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Summary
This Medical Microfabrication Consultant is an expert in microfabrication in healthcare applications including implantable devices, neurotech, microelectrodes, microneedles, sensors, and nanopore membranes. This includes experience working with a versatile range of process technologies and materials. His experience includes thin-film process design for neuroprobes for neuromodulation by deep brain stimulation. This Medical Microfabrication Consulltant has deep thin-film experience and has the ability of applying that knowledge in the design and development of medical devices using thin film techniques.
Highlights
- Microfabrication process technology design, development and characterization
- Thin-film process design for medical applications
- New fabrication process development
- Thin Film Optics
- Product design to development of working prototypes
- Mask design, photolithography, dry/wet oxidation, thin film deposition & testing, CVD, LPCVD, PECVD, ALD, evaporation, sputtering, lift-off, dip-coating, spray-coating, micromolding, dry & wet etch, electroplating, CMP, dicing, wafer bonding, laser/waterjet cutting, packaging, SEM, ellipsometry, confocal microscopy, 2-photon lithography, SPS, AFM, TOF-SIMS, XRD, ICP-MS, ICP-OES, XRF, EDX, AAS, LCMS, HPLC-MS, FT-IR, XRPD, NMR, HRMS, XAFS
- Microfabrication and packaging of thin-film nanopore membranes
- Ultra Thin Chip Package (UTCP)
- Si microneedle=based dry electrodes
- Transdermal Drug Delivery Technology
- 3D-printing and mechanical assembly techniques
- Materials experience: Thin Films, Si / glass / fused silica, polymers (SU-8, PDMS, parylene, polyimide, chitosan, cellulose) ceramics, metals / non-metals (Cu, Cr, Ti, TiN, TiW, Au, PT, AI2O3, polySi, SiO2, Si3N4)
- Interacting with Device regulatory bodies (FAGG / CE / EMA / FDA)
Relevant Accomplishments
- Thin-film process design of flexible neuroprobes for neuromodulation by deep brain stimulation for Sapiens (now Medtronic). Hands-on fabrication and characterization of unit process steps employing DOE techniques, at MiPlaza cleanroom together with failure analysis, troubleshooting and optimization.
- Led the microfabrication process technology design, development and characterization in developing a novel microneedle architecture and fabrication processes for core sensor platform. Identified potential foundries, held technical discussions to vet capabilities, selected final partners.
- Led the full lab-to-fab process transfer, techno-commercial negotiations with foundry partners. Managed full technical programs for transferred process to external foundry. Developed full spectrum inspection, testing & validation of incoming microsystems parts.
- Led the DFMEA and specifications definition for microsystems components. Collaborated with external partners to define wafer-level AOI capabilities. Collaborated with external partners to develop wafer-level packaging. Led medical device sterilization validation efforts and actively involved in the engineering design of mechanical applicator.
- Defined, developed and optimized the MEA fabrication process for prototype production.
- Performed electrical and surface characterization of fabricated devices.
- Built a 3-D microfluidic polymer platform on top of MEAs and developed a fabrication process for Si micropore membrane device for neural sensing application. Developed a low temperature anti-adsorption thin-film coating method for polymer membranes and was actively involved in vendor selection & interfacing, building and expanding team.
- Microfabrication and packaging of thin-film nanopore membranes (nanosieves) for high-throughput microfiltration systems to be used in artificial implantable organs, namely, kidney, lungs and pancreas. 2 Process development and design of short-loop tests, optimization of process parameters and troubleshooting process issues, design of experiments (DOE), membrane characterization, interacting with clinicians, mechanical design team, feeding back response to process design to improve membrane efficiency and transport characteristics.
- Development and optimization of process for clean release of Ultra Thin Chip Package (UTCP) module comprising a thinned-down (50 μm thick) flexible silicon chip, embedded in polyimide interposer layer, from a glass wafer substrate, and integrating the UTCP into the next stage of the PCB manufacturing process.
- Design, fabrication, characterization and packaging of Si microneedle-based dry electrodes for neurophysiological (EEG) monitoring of neonates, including testing in clinical environment, under the auspices of the NeoGuard EU project.
- Resolved the issue of low SNR due to high skin-electrode impedance, by reducing polarizability of the electrodes with a novel Ag|AgCl coating process.
- Product design to development of working prototypes for transdermal drug delivery technology including new fabrication process development for Si / polymer microneedles, dry electrodes for ECG / EEG, and drug delivery technology employing 3D-printing and mechanical assembly techniques.
- Collaboration with health care professionals, exploration of suitable drug candidates, design of in-vivo animal experiments for pre-clinical validation replete with experiment protocol ratifications.
- Regular interaction with device / regulatory bodies (FAGG / CE / EMA / FDA) to chart out an optimal regulatory approval pathway, collaboration with GMP-certified manufacturers, GLP-certified CROs, extensive market survey with clinicians, pharmaceutical firms, writing grant proposals, making investor pitches.
Roles
- CEO / Founder
- Director – Microsystems Engineering
- Manager – Microsystems Engineering
- Process Integration Engineer
- Research Associate
- Research Scientist
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