Manufacturing & Prototyping

Fabrication of a Kilopixel Array of Superconducting Microcalorimeters With Microstripline Wiring

A document describes the fabrication of a two-dimensional microcalorimeter array that uses microstrip wiring and integrated heat sinking to enable use of high-performance pixel designs at kilo - pixel scales (32×32). Each pixel is the high-resolution design employed in small-array test devices, which consist of a Mo/Au TES (transition edge sensor) on a silicon nitride membrane and an electroplated Bi/Au absorber. The pixel pitch within the array is 300 microns, where absorbers 290 microns on a side are cantilevered over a silicon support grid with 100-micron-wide beams. The high-density wiring and heat sinking are both carried by the silicon beams to the edge of the array. All pixels are wired out to the array edge.

Posted in: Manufacturing & Prototyping, Briefs, TSP

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Improvements in Cold-Plate Fabrication

Improvements in fabrication, cooling fluid, structural parts, and components reduce weight, fabrication steps, and costs. Five improvements are reported in cold-plate fabrication. This cold plate is part of a thermal control system designed to serve on space missions.

Posted in: Manufacturing & Prototyping, Briefs

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Self-Healing, Inflatable, Rigidizable Shelter

Military applications include self-sealing fuel tanks on vehicles or aircraft. Commercial applications include leak protection systems for railroad tank cars or tanker trucks carrying hazardous materials. Any manned missions to extraterrestrial locations will require shelter structures for a variety of purposes ranging from habitat to biomass production. Such shelters need to be constructed in such a way as to minimize stowed volume and payload weight. The structures must also be very durable and have the ability to survive punctures without collapsing. Ways of increasing available crew-load volume without greatly increasing launch weight or volume are also sought.

Posted in: Manufacturing & Prototyping, Briefs

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Controlling Heat Curing Adhesive Processes Using Infrared Spot Curing

Novel infrared fibers provide precision heating and curing of glues in medical device assemblies, improving workflow and design. Adhesives are often used as the joining compound between substrates in the medical device industry. Typical applications for adhesives include tube-to-connector bonding, steel-cannula-to-hub bonding, and any other joining process. Adhesives work particularly well in the assembly of dissimilar materials where traditional solvent-welding methods are being eliminated due to workplace safety legislation and where other joining methods such as ultrasonic welding and laser welding are inadequate.

Posted in: Bio-Medical, Photonics, Manufacturing & Prototyping, Medical, Briefs, MDB

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Precise Chemical Etching Method for Diamond Crystal Components

This technique could help semiconductor makers create key components of long-lasting micro-electromechanical systems for medical implants. A new method developed at the National Institute of Standards and Technology (NIST) offers a precise way to engineer microscopic cuts in a diamond surface, yielding potential benefits in both measurement and technological fields.*

Posted in: Bio-Medical, Manufacturing & Prototyping, Implants & Prosthetics, Medical, Briefs, MDB

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Advanced CO2 Removal and Reduction System

An advanced system for removing CO2 and H2O from cabin air, reducing the CO2, and returning the resulting O2 to the air is less massive than is a prior system that includes two assemblies — one for removal and one for reduction. Also, in this system, unlike in the prior system, there is no need to compress and temporarily store CO2. In this present system, removal and reduction take place within a single assembly, wherein removal is effected by use of an alkali sorbent and reduction is effected using a supply of H2 and Ru catalyst, by means of the Sabatier reaction, which is CO2 + 4H2 → CH4 + O2. The assembly contains two fixed-bed reactors operating in alternation: At first, air is blown through the first bed, which absorbs CO2 and H2O. Once the first bed is saturated with CO2 and H2O, the flow of air is diverted through the second bed and the first bed is regenerated by supplying it with H2 for the Sabatier reaction. Initially, the H2 is heated to provide heat for the regeneration reaction, which is endothermic. In the later stages of regeneration, the Sabatier reaction, which is exothermic, supplies the heat for regeneration.

Posted in: Manufacturing & Prototyping, Briefs

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Correcting Thermal Deformations in an Active Composite Reflector

Composite actuators can be embedded into an easy-to-manufacture flat surface. Large, high-precision composite reflectors for future space missions are costly to manufacture, and heavy. An active composite reflector capable of adjusting shape in situ to maintain required tolerances can be lighter and cheaper to manufacture.

Posted in: Manufacturing & Prototyping, Briefs, TSP

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