Manufacturing & Prototyping

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.

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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.

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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.

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Making Complex Electrically Conductive Patterns on Cloth

Circuit patterns are implemented in tightly woven cloth instead of stitched conductive thread. A method for automated fabrication of flexible, electrically conductive patterns on cloth substrates has been demonstrated. Products developed using this method, or related prior methods, are instances of a technology known as “e-textiles,” in which electrically conductive patterns are formed in, and on, textiles. For many applications, including high-speed digital circuits, antennas, and radio frequency (RF) circuits, an e-textile method should be capable of providing high surface conductivity, tight tolerances for control of characteristic impedances, and geometrically complex conductive patterns. Unlike prior methods, the present method satisfies all three of these criteria. Typical patterns can include such circuit structures as RF transmission lines, antennas, filters, and other conductive patterns equivalent to those of conventional printed circuits.

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Direct Metal Laser-Sintering of Titanium

DMLS titanium parts can be used in aerospace and medical applications. During the first decade of direct metal laser-sintering (DMLS), the metals employed were generally ones developed specifically for DMLS, rather than those used in traditional metalforming methods. But in recent years, the range of available powder metals and the production quality of DMLS parts have advanced considerably, driving new interest in rapid manufacturing.

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Embossed Teflon AF Laminate Membrane Microfluidic Diaphragm Valves

A new fabrication strategy for valve manifolds uses flexible, durable materials. A microfluidic system has been designed to survive spaceflight and to function autonomously on the Martian surface. It manipulates microscopic quantities of liquid water and performs chemical analyses on these samples to assay for the presence of molecules associated with past or present living processes. This technology lies at the core of the Urey Instrument, which is scheduled for inclusion on the Pasteur Payload of the ESA ExoMars rover mission in 2013.

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Fabricating High-Resolution X-Ray Collimators

A process and method for fabricating multi-grid, high-resolution rotating modulation collimators for arcsecond and sub-arcsecond x-ray and gamma-ray imaging involves photochemical machining and precision stack lamination. The special fixturing and etching techniques that have been developed are used for the fabrication of multiple high-resolution grids on a single array substrate.

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