Manufacturing & Prototyping

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.

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...

A microfabrication process is proposed to produce a nanopore membrane for continuous passive drug release to maintain constant drug concentrations in the patient’s blood throughout the delivery period. Based on silicon microfabrication technology, the dimensions of the...

High-power ultrasonic actuators are generally assembled with a horn, backing, stress bolt, piezoelectric rings, and electrodes. The manufacturing process is complex, expensive, difficult, and time-consuming. The internal stress bolt needs to be insulated and presents a potential internal discharge...

A high-performance design, and fabrication and growth processes to implement the design, have been devised for encapsulating a hydrated salt in a container that both protects the salt and provides thermal conductance between the salt and the environment surrounding the container. The unitary...

As the recycling of plastic continues in the United States, there is a great need for the increased utilization of recycled products. Some of the plastic being recycled is extruded into a product known as plastic lumber, which is similar in shape and texture to its wood...

Broad area cooling shields are a massefficient alternative to conductively cooled thermal radiation shielding. The shield would actively intercept a large portion of incident thermal radiation and transport the heat away using cryogenic helium gas. The design concept...

Etalon mounts for tunable Fabry-Perot interferometers can now be fabricated from reaction-bonded silicon carbide structural components. These mounts are rigid, lightweight, and thermally stable. The fabrication of these mounts involves the exploitation of post-casting capabilities that (1)...

The fabrication of large optics is traditionally a slow process, and fabrication capability is often limited by measurement capability. While techniques exist to measure mirror figure with nanometer precision,...

A solvent/non-solvent sintering tech- nique has been devised for joining poly- meric microspheres to make porous matri- ces for use as drug-delivery devices or scaf- folds that could be seeded with cells for growing tissues. Unlike traditional sinter- ing at elevated temperature and...

Metallic magnetic calorimeters (MMC) are one of the most promising devices to provide very high energy resolution needed for future astronomical x-ray spectroscopy. MMC detectors can be built to large detector arrays having thousands of pixels. Position-sensitive magnetic...

A connector retainer and mounting system has been designed to replace screw-mounting of Winchester connectors. Countersunk screws are normally used to secure connectors to structures, and to keep them from coming apart. These screws are normally put into...

The use of high-strength, lightweight composites for the fixture is the novel feature of this innovation. The main advantage is the light weight and high stiffness-to-mass ratio relative to aluminum.

In an alternative approach to increasing the degrees of wetting and adhesion between the fiber and matrix components of organic-fiber/polymer matrix composite materials, the matrix resins are modified. Heretofore, it has been common practice to modify the fibers rather than the matrices:...

This work proposes to establish the feasibility of fabricating isolated ridge waveguides in 5% MgO:LN. Ridge waveguides in MgO:LN will significantly improve power handling and conversion efficiency, increase photonic component integration, and be well suited to space-based applications....

Oxygen system components fabricated by Laser Engineered Net Shaping™ (LENS™) could result in improved safety and performance. LENS™ is a near-net shape manufacturing process fusing powdered materials injected into a laser beam. Parts can be fabricated with a variety of elemental...

Flip-chip hybridization, also known as bump bonding, is a packaging technique for microelectronic devices that directly connects an active element or detector to a substrate readout face-to-face, eliminating the need for wire bonding. In order to make conductive links between the...

A method is based on two unique processing steps that are both based on deterministic machining processes using a single-point diamond turning (SPDT) machine. In the first step, a high-MRR (material removal rate) process is used to machine the part within several microns of the final geometry. In the...

Gas introduction from near-ambient pressures to high vacuum traditionally is accomplished either by multi-stage differential pumping that allows for very rapid response, or by a capillary method that allows for a simple, single-stage introduction, but which often has a delayed response. Another means to...

Integrated circuits that