KETs Impact: Self-assembling polymers enable efficient semiconductor fab

The recent SusChem White paper ‘Impact: Key Enabling Technologies (KETs) in Horizon Europe’ included a number of success stories highlighting publicly funded innovation involving KETs and the SusChem News blog is featuring a selection of these fruitful 'SusChem inspired' initiatives.

KETs are technologies selected for their ability to address global challenges, support the development of new products, and stimulate economic growth.

Sustainable chemistry is essential to the technological advance of KETs including advanced materials, advanced manufacturing technologies, industrial biotechnology, micro and nanoelectronics, nanotechnology and photonics. SusChem's key enabling technologies provide the critical building blocks for the solutions needed to achieve a sustainable low carbon circular economy. You can find out more here.

Our ninth KETs success story highlights PLACYD, a FP7 project funded via the Electronic Components and Systems for European Leadership (ECSEL) Joint Undertaking, and led by Arkema to establish a dedicated material manufacturing facility to produce block copolymers meeting the rigorous standards required for use in industry as nanolithographic templates for electronics and semiconductors. PLACYD brought together leading researchers and industries to allow for the first time the integration of synthesis through to wafer scale production and system/device characterisation developing an industrial solution including all key technologies including Materials, Metrology, Integration Processes, and Design tools.

Pilot Line for Self-Assembly Copolymers Delivery

A disruptive technology breakthrough strengthened EU leadership in semiconductors

Public funding aligned an eco-innovation system. Synergies enabled a breakthrough development

The semiconductor industry economy relies on geometrical scaling of transistors to insure performances improvement, power consumption reduction and cost per transistor reduction. Therefore, the well-known Moore’s law, relating to the reduction of devices’ critical dimensions by a factor of two every 18 months, has been driving the semiconductor roadmap. Up to now, devices scaling has been enabled by continuous improvements of optical lithography. Directed Self Assembly (DSA) lithography is a disruptive patterning technology that no longer relies on optics but on the polymer’s characteristics (composition and molecular weight). In DSA technology, the pattern is included within the material as the molecular weight defines the critical dimensions and the pitch the composition of the pattern.

How was the breakthrough innovation achieved? 

PLACYD project relied on a strong consortium gathering companies and academic laboratories that covered the full eco innovation system and all necessary skills from material to end-users including process and equipment manufacturers. The success of the project was established through synergies and complementarities of the partners along the value chain.

In DSA technology “the pitch is in the bottle”, the polymer and resists quality and reproducibility were key to the success of the technology. Therefore, specific efforts in developing new processes as well as new metrology techniques have been carried out leading to excellent performance and the state of the art in this sector. The metallic contamination of the resist is bellow 10ppb for all metals, the organic purity of the polymer is greater than 99.9% thanks to a unique proprietary technique that allows to discriminate homopolymers from copolymers and the copolymer dispersity has been reduced to less than 1.05.

On the patterning quality aspect, CEA-Leti developed new integration schemes that allows a wide range of configurations while insuring optimum pattern performances. 

Impact

• Increasing European leadership in microelectronics and more specifically in lithography both in terms of academic recognition (more than 60 papers and conferences), Intellectual Property position (i.e. more than 25 patent families were applied for within the project, half of them are already public) and in terms of industrial leadership.
• Commercial products have been launched based on PLACYD results. On the material side, ARKEMA launches its Nanostrength EO material suite that includes a full range of DSA resists for both lamellar and cylindrical patterns ranging from 20 nm to 50 nm pitches. On the design side, project partner MENTOR commercialises the DSA module within its EDA CALIBRE software suite. 

In summary, PLACYD allowed the development of a full DSA solution that covers all key axes of the technology (material, process, metrology and design) strengthening European leadership in semiconductor technology and demonstrating the compatibility of DSA with manufacturing requirements. Moreover, commercial products have been derived from PLACYD developments: the DSA material suite by ARKEMA and DSA software module by MENTOR.

