Microelectronic Repair Techniques for Wafer-Level Integration

Goddard Space Flight Center, Greenbelt, Maryland Wafer-level integration was employed to mount the microshutter array for the James Webb Space Telescope (JWST) and the detector-read-out hybrid for TIRS (Thermal Infrared Sensor). In the case of the JWST substrate, two conductors (polysilicon and aluminum) separated by a silicon oxide insulating layer were fabricated on a roughly 85-mm-square silicon wafer. The size of the substrate, the density and length of the conductive traces, and the requirement of zero shorts and zero opens on the finished device necessitated nearly impossible cleanroom requirements. Techniques were developed to repair the inevitable shorts and opens created during the wafer fabrication process. The wafers were repaired to zero shorts and zero opens without degradation of device performance.

Posted in: Briefs


Multi-Gigabit-Rate Radiation Hard Bus

Goddard Space Flight Center, Greenbelt, Maryland A concept was developed for a multi-gigabit-rate, radiation-hardened (RH) bus that would support open-system architecture and provide a cost-effective, high-speed interconnect. This concept is based on Advanced Science and Novel Technology Company’s SerDes system, which supports a variety of interfaces, and operates at frequencies from DC to more than 15 GHz. The design of the improved SerDes is based on the company’s proprietary library of RH cells and functional blocks using annular FETs (field-effect transistors) that are available in commercial CMOS (complementary metal-oxide-semiconductor) technologies. Bus architecture and preliminary SerDes circuit design have been accomplished during this phase. At the time of this reporting, the complete chip was to be designed and fabricated in the next phase.

Posted in: Briefs


Re:Vision: A New Paradigm for Mid-Lifecycle Design Changes

For decades, replacing key components during the mid-lifecycle design refresh was seen as simply too costly and burdensome. Changes had to wait until the next generation. Today, technology changes too fast to wait to add new capabilities. Fortunately, there are other options. With the right partners and suppliers involved, a mid-lifecycle component change can provide cost savings and greater performance capabilities. This white paper explores when and why a mid-lifecycle component change makes sense.

Posted in: White Papers


3D Printer That Could Build a Home in 24 Hours Wins Global Design Competition

New York, NY – Contour Crafting, a computerized construction method that rapidly 3D prints large-scale structures directly from architectural CAD models, has been awarded the grand prize of $20,000 in the 2014 "Create the Future" Design Contest. Contour Crafting automates the construction of whole structures and radically reduces the time and cost of construction. The large-scale 3D printing technology is revolutionary to the construction industry and could lead to affordable building of high-quality, low-income housing; the rapid construction of emergency shelters; and on-demand housing in response to disasters. NASA is looking at the technology for building moon and Mars bases. Behrokh Khoshnevis, a professor at University of Southern California, who invented Contour Crafting, views this invention as a proven concept. “Bringing 3D printing to construction is bringing a concept to a proven application. For many years, building has been done in layers – concrete foundation blocks, brick laying, structural framing, etc.” “I am very happy to receive this award and find it to be very timely as I am in the process of fund raising and I think this recognition will help me greatly in furthering the project,” said Khoshnevis. Contour Crafting was among the 1,074 new product ideas submitted in the 12th annual design contest, which was established in 2002 to recognize and reward engineering innovations that benefit humanity, the environment, and the economy. This year’s design contest was co-sponsored by COMSOL (www.comsol.com) and Mouser Electronics (www.mouser.com). Analog Devices and Intel were supporting sponsors. In addition to the grand prize of $20,000, first-place winners (of Hewlett-Packard workstations) were named in seven categories: *Aerospace & Defense: The Polariton Interferometer - a Novel Inertial Navigation System Frederick Moxley A stealth navigation system that provides precise course-plotting while operating independently from GPS. *Automotive/Transportation: Continuously Variable Displacement Engine Steve Arnold A continuously variable stroke engine that operates at 30% better fuel efficiency than conventional thick stroke engine designs. *Consumer Products: NanoFab Lab...in a Box! Jonathan Moritz (Team Leader) An educational kit that brings nanomanufacturing out of the cleanroom and into the classroom. *Electronics: A Paradigm Shift for SMT Electronics Jim Hester (Team Leader) Micro-coil springs that provide flexible electrical interconnections for integrated circuit packages, preventing connection breaks due to heat and vibration. *Machinery/Automation/Robotics  – sponsored by Maplesoft: Automatic Eye Finder & Tracking System Rikki Razdan (Team Leader) Real-time point-of-gaze eye tracking system that allows users to control computer input through "Look and Click" applications.  *Medical: HemeChip for Early Diagnosis of Sickle Cell Disease Yunus Alapan (Team Leader) A biochip that can rapidly, easily, and conclusively identify the hemoglobin type in blood to diagnose Sickle Cell Disease in newborns. *Sustainable Technologies: Ecovent Systems - Making Every Room the Right Temperature Dipul Patel (Team Leader) A system of wireless vents and sensors that makes any forced air heating and cooling system smarter by directing conditioned air where it’s needed most. Finalists were selected by senior editors at Tech Briefs Media Group and judged by an independent panel of design engineers. Visitors to the contest Web site could vote on entries, with the 10 most popular designs awarded a Sphero mobile game system by Orbotix. For more information, visit www.createthefuturecontest.com.          

