Manufacturing & Prototyping

Two-Step Plasma Process for Cleaning Indium Bonding Bumps

This process could increase yields in the manufacture of consumer electronic products. A two-step plasma process has been developed as a means of removing surface oxide layers from indium bumps used in flip-chip hybridization (bump bonding) of integrated circuits. This process has considerable commercial potential in that flip-chip hybridization is used in the manufacture of cellular telephones and other compact, portable electronic products.

Posted in: Briefs, Manufacturing & Prototyping

Read More >>

Tool for Crimping Flexible Circuit Leads

A hand tool has been developed for crimping leads in flexible tails that are parts of some electronic circuits — especially some sensor circuits. The tool is used to cut the tails to desired lengths and attach solder tabs to the leads. For tailoring small numbers of circuits for special applications, this hand tool is a less expensive alternative to a commercially available automated crimping tool. The crimping tool consists of an off-the-shelf hand crimping tool plus a specialized crimping insert designed specifically for the intended application.

Posted in: Briefs, TSP, Manufacturing & Prototyping

Read More >>

Improved Assembly for Gas Shielding During Welding or Brazing

Inert gas is distributed evenly over the region surrounding the weld joint. An improved assembly for inert-gas shielding of a metallic joint is designed to be useable during any of a variety of both laser-based and traditional welding and brazing processes. The basic purpose of this assembly or of a typical prior related assembly is to channel the flow of a chemically inert gas to a joint to prevent environmental contamination of the joint during the welding or brazing process and, if required, to accelerate cooling upon completion of the process.

Posted in: Briefs, Manufacturing & Prototyping

Read More >>

Fabricating PFPE Membranes for Microfluidic Valves and Pumps

This process contributes to development of “laboratory-on-a-chip” devices. A process has been developed for fabricating membranes of a perfluoropolyether (PFPE) and integrating them into valves and pumps in “laboratory-on-a-chip” microfluidic devices. Membranes of poly(tetrafluoroethylene) [PTFE] and poly(dimethylsilane) [PDMS] have been considered for this purpose and found wanting. By making it possible to use PFPE instead of PTFE or PDMS, the present process expands the array of options for further development of microfluidic devices for diverse applications that could include detection of biochemicals of interest, detection of toxins and biowarfare agents, synthesis and analysis of proteins, medical diagnosis, and synthesis of fuels.

Posted in: Briefs, Manufacturing & Prototyping

Read More >>

Fabricating PFPE Membranes for Capillary Electrophoresis

Precisely sized and positioned holes are defined by photomasks. A process has been developed for fabricating perfluoropolyether (PFPE) membranes that contain microscopic holes of precise sizes at precise locations. The membranes are to be incorporated into “laboratory-on-a-chip” microfluidic devices to be used in performing capillary electrophoresis.

Posted in: Briefs, Manufacturing & Prototyping

Read More >>

Linear Actuator Has Long Stroke and High Resolution

There are potential applications in precise measurement and precise fabrication. The term “precision linear actuator, direct drive” (“PLADD”) refers to a robust linear actuator designed to be capable of repeatedly performing, over a lifetime of the order of 5 to 10 years, positioning maneuvers that include, variously, submicron increments or slews of the order of a centimeter. The PLADD is capable of both long stroke (120 mm) and high resolution (repeatable increments of 20 nm). Unlike precise linear actuators of prior design, the PLADD contains no gears, levers, or hydraulic converters. The PLADD, now at the prototype stage of development, is intended for original use as a coarse-positioning actuator in a spaceborne interferometer. The PLADD could also be adapted to terrestrial applications in which there are requirements for long stroke and high resolution: potential applications include medical imaging and fabrication of semiconductor devices.

Posted in: Briefs, Manufacturing & Prototyping

Read More >>

Installing a Test Tap on a Metal Battery Case

A mechanical fitting and relatively simple and safe method of installing it on the metal case of a battery have been devised to provide access to the interior of the battery to perform inspection and/or to measure such internal conditions as temperature and pressure. A metal boss or stud having an exterior thread is attached to the case by capacitor-discharge stud welding (CDSW), which takes only 3 to 6 milliseconds and in which the metallurgical bond (weld) and the heat-affected zone are limited to a depth of a few thousandths of an inch (a few hundredths of a millimeter).

Posted in: Briefs, TSP, Manufacturing & Prototyping

Read More >>

The U.S. Government does not endorse any commercial product, process, or activity identified on this web site.