More information

PLACYD - Pilot Line For Self Assembly Copolymer Delivery (FP7 / ECSEL JU GA 621277)

Read the SusChem White Paper ‘Impact: Key Enabling Technologies (KETs) in Horizon Europe’

Spotlight on Digital Technologies at #SusChem2018

Join us at the 2018 SusChem Stakeholder Event - #SusChem2018 - your number one destination for innovation policy dialogue and debate this summer. The 2018 Stakeholder event takes place at the Thon Hotel City Centre in Brussels on 20 June 2018 and will give you the opportunity to voice your priorities and help define SusChem’s input into the next EU Framework Funding Programme: Horizon Europe.

This year’s theme is "The Future of Research & Innovation in Europe: Defining Technology Priorities for Sustainable Growth" and will bring together global audiences, senior players from the chemical industry, academia, research technology organisations (RTOs) and EU institutions to address common innovation challenges and debate priorities crucial to the sustainability of the European chemical and biotechnology sectors.

At the event Stakeholder input will be collected through two carefully designed parallel breakout sessions: one on Advanced Materials and the other on Advanced Process Technologies. Input from both sessions will contribute to our future strategic research and innovation agenda beyond 2020.These two technology areas are complimented by Digital Technologies and will also feature at #SusChem 2018.

Spotlight on Digital Technologies
The chemical industry is an enabler for the continuous development of smarter and more sustainable electronic devices and equipment in other industries. The chemical industry is itself being transformed and disrupted through digitalisation. We have a real opportunity to leverage the immense capabilities of information and communication technologies (ICT) to optimise our processes and improve our production efficiency. Watch our social spotlight video ‘LEVERAGE’ with Martin Winter from the SusChem Management Team.



Watch out for our other Social Media Spotlights on Advanced Materials (CREATE) and Advanced Processes (MAKE).

All three of these SusChem Key Enabling Technologies (KETs) featured in SusChem’s recent white paper on the potential for KETs in Horizon Europe. The white paper outlined the major technology developments and initiatives needed to ‘create’ advanced materials, ‘develop’ advanced process technologies and ‘leverage’ digital technologies.

Debate at #SusChem2018
All three SusChem KETs will be debated and discussed at #SusChem2018. Our keynote speakers include: Signe Ratso, Deputy Director-General – Directorate Research and Innovation (RTD), EU Commission; Joanna Dupont-Inglis, Director of Industrial Biotechnology at EuropaBio, and SusChem Board Member; Markus Steilemann, Chief Commercial Officer & Member of Management Board, Covestro and Chair of the SusChem Board; and Marco Mensink, Director General of Cefic, the European Chemical Industry Council.

Register today for a chance to define the technology priorities needed to shape Europe’s sustainable future. You can download a full list of speakers here.

First Open Call for ‘CloudiFacturing’ announced

The first open call for involvement with the 'CloudiFacturing' project in the European Commission’s I4MS Funding Programme has been announced. This great funding opportunity, especially focused on SME participation, is for: Testing and implementation of the latest high-performance computing and modelling technologies.

The European Union's initiative ICT Innovation for Manufacturing SMEs (I4MS) connects SMEs, startups and mid-cap companies with European Digital Innovation Hubs, who can help companies to test and adopt the latest digital technologies.

CloudiFacturing - Cloudification of Production Engineering for Predictive Digital Manufacturing - is a European Innovation Action (IA) in the framework of Factories of the Future (FoF) PPP with the mission of optimising production processes and producibility, using Cloud/HPC-based modelling and simulation, and leveraging online factory data with advanced data analytics; thus, contributing to the competitiveness and resource efficiency of manufacturing companies, especially SMEs.

To pursue this mission, computationally demanding production engineering and simulation, as well as data analytics tools, are to be provided as Cloud services to ease accessibility and make their use more affordable. With the Open Call, I4MS is seeking innovative use cases in the context of the project’s mission.

Use case impact

The use cases should clearly state their industrial impact for the involved manufacturing companies, based on their expected benefit from exploiting computational engineering and production services and workflows powered by the CloudiFacturing technology.  

The call comprises:

1. simulations of manufacturing processes or manufacturing tools,
2. leveraging factory data to learn from it, and
3. optimising manufacturing processes and/or the manufacturability of goods

The use cases need to be driven by the ultimate end user, preferably SMEs. Seven or more Application Experiments are planned to be funded in this call which has an overall European Commission contribution of roughly EUR 700 000.