Posted in: News, Electronic Components, Rapid Prototyping & Tooling, Diagnostics, Machinery & Automation, Computer-Aided Design (CAD)


Motion Analysis Detects Joint Degeneration

If joints do no longer work as usual, humans tend to compensate this by unconsciously adapting their motions. In the case of knee arthrosis, or excessive joint wear, they shift the weight to the healthy leg. This relieves the worn knee joint, but also delays the pain that would indicate the start of arthrosis. Based on a computer-supported gait analysis, researchers are developing an early warning system for routine prevention.

Posted in: News, Cameras, Patient Monitoring, Measuring Instruments, Monitoring


Researchers Control Surface Tension of Liquid Metals

Researchers from North Carolina State University have developed a technique for controlling the surface tension of liquid metals by applying very low voltages, opening the door to a new generation of reconfigurable electronic circuits, antennas and other technologies. The technique hinges on the fact that the oxide “skin” of the metal – which can be deposited or removed – acts as a surfactant, lowering the surface tension between the metal and the surrounding fluid.The researchers used a liquid metal alloy of gallium and indium. In base, the bare alloy has a remarkably high surface tension of about 500 millinewtons (mN)/meter, which causes the metal to bead up into a spherical blob. “But we discovered that applying a small, positive charge – less than 1 volt – causes an electrochemical reaction that creates an oxide layer on the surface of the metal, dramatically lowering the surface tension from 500 mN/meter to around 2 mN/meter,” says Dr. Michael Dickey, an associate professor of chemical and biomolecular engineering at NC State and senior author of a paper describing the work. “This change allows the liquid metal to spread out like a pancake, due to gravity.”The researchers also showed that the change in surface tension is reversible. If researchers flip the polarity of the charge from positive to negative, the oxide is eliminated and high surface tension is restored.  The surface tension can be tuned between these two extremes by varying the voltage in small steps.SourceAlso: Learn about Gradient Metal Alloys Fabricated Using Additive Manufacturing.

Posted in: News, Electronics, Power Management, Metals, Antennas


Engineers Prepare Battery Module Swapping Approach for Electric Cars

Imagine being able to switch out the batteries in electric cars just like you switch out batteries in a photo camera or flashlight. A team of engineers at the University of California, San Diego, are trying to accomplish just that, in partnership with a local San Diego engineering company.Rather than swapping out the whole battery, which is cumbersome and requires large, heavy equipment, engineers plan to swap out and recharge smaller units within the battery, known as modules.Swapping battery modules could also have far-reaching implications for mobile and decentralized electrical energy storage systems such as solar backup and portable generators. The technology can make energy storage more configurable, promote safety, simplify maintenance and eventually eliminate the use of fossil fuels for these applications.Engineers not only believe that their approach is viable, but also plan to prove it. They will embark on a cross-country trip with a car powered by the removable, rechargeable M-BEAM, or Modular Battery Exchange and Active Management, battery modules.  They plan to drive from coast to coast only taking breaks that are a few minutes long to swap out the modules that will be recharged in a chase vehicle. They believe they can drive from San Diego to the coast of South Carolina less than 60 hours — without going over the speed limit.SourceAlso: Learn about a Full-Cell Evaluation/Screening Technique for New Battery Chemistries.

Posted in: News, Batteries, Power Management, Renewable Energy, Solar Power


White Papers

Building a Test System for High-Speed Data Streaming Applications
Sponsored by ADLINK Technology
Next-Generation, Miniature High Voltage Power Modules
Sponsored by EMCO High Voltage
SpaceClaim in Manufacturing
Sponsored by SpaceClaim
Antenna Basics
Sponsored by Rohde and Schwarz
How to Choose the Appropriate Rack Size for a Chassis System
Sponsored by harting
How Paper-based 3D Printing Works: The Technology and Advantages
Sponsored by Mcor Technologies

White Papers Sponsored By: