important topic. The pa...

Determination of the life-cycle environmental and human health impacts of semiconductor logic is essential to a better understanding of the role information technology can play in achieving energy efficiency or global warming potential reduction goals. This study provides a life-cycle assessment for digital logic chips over seven technology generat...

Millisecond scale benzotriazole (BTA) adsorption kinetics in acidic aqueous solution containing 0.01 M glycine and 0.01 M BTA have been investigated. Chronoamperometry was used to measure current densities on the surface of a micro-copper electrode in pH 4 aqueous solutions containing 0.01 M glycine with or without 0.01 M BTA. In the presence of BT...

Direct write dispenser printing technology is a versatile and scalable manufacturing technique for additive deposition of novel materials. We present a versatile prototyping dispenser printer capable of rapid fabrication of unique microscale devices. A theoretical error analysis of the printer is performed to evaluate the repeatability and accuracy...

Increasing demands on function and performance call for burr-free workpiece edges after machining. Since deburring is a costly and non-value-added operation, the understanding and control of burr formation is a research topic with high relevance to industrial applications. Following a review of burr classifications along with the corresponding meas...

In this work a multibody collision model, amenable to large-scale computation, is developed to simulate a jet of near-field grains impinging on a surface. This model is developed by computing momentum exchange for grain–grain and grain–surface interactions. The grain–grain interactions consist of collisions as well as near-field interactions. The a...

The material removal characteristics of a silicon wafer were experimentally investigated with respect to the chemical dissolution and mechanical abrasion of the wafer during silicon chemical mechanical polishing (CMP) using an alkali-based slurry The silicon surface without native oxide is rapidly dissolved by the slurry containing an amine agent,...