The call opening date is 1 July 2018 and the closing date will be 30 September 2018. The duration of the successful funded experiments will be 12 months from 1 January to 31 December 2019.

More information including how to access the call through regional Digital Innovation Hubs can be found in this download document and/ or via this web link.

SusChem Stakeholder 2016: ICT and #DigitiseEU

This year’s SusChem stakeholder event takes place on 16 June in Brussels. One of the major areas for discussion at the stakeholder event will be advances and issues in information and communication technologies (ICT) in the process industries. Martin Winter, Cefic Innovation Manager responsible for this SusChem priority area, outlines some of the issues up for debate and where your input is sought.

ICT for process was one of the five priority areas for innovation identified at our successful 2015 Stakeholder event. The recent European Commission communication on ‘Digitising European Industry – Reaping the full benefits of a Digital Single Market’ highlighted the role of the SusChem supported PPPs - Sustainable Process Industry through Resource and energy Efficiency (SPIRE) and Bio-Based Industries (BBI) - to help industry seize the new opportunities offered by ICT enabled innovation.

On 10 March SusChem organised a workshop involving around 20 ICT experts from companies and academia to discuss ‘Digitisation’ on the European level and to build the base for future funding calls, projects and collaborations.

SusChem, Process ICT and #DigitiseEU

From new forms of production to innovative business models the process industry is about to experience a revolution enabled by digital technologies.  Digitisation is expected to have a high impact on modernising Europe's production capabilities and can boost European process industries in the race for global competitiveness and sustainability.

The European chemical industry is a strong contributor to the roots of the European economy. Digitisation is already present in all aspects of the sector’s activities as it is essential from logistics, product and process design, planning, plant operations and plant safety to marketing/sales and customer integration.

In addition, smart materials developed by the chemical industry enable new and higher performing  ICT developments in printable-, wearable-, nano-electronics or 3D printing techniques and also allow more sustainable manufacture of new electronic devices avoiding material losses and waste generation.

To remain competitive, future factories will need well-integrated ICT systems as production increasingly uses digital innovations such as data capture, planning and control, modelling and simulation, cloud computing and big data analysis enabled by high performance computers and data connections. Data analytics will allow enterprises to convert data into knowledge, and effectively contribute to more efficient and safer processes with less environmental impact by more efficient management of resources, water and energy.

Focus for chemicals

With a focus on the manufacturing environment, important categories for further development for the chemical industry include:

• Modelling, Simulation and Forecasting: Integration of modelling of single processes into production routes with modelling extended to all levels of automation, including scheduling and management systems as well as on-line decision making processes.
• Real Time Data Availability: Development of hard- and soft-sensors for continuous processes that are reliable, fast, accurate and contact-less for use in intelligent self-optimising measurement systems along the whole production route and fully integrated in the plant automation environment.
• Transformation of ‘Big Data’ into Lean Information: Identifying universal solutions for handling large amounts of data, methods to improve their reliability, techniques to assign them to product performance and explaining their practical meaning to all relevant applications.
• Intelligent Self-learning Systems: Building models based on data and results, which continue to learn and broaden the scope of the models, based on closed loop performance monitoring.
• Condition Based Advanced Maintenance: Developing tools and methods based on models, sensors, diagnosis and data analysis to allow remote control of equipment, prediction and prevention of failures, identification of trends and avoidance of efficiency losses and unwanted stoppages.
• Product Quality Monitoring: Implementing integrated quality control factory-wide systems to monitor the evolution of quality across the production route by calling on information technology to better link process operations and plant logistics to give production flexibility.
• Resource and Energy/ Lifecycle analysis (LCA): Enabling monitoring of environmental targets (energy / water use, CO₂-emissions etc.) in all control systems as an additional set of constraints to optimise the overall sustainable performance.
• Data Privacy: Developing advanced security solutions to prevent misuse of stored data and protect plant control systems or cloud-stored data from malicious attack.
• Human-Machine Interface: Developing intuitive and user friendly interfaces for (plant)-managers, operators etc., information and their interpretation have to be available at all times in all locations.

Digital potential

However, digitisation has even greater potential to improve the European chemical industry. By using the full potential of high speed connectivity, the internet of things, cloud computing and cyber-physical systems in and for manufacturing, Europe can create new high-skilled jobs, reduce its consumption of resources and energy, increase its production capacity and continue to create the innovative products which a changing society needs.

SusChem inspired initiatives such as SPIRE are helping to make digitisation of European industries a reality. Close cooperation and alignment in the definition phases of the funding calls available under Horizon 2020 across all PPPs and all levels of stakeholder involvement is necessary to ensure that all the needs of the process industries are fully considered.

Stakeholder discussions

A highly interactive debate is expected at the Stakeholder event on 16 June and your questions and expectations on the outcomes for the panel debates, in particular on ICT and process issues, are welcome in advance.

Registration for the 2016 SusChem Stakeholder event is now open. This dedicated registration website includes links to discounted accommodation at the Hotel Bloom in Brussels - the venue for the event.

You are invited to submit your questions and comments and also your expectations for outcomes as part of the registration process. You can submit your questions and comments when you register and there will also be a link for question submission sent with the registration confirmation email.

Meet the Manager – Martin Winter

Martin is a chemist by education and received his PhD on a nanomaterial science topic in 1998 from the Max Planck Society before leaving for postdoctoral study at the Scripps Research Institute in the U.S. He joined Clariant in 1999 managing several innovation projects as Research and Development group leader and focusing on innovation and growth of new businesses. This included setting up external innovation activities through venture capital mechanisms. In addition a marketing and sales responsibility for one of Clariant’s start-up businesses brought him to Asia/Japan for a two year assignment. Since June 2015 Martin has been seconded from Clariant to Cefic in Brussels as an Innovation Manager responsible for driving the innovation agenda for the Chemical Industry.

His main area of responsibility is networking with the industry regarding their research and innovation priorities and connecting them with the European Commission’s funding instruments under Horizon 2020, for example, as the chemical sector’s representative in the SPIRE PPP. His main focus is on ICT, chemical process technologies and catalyst topics.

He likes to spend his free time with his family and is also an enthusiastic skydiver.

SusChem Stakeholder Event 2016: Sustainable Chemistry Innovation for Competitiveness

Registration is now open for this year’s SusChem Stakeholder event! Under the overarching theme ‘Sustainable Chemistry Innovation for Competitiveness’ the event will take place on 16 June 2016 at The Bloom Hotel in Brussels, Belgium.

The SusChem Stakeholder Event is the biggest annual event held by the European Technology Platform for Sustainable Chemistry (SusChem) and brings together the chemical industry, academia, Research Technology Organisations and EU policy representatives to address common challenges and debate priorities in the European chemical and biotechnology innovation sectors.

Following the extensive discussions at our successful 2015 Stakeholder event, significant progress has been made on five crucial innovation priorities areas that were identified at that event:

• Sustainable bio-economy
• ICT for processes
• Water
• Catalysis
• Materials for energy

What’s happening?
This year’s event will include a number of exciting activities and present important new developments for the SusChem community, including two lively high-level panel debates to discuss the recently published European Commission Innovation Strategy packages on:

• Circular economy and the
• Energy Union and Digitization.

These two interactive panels will bring together strategy experts from the European Commission and captains of industry to discuss the hot topics surrounding these major policy packages such as:

• Identifying new challenges in and opportunities for sustainable chemistry,
• Identifying areas of consensus that align with the priorities of the European Commission and the European chemical industry, and
• Defining news ways forward to ensure that the five crucial SusChem innovation priorities identified above are systematically considered in these two high-level policy initiatives.

We hope for a highly interactive debate and welcome your questions and expectations on the outcomes of the panels before the event (see below).

The SusChem event will also present the latest news and activities from our SusChem National Technology Platforms (NTPs).

Event objectives
The SusChem Stakeholder Event will be, as usual, a high-level initiative that aims to:

• Improve dialogue between our stakeholders;
• Identify innovation drivers for the future;
• Present the European chemical industry as a solution provider to address societal challenges;
• Promote a common view between the chemical industry and the European Commission to increase synergies and develop shared solutions on innovation priority areas.

Registration
A dedicated registration website has been set up for the event that includes links to discounted accommodation at the Hotel Bloom.

