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Material Gradients in Oxygen System Components Improve Safety

Oxygen system components fabricated by Laser Engineered Net Shaping™ (LENS™) could result in improved safety and performance. LENS™ is a near-net shape manufacturing process fusing powdered materials injected into a laser beam. Parts can be fabricated with a variety of elemental metals, alloys, and nonmetallic materials without the use of a mold. The LENS™ process allows the injected materials to be varied throughout a single workpiece. Hence, surfaces exposed to oxygen could be constructed of an oxygen-compatible material while the remainder of the part could be one chosen for strength or reduced weight. Unlike conventional coating applications, a compositional gradient would exist between the two materials, so no abrupt material boundary exists. Without an interface between dissimilar materials, there is less tendency for chipping or cracking associated with thermal-expansion mismatches.

Posted in: Manufacturing & Prototyping, Briefs

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Optimization of Indium Bump Morphology for Improved Flip Chip Devices

Flip chips have applications in cell phones and other small electronic devices.Flip-chip hybridization, also known as bump bonding, is a packaging technique for microelectronic devices that directly connects an active element or detector to a substrate readout face-to-face, eliminating the need for wire bonding. In order to make conductive links between the two parts, a solder material is used between the bond pads on each side. Solder bumps, composed of indium metal, are typically deposited by thermal evaporation onto the active regions of the device and substrate. While indium bump technology has been a part of the electronic interconnect process field for many years and has been extensively employed in the infrared imager industry, obtaining a reliable, high-yield process for high-density patterns of bumps can be quite difficult.

Posted in: Manufacturing & Prototyping, Briefs, TSP

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Pre-Finishing of SiC for Optical Applications

A method is based on two unique processing steps that are both based on deterministic machining processes using a single-point diamond turning (SPDT) machine. In the first step, a high-MRR (material removal rate) process is used to machine the part within several microns of the final geometry. In the second step, a low-MRR process is used to machine the part to near optical quality using a novel ductile regime machining (DRM) process.

Posted in: Manufacturing & Prototyping, Briefs, TSP

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A Method of Strengthening Composite/Metal Joints

This method is a less-expensive, easier alternative to a prior method.The term “tape setback method” denotes a method of designing and fabricating bonded joints between (1) box beams or other structural members made of laminated composite (matrix/ fiber) materials and (2) metal end fittings used to fasten these structural members to other structural members. The basic idea of the tape setback method is to mask the bonded interface between the metallic end fitting and composite member such that the bond does not extend out to the free edges of the composite member.

Posted in: Manufacturing & Prototyping, Briefs, TSP

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Die Extrusion Technology for Medical Tubing Applications

Patent-pending process would allow 1000-plus layers from a single extruder.Although the concept of nanotechnology (controlling matter on an atomic scale) dates back to 1959, it is only now becoming more commercially realized. It has the potential to challenge the way all products are extruded in almost every type of medical tubular or related industrial product applications.

Posted in: Bio-Medical, Briefs, Briefs, Custom & Contract Manufacturing

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Laser Sintering for Customized Medical Applications

Additive, layer-by-layer manufacturing process allows for the manufacture of complex geometries in plastic and metal implants and orthoses.Engineers have long been aware of the potential of laser sintering to create innovative and beneficial medical products. Because it is an additive (layer-by-layer) manufacturing process, laser sintering can build parts free of the traditional constraints imposed by machining or molding.Recent medical applications of laser sintering are now demonstrating the technology’s unique capabilities for mass customization and the manufacture of designs with complex geometries in both plastics and metals.

Posted in: Bio-Medical, Briefs, Briefs, Custom & Contract Manufacturing, Implants & Prosthetics

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Single, Stationary Lens Able to Create Microscopic 3D Images

Freeform lens could someday provide a proof of concept for manufacturers of microelectronics and medical devices.A lens that enables microscopic objects to be seen from nine different angles at once to create a 3D image has been developed. Other 3D microscopes use multiple lenses or cameras that move around an object; the new lens is the first single, stationary lens to create microscopic 3D images by itself.

Posted in: Bio-Medical, Briefs, Briefs, Diagnostics, Photonics

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