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Research paper : The aerosol deposition method (J. Akedo et al.)−129 Synthesiology - English edition Vol.1 No.2 (2008) AuthorsJun AkedoHe graduated from Applied Physics Department, Faculty of Engineering and Science, Waseda University in 1984. Assistant at the Faculty of Engineering and Science, Waseda University from 1988 to 1991, he joined the Mechanical Engineering Laboratory (MEL), Agency of Industrial Science and Technology, Ministry of International Trade and Industry in 1991. Group leader of AIST from 2001. Doctor of Engineering. Had been involved widely in material and device development in magneto-optical recording and optic sensor in university, and worked on product development at venture company that manufactured barcode reader. After joining MEL, in 1994, gained the idea of its current study (AD method). Project leader of NEDO Nano Level Electronic Ceramics Material Low Temperature Formation and Integration Technology for 6 years since 2002. For this paper, worked on development of AD method and metal base optical scanner, investigated energy conservation effect, and coordinated overall concept.Shizuka NakanoJoined Mechanical Engineering Laboratory, Agency of Industrial Science and Technology in 1989, and has worked on development of micromachine technology using ion injection technology and others. Investigated useful function of material surface. After working at NEDO (New Energy and Industrial Technology Development Organization) in 2001, has been involved in aerosol deposition method, and worked on microgravity experiment and developed on-demand manufacturing technology. Doctor of Engineering from The University of Electro-Communications in 2003. In this paper, worked mainly on development of device for on-demand manufacturing system including small AD device.Jaehyuk ParkJoined AIST in 2004. Works on practical application research for ultra high-speed micro MEMS scanner and development of on-demand MEMS small-scale manufacturing device for this optical device, by conducting R&D for transparent nano-composite for magneto- electro-optics using AD method for the development of new optical material and for its application to optical device. Completed electronic information engineering course at Graduate School, Toyohashi University of Technology in 2003. For this paper, worked mainly on development of metal base optical scanner.So BabaJoined AIST in 2003, after working as researcher of pre-venture business, Japan Science and Technology Corporation. Has worked on development of laser aided aerosol deposition method to create high performance piezoelectric film actuator on metal substrate, which was very difficult to achieve, in NEDO project. Currently working on development of on-demand manufacturing and process enhancement technology using aerosol deposition method. Completed doctorate in material application engineering, Graduate School of Engineering, Osaka University in 2001. For this paper, worked mainly on development of heat processing (laser aided AD method) for on-demand manufacturing system.Kiwamu AshidaAfter receiving doctorate from Graduate School, Chiba University in 1998, joined the Mechanical Engineering Laboratory, Agency of Industrial Science and Technology, Ministry of International Trade and Industry. Based on concept of “micro factory” where “small things are made with small machines,” works on developing prototypes of “small processing machines” such as portable factory. Also works on micro nano-scale machine processing technology for “small machine processing.” In this paper, designed system architecture and delivery device, where production line can be freely constructed and reconstructed by joining small unit cells, in the on-demand manufacturing system. Also worked on micro-press processing cell that was the initial process.Discussion with Reviewers1 Overall compositionQuestion (Kazuo Igarashi)This paper describes how the AD method and its application will lead to innovation in manufacturing, and it is appropriate for the objective of this journal. However, the subtitle and the content do not necessarily match, and this hinders understanding. I think by selecting an appropriate subtitle, the relationship to low cost and energy conservation manufacturing stated in the title will become clearer.Answer (Jun Akedo)It is exactly as you indicated. I revised the subtitle according to your indications.2 Problems in introduction and practical application of AD methodQuestion (Kazuo Igarashi)In the manufacturing of electrostatic chuck, it is stated that by using the AD method, 80% reduction in energy consumption and 1/10 of manufacturing time was achieved, but how is this technological innovation actually used in actual manufacturing line? If it is being employed somewhere, I think you should mention this. If it is not being employed, what are the factors that prevent that from happening?Answer (Jun Akedo)As mentioned in the text, major commercialization is about to be started in the plasma corrosion resistance coating material (announced in The Chemical Daily, April 13).Reduction in process energy consumption and shortening of process time cannot be assessed easily because they are dependent on production volume and number of AD devices installed. Here, we give estimates based on initial facility cost and production volume projected by the company. For energy conservation, it is extremely complicated since other factors such as product yield are involved, so practical use will depend on the final product cost.Also, for introduction and deployment of new manufacturing process without previous record like our AD method, substantial time must be taken on sample production to confirm reliability, even if it is satisfactory in terms of performance and cost. Therefore, it took time before practical application. The optical scanner discussed here took about a year and a half for durability tests.3 Relationship to minimal manufacturing conceptQuestion (Kazuo Igarashi)In “Summary and future prospect,” you refer to “totally optimized (minimal)” and “drastic optimization (minimization),” but I feel that the meaning of “minimal” cannot be understood (57)−

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