To ensure full, open and interactive discussions on current innovation priorities and to identify those that are missing from the European Commission packages, you are invited to submit your questions for the panels and also your expectations for outcomes from these two high-level panel debates as part of the registration process. You can submit your questions and comments when you register and there will also be a link for question submission sent with the registration confirmation email.

You can register here. For more information on registration, please contact the SusChem secretariat.

Sustainable Chemistry, Smart Industry and #Digital4EU

Today (24 February) the #Digital4EU stakeholder forum is taking place in Brussels. This one-day event organised by the European Commission includes four main workshops including one on Smart Industry. Sustainable chemistry has a major role to play in supporting the digital agenda in Europe.

ICT and digital innovation is an important technology area for the chemical industry. For decades the chemical industry has made extensive use of ICT systems throughout its value chain, from logistics, to modelling, design, control, monitoring and repair. In addition, the chemical industry is a key provider of materials and technologies that form the basis for many ICT and digital solutions.

Smart Chemical Processes
Within the total chemical industry value chain from product design to delivery to the customer, ICT plays a key role. ICT is key to a successful, efficient and competitive industry.

As chemical products, process and plants become ever more complex and resource usage and performance requirements become tougher, ICT can deliver a large portion of the innovation needed to keep the European chemical industry competitive on the global stage.

Process Control is a critical factor for sustainability in the production process. Advanced process methods allow production units to run at optimal operating points under appropriate constraints. Monitoring is a related area of importance for the process industry where improved digital modelling can contribute to increased plant availability, reduced costs and improved product quality.

Modelling for innovation is also a key topic. ICT-enabled innovation can significantly reduce (20-40%) time lines for product and process developments and save costs. Overall ICT technologies can enable increased resource efficiency, will enable new process and product capabilities, and strengthen the chemical industry and European competitiveness.

Smart Materials for smart industry
Sustainable chemistry is all about developing ‘Smart materials’ – materials that will enable the development of important ICT such as nanoelectronics and haptic devices. Sustainable chemistry also provides the specialty polymers and other materials that will be required for new 3D printing technologies to produce components with demanding specifications.

Sustainable chemistry is looking to develop polymers that enable nano-structured self-organisation for use as templates to support advanced nano-lithography or other nanoelectronic fabrication techniques for the fast prototyping and production of complex electronic devices. Such advanced fabrication techniques can reduce development time for microelectronic devices and boost the capability and competitiveness of the European ICT sector.

Polymers and polymer-based ink formulations are also essential for printed fabrication techniques, such as roll-to-roll lithography that allow mass production of low-cost microelectronic circuits for a wide range of applications including RFID tags, flexible displays and OLED lighting.

Future chemical developments include improved conductive polymers, piezoelectric and electro-active polymers that can inspire new and emerging end-use applications including wearable electronics.

Additive manufacturing aka 3D printing
3D printing will change the way society manufactures and its development heralds an era of mass-customisation. 3D printing or Additive Manufacturing produces a three-dimensional object from an electronic data set through an additive process making material layers in successive steps under computer control – truly digital manufacturing.

The global market for materials and services for 3D printing (excluding printer equipment) was estimated to be US$ 1.8 billion in 2013 and is projected to grow to US$ 10.8 billion by 2018.

The ability to produce small lot sizes and highly specialised added value products makes 3D printing technology a key technology for the next generation of industry: Industry 4.0. Innovation and pre-industrialisation, competitive small series production, improved time-to-market, custom made parts for personalised products, manufacturing of complex structures and geometries are all drivers for the development of additive manufacturing technologies. 3D printing also contributes to lower energy and resource use.

Polymers with appropriate end-use performances and adapted to specific 3D printing technologies are needed along with suitable metallic or ceramic materials. The European chemical industry already delivers many of these materials, but research is needed to widen the range of materials and mechanical properties of polymers available for 3D printing. Development of new electrically and thermally conductive materials will provide new opportunities for the development of additive manufacturing. Solutions to improve the surface finish of manufactured parts are also required.

Sustainable chemistry is key
Additive manufacturing is a key technology for fostering the European innovation and manufacturing industries. And its full development requires key inputs from sustainable chemistry.

Digital technologies, such as 3D printing technologies, can reduce the gap between innovation and manufacturing, stimulate the renewal of European manufacturing industry and boost industrial research and design opportunities too.