This project is proposed by Dr. Muammer Koç (Principal Investigator, PI) under the International Re-integration Grant (IRG) program to support his re-integration to research and education activities in EU and at the Istanbul Sehir University (SEHIR), and to facilitate a successful and continuous integration of his research in the micro-manufacturing field of science and engineering into the EU’s needs and trends.The overarching goal of this research proposal is to investigate, develop and validate accurate multi-scale material behavior models for micro-manufacturing technology. Micro-manufacturing research deals with the material behavior, process control, deformation mechanics, tribology and machine design for robust, precise, cost-effective and zero-waste fabrication of micro-scale parts (e.g., pins, connectors, gears, pumps, etc.) and micro-feature arrays on large surface areas (e.g., micro-channels, micro-pyramids, micro-cones, micro-bumps). Products or components of the second type represents good examples, and thus challenges, of multi-scale design, material modeling and manufacturing.To enable cost effective, robust and quality manufacturing of fuel cells and other similar applications, accurate modeling of micro-manufacturing processes is a must. Only with such accurate and proven models, scientists and engineers may effectively design, analyze, and manufacture micro-feature arrays on large surface areas, as in bipolar plates (BPP) of fuel cells. The prediction accuracy and effectiveness of such models hinges on the accuracy of the material behavior models at the micro-scale, where size effects become significant. The ultimate objective of this research is to establish a systematic approach for rapidly and accurately testing and modeling the behavior of metallic materials between different length scales (macro-, meso-, and micro-scales).