Manufacturing & Prototyping

Thermal Spray Formation of Polymer Coatings

This innovation forms a sprayable polymer film using powdered precursor materials and an in-process heating method. This device directly applies a powdered polymer onto a substrate to form an adherent, mechanically-sound, and thickness-regulated film. The process can be used to lay down both fully dense and porous, e.g., foam, coatings. This system is field-deployable and includes power distribution, heater controls, polymer constituent material bins, flow controls, material transportation functions, and a thermal spray apparatus.

Posted in: Briefs, Manufacturing & Prototyping

Read More >>

Fabricating Large-Area Sheets of Single-Layer Graphene by CVD

Such sheets are components for high-speed digital and RF electronics for defense and commercial communications. This innovation consists of a set of methodologies for preparing large area (>1 cm2) domains of single-atomic-layer graphite, also called graphene, in single (two-dimensional) crystal form. To fabricate a single graphene layer using chemical vapor deposition (CVD), the process begins with an atomically flat surface of an appropriate substrate and an appropriate precursor molecule containing carbon atoms attached to substituent atoms or groups. These molecules will be brought into contact with the substrate surface by being flowed over, or sprayed onto, the substrate, under CVD conditions of low pressure and elevated temperature. Upon contact with the surface, the precursor molecules will decompose. The substituent groups detach from the carbon atoms and form gas-phase species, leaving the unfunctionalized carbon atoms attached to the substrate surface. These carbon atoms will diffuse upon this surface and encounter and bond to other carbon atoms. If conditions are chosen carefully, the surface carbon atoms will arrange to form the lowest energy single-layer structure available, which is the graphene lattice that is sought.

Posted in: Briefs, TSP, Manufacturing & Prototyping

Read More >>

Heat Transfer Analysis for Optimizing Solar Cell Casting Equipment

Finite element analysis was used to develop a miniature furnace to cast the solar cell wafers. Solar Power Industries’ (SPI) current annual production capacity for processing polycrystalline silicon feedstock into completed solar cells has grown to 40 megawatts, with plans to increase capacity to 250 megawatts over the next several years. SPI’s solar cell manufacturing process consists of three main steps:   Ingot and Wafer Production—High-quality silicon feedstock (containing specific quantities of dopants such as boron in order to alter electrical properties) is melted and solidified inside a directional solidification furnace to cast polycrystalline silicon ingots. The ingots are cut into rectangular blocks with a square cross-section, and then the blocks are sawed into thin multicrystalline wafers. Cell Production — The wafers are etched to remove surface damage caused by sawing. The wafers are then processed in a series of steps to produce photovoltaic cells. Module Assembly — Individual cells are connected by soldering to flat wires. Strings of cells are then joined to parallel connector wires and laminated to produce a solar module.

Posted in: Briefs, Manufacturing & Prototyping

Read More >>

Improved Sand-Compaction Method for Lost-Foam Metal Casting

The flow of sand is redirected for better filling and compaction. An improved method of filling a molding flask with sand and compacting the sand around a refractory- coated foam mold pattern has been developed for incorporation into the lost-foam metal-casting process. In comparison with the conventional method of sand filling and compaction, this method affords more nearly complete filling of the space around the refractory-coated foam mold pattern and more thorough compaction of the sand. In so doing, this method enables the sand to better support the refractory coat under metallostatic pressure during filling of the mold with molten metal.

Posted in: Briefs, Manufacturing & Prototyping

Read More >>

Improved Probe for Evaluating Compaction of Mold Sand

Sand is not perturbed during switching among different measurement positions. A nominally stationary tubular probe denoted a telescopic probe has been developed as an improved alternative to a prior movable probe used to evaluate the local degree of compaction of mold sand. The prior movable probe consists mainly of a vertically oriented tube with screen vents at its lower end. The upper end is connected to a source of constant airflow equipped with a pressure gauge. The probe is inserted vertically to a desired depth in a sand-filled molding flask and the back pressure at the given rate of flow of air is recorded as a measure of the degree of partial impermeability and, hence, of the degree of compaction of sand in the vicinity of the probe tip.

Posted in: Briefs, Manufacturing & Prototyping

Read More >>

Micromachined Slits for Imaging Spectrometers

Slits can now be made about 100× the precision previously attainable. Slits for imaging spectrometers can now be fabricated to a precision much greater than previously attainable. What makes this possible is a micromachining process that involves the use of microlithographic techniques. This micromachining process supplants a prior machine-shop process.

Posted in: Briefs, Manufacturing & Prototyping

Read More >>

Fabricating Nanodots Using Lift-Off of a Nanopore Template

Applications include nano-scale electronic and magnetic devices. A process for fabricating a planar array of dots having characteristic dimensions of the order of several nanometers to several hundred nanometers involves the formation and use of a thin alumina nanopore template on a semiconductor substrate. The dot material is deposited in the nanopores, then the template is lifted off the substrate after the dots have been formed. This process is expected to be a basis for development of other, similar nanofabrication processes for relatively inexpensive mass production of nanometer- scale optical, optoelectronic, electronic, and magnetic devices.

Posted in: Briefs, Manufacturing & Prototyping

Read More >>

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