Research Project
STAMP: Sensor Tape Application via Mechanized Pressing
Research Team
Lead Researchers:
- Dr. Seunghoon Hwang, Mechanical Engineering
- Dr. Nhut Ho, Mechanical Engineering
- Heramb Nemlekar, Assistant Professor, Mechanical Engineering
Collaborators:
- MiniMed Flex™ System
Student Team:
- Christian Guevara, BS Mechanical Engineering
- Hao Phan, BS Mechanical Engineering
- Jorge Alvarez, BS Mechanical Engineering
- Oscar Garcia, BS Mechanical Engineering
Funding
- Funding Organization: MiniMed
- Funding Program:
SYNOPSIS
This project develops an automated, human-in-the-loop peel coat tape application system for sensor fabrication. The work includes sensor chip position detection, alignment with the tape applicator, precise tape placement on contact pads, post-application inspection, and integrated system validation for reliable batch processing.
Abstract
The proposed work aims to automate the peel coat tape application process used in sensor fabrication by replacing a variable manual workflow with a requirement-driven automation system. The project includes problem definition, system requirement specification, prototype development, subsystem integration, performance validation, optimization, and deployment preparation in a manufacturing environment.
Motivation/Research Problem
The current manual taping process is subject to variability, failure modes, and operator dependency, making it difficult to ensure consistent accuracy, repeatability, and throughput. The project addresses the need for a precise, cleanroom-compatible, and reliable automated solution for tape application in sensor manufacturing.
Research Objectives
The objective is to design, develop, and validate an automated peel coat tape application system that can accurately detect sensor chip positions, align the tape applicator, apply tape with controlled force and precision, and perform post-application inspection under real manufacturing conditions.
Research Methods
The project will follow a three-phase, requirement-driven approach:
- define the operational problem and system requirements through workflow analysis, on-site observation, and stakeholder meetings;
- develop and integrate mechanical, actuation, perception, and control subsystems into a functional prototype; and
- optimize and validate the system through structured testing, long-duration performance evaluation, and deployment preparation.
Research Results and Deliverables
Expected results include a fully integrated and validated automated taping system, developed datasets, control algorithms, digital models, initial and final performance validation reports, and documentation and training materials to support operational deployment. The project also aims to demonstrate measurable improvement over the current manual process.
Commercialization Opportunities
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Applications: automated tape application for sensor fabrication, medical device manufacturing, and other precision assembly processes requiring accurate tape placement.
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Key Values: reduced operator dependency, improved repeatability and precision, increased throughput, cleanroom compatibility, and readiness for batch processing in manufacturing environments.
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Potential Customers: Minimed, medical sensor manufacturers, medical device companies, and advanced manufacturing organizations requiring precision automation solutions.
Research Timeline
The total project duration is 6 months:
- Phase 1 (1 month): problem definition and requirement finalization
- Phase 2 (3.5 months): prototype development and system integration
- Phase 3 (1.5 months): validation, refinement, and deployment readiness
Lead Researchers:
- Dr. Seunghoon Hwang, Mechanical Engineering
- Dr. Nhut Ho, Mechanical Engineering
- Heramb Nemlekar, Assistant Professor, Mechanical Engineering
Collaborators:
- MiniMed Flex™ System
Student Team:
- Christian Guevara, BS Mechanical Engineering
- Hao Phan, BS Mechanical Engineering
- Jorge Alvarez, BS Mechanical Engineering
- Oscar Garcia, BS Mechanical Engineering
Funding
- Funding Organization: MiniMed
- Funding Program: