Manufacturing & Prototyping

Multi-Step DRIE Process to Fabricate Silicon-Based THz Components

Commercial applications include airport screening systems, explosives detectors, nondestructive testing, and wireless communications. NASA’s Jet Propulsion Laboratory, Pasadena, California Terahertz (THz) frequency radiometers, spectrometers, and radars are promising instruments for the remote sensing of planetary atmospheres such as Mars, Venus, Jupiter, and Saturn, and their moons such as Titan, Europa, Ganymede, and others. For these long-term planetary missions, severe constraints are put on the mass and power budget for the payload instruments.

Posted in: Manufacturing & Prototyping, Briefs, TSP

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Plasma Reduction of Lunar Regolith for In-Space Fabrication

Plasma processing effectively produced agglutinate and glassy spherules — analog particles similar to those found on the lunar surface. Marshall Space Flight Center, Alabama The in situ production of vital gases and raw materials on the lunar surface is an integral part of NASA’s exploration vision. Development of processes for extraction of oxygen and metallics from the lunar regolith will be vital not only for life support on the lunar surface, but also for spacecraft propulsion to travel further beyond low Earth orbit. This will have a direct impact on cost reduction associated with minimizing the raw material mass from Earth. Aside from utilization of in situ resources, one of the significant limitations of current simulant is the lack of constituents, such as agglutinates. These agglutinates are typically mineral fragments of the lunar regolith that are held together by glass and, depending on location, may constitute 60% to 70% of the lunar regolith.

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Method for Determining Self-Reacting Friction Stir Weld Schedules

This new process is quicker and more effective. Lyndon B. Johnson Space Center, Houston, Texas This invention establishes a process to define a viable self-reacting friction stir weld (SR-FSW) schedule (parameter settings) for a given material combination. The focus of this process results in a SR-FSW schedule that is insensitive to intentional changes or normal process variation in pin force at a given rotation and travel speed. Viable is defined as a weld schedule that is usable in a production environment and is able to accommodate normal production variations.

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Flexible, Lightweight Vacuum Shell for Load-Responsive Multilayer Insulation for High Thermal Performance

There are substantial reductions in weight and improvements in performance. Goddard Space Flight Center, Greenbelt, Maryland Better thermal insulation is needed to insulate cryogenic propellants used by NASA for launch vehicles, spacecraft, and orbiting fuel depots. In particular, cryotank insulation during in-air pre-launch and launch ascent stages currently uses spray-on foam insulation (SOFI), which is extremely problematic.

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Bulk Separation and Manipulation of Carbon Nanotubes by Type

Lyndon B. Johnson Space Center, Houston, Texas The utility of this invention is to extract metals (semi-metals) or semiconductors from bulk nanotube samples. The bulk material is a mixture of the two. These materials can then be used to clone a particular type of nanotube, place a particular type in a device, generate smart materials, or make sensing elements.

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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: Electronics & Computers, Electronic Components, Manufacturing & Prototyping, Rapid Prototyping & Tooling, Green Design & Manufacturing, Software, Computer-Aided Design (CAD), Medical, Diagnostics, Machinery & Automation, Semiconductors & ICs, Nanotechnology, News, Automotive

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3D Printer Heads to International Space Station

The first 3D printer is soon to fly into Earth orbit, finding a home aboard the International Space Station (ISS). The size of a small microwave, the unit is called Portal. The hardware serves as a testbed for evaluating how well 3D printing and the microgravity of space combine. The soon-to-fly 3D printer can churn out plastic objects within a span of 15 minutes to an hour.The technology works by extruding heated plastic, and then builds successive layers to make a three-dimensional object. In essence, the test on the ISS might well lead to establishing a “machine shop” in space. The 3D printer experiment is being done under the tech directorate's Game Changing Development Program, a NASA thrust that seeks to identify and rapidly mature innovative/high impact capabilities and technologies for infusion in a broad array of future NASA missions.According to the team, manufacturing assets in space, as opposed to launching them from Earth, will accelerate and broaden space development while providing unprecedented access for people on Earth to use in-space capabilities. SourceAlso: Learn about Ammonia Leak Detection on the ISS.

Posted in: Manufacturing & Prototyping, Rapid Prototyping & Tooling, Materials, Plastics, Test & Measurement, Aerospace, News

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