Winning Ways
This year’s winner of the EuroAsia IC Industry Foundry of the Year Award was Canadian based Micralyne. The company specialises in MEMS manufacturing and the feedback the award organisers have received suggest this was a popular winner.
Introduction
Winner of EuroAsia IC Industry Award ‘Foundry of the Year’, Micralyne is a name you don’t want to forget, especially if you’re looking for a foundry to manufacture your MEMS-based product.
Located in Edmonton, Alberta – the micro-nano technology (‘MNT’) capital of Canada, Micralyne develops and manufactures MEMS (Micro-Electro-Mechanical-Systems) based products for leading instrumentation companies around the world.
Originating at the University of Alberta in 1982, Micralyne started off as the Alberta Microelectronic Corporation (‘AMC’), a government subsidised research facility focused on developing cutting-edge technology in Alberta. In 1998, management and employees decided to take a risk and turn AMC into a private company, now known as Micralyne. The majority of assets were bought from the University of Alberta and Micralyne continues to fund research at the U of A and the University of Calgary.
Since then, Micralyne has become one of the leading independent MEMS manufacturers in the world. Wicht Technologie Consulting (WTC) released in spring 2007 a market report on the ‘Top 10 MEMS Foundries’ in the world. Based on contract manufacturing revenues for 2006, Micralyne ranked 4th a clear indication that Micralyne is making a significant impact on MNT development and manufacturing both at home in Canada and abroad.
How did Micralyne get here? Perhaps it’s their close tie to the University of Alberta, recruiting top talent, or management’s focus on encouraging innovation, or their state-of-the-art 50,000 sq-ft, Class 10 and Class 1000 manufacturing facility? Whatever the formula may be, Micralyne has been able to do something many of its competitors have not: turn a profit year after year.
Today, revenues continue to grow. From $1.7 million in 1994 to over $20 million for this year. Over the past two years, Micralyne has double its size both in terms of revenue and staff count (which has doubled from 82 to 175).
Micralyne has consistently generated strong financial results in an industry known for high profile failures. In fact, Micralyne has been profitable every year except one since it started as a private company.
Technical Capabilities
Technological innovation and know-how are at the foundation of Micralyne’s differential advantage. Micralyne has been able to create world-leading core competencies in several specialised fields including micromachining, thin film technologies, microfluidics, and MEMS assembly & test.
Examples of MEMS capabilities offered at Micralyne include:
lithography, metal & plasma deposition, plasma etching, deep reactive ion etching (Bosch & Cryo processes), wet etching, electroplating (AuSn solder alloy), bonding and dicing, plus more.
One of Micralyne’s strengths is in transfer-to-manufacturing. It is one thing to make a single device, but the real challenge is to go from 1 to 1,000 or 100,000 of the same product. The engineers at Micralyne are able to successfully take a customer’s design and turn it into a volume, manufacturable product.
As well, the company has recently implemented their Micralyne Product Quality Planning (‘MPQP’) process that formalises the transfer into manufacturing and gives customers a better view of how the system works.
“The talent pool at Micralyne can not be beat,” said Chris Lumb, CEO of Micralyne. “The ability of our engineers to constantly think creatively and out-of-the-box gives us a huge advantage. Even our customers are amazed at how they are able to solve problems in a timely manner.”
Solutions
Customers are using micro-nano technologies to develop products that have the potential to revolutionise our lives. This impact, however, is not possible if MNT systems cannot be manufactured in a cost effective manner and in volume. This is where Micralyne comes into play.
Applications of MEMS products manufactured at Micralyne that are driving significant innovations in all parts of society include:
● Optical switch components installed into telecommunication networks to facilitate the increase in Internet bandwidth to homes and businesses.
● Bioanalysis instruments using microfluidic devices that detect the presence of diseases or analyse DNA from a blood sample. These miniature devices reduce the time to find a result from days down to minutes.
● A component within the pre-press equipment that prints most of the widely read, high gloss magazines in the world today.
● Control systems for automotive transmission and A/C systems
● Implantable drug delivery devices developed in collaboration with MicroCHIPS Inc. Micralyne and MicroCHIPS is developing a device that can be implanted into a human body and used to deliver particular drugs when activated by an outside source, like a remote control. This new technology is an important step for the effective implementation of therapeutic regimens. It also highlights the huge potential of using MEMS devices in the life sciences industry.
Another interesting example of Micralyne’s innovative solutions is its collaboration with Polychromix, a leading developer of innovative spectroscopy solutions. Micralyne and Polychromix are working together to develop MEMS NIR (near-infrared) devices, a core component in the Polychromix Phazir product line. The Polychromix Phazir combines Digital Transform Spectroscopy (DTS) with MEMS technology to reduce large, stationary analytical laboratory instruments into one handheld NIR analyser that can identify materials directly at their source - the first of its kind in the industry.
The MEMS devices, manufactured at Micralyne, can be mass-produced, resulting in low-cost reproducible products. In addition, the MEMS engine minimises power usage and maximises battery life. The Phazir can be used for a variety of applications, including:
● Forensics - analyse and identify crime scene evidence or narcotic white powder substances on-the-spot
● Inspection of incoming raw materials - test the quality or identity of incoming materials in the pharmaceutical, food and beverage, and chemical / petrochemical industries
● Recycling - sort petrochemical products, such as plastics and carpet, before reprocessing
● Agriculture - analyse the properties of crops, fruits, vegetables, and spices in the field to maximise quality and value
● Fraud identification - perform field inspections to determine original formulations from counterfeits, analyse and identify counterfeit drugs and fabrics
With this innovative MEMS technology manufactured by Micralyne, the Polychromix Phazir is a cost-effective analytical tool for a variety of industries. The Phazir, as the first handheld NIR analyser, introduces new value and cost savings to applications previously considered technically impossible.
The Future
As an independent MEMS foundry, Micralyne has proven it has created a successful business model. Micralyne has worked with over 300 OEM manufacturing customers, including start-ups, research institutions and large multi-national corporations, since 1982. These customers look to Micralyne for advice in transferring their MNT-based products to manufacturing and for continuous process improvements. Customers trust Micralyne’s established business model and in return, Micralyne delivers. At the same time, Micralyne has grown its revenue and profits.
So what lies in the future for Micralyne?
This November, Micralyne will be opening its new expanded facility, increasing Class 10 clean room space by 70% and Class 1000 clean room space by 50%. With this expansion Micralyne will be able to serve the needs of current customers plus have the capacity to take on prospective customers wanting to outsource their current MEMS production.
“This coming year will be an exciting time for both staff and customers of Micralyne,” said Chris Lumb. “The expansion of our facility is a big step forward for growing our business and reinforcing our position as a leader in MEMS manufacturing.”
Micralyne also plans on expanding its reach into the United States and Asian markets. Within the past few years, business in Japan has grown to 10% of overall revenues and Micralyne is now a supplier of MNT products to 7 major companies in Japan, China and Thailand. Micralyne also hopes to penetrate the European market and attract those customers who require a long-term manufacturing partner, rather than a one-time manufacturing job.
Conclusion
Micralyne has come a long way from its foundation as a university-owned not-for-profit group to a thriving profitable and globally competitive corporation. With ongoing financial stability, Micralyne will continue to help its customers translate their MEMS concepts and designs into successful MNT products. Micralyne has also proven that the independent foundry business model can be successful with strong business practices and the right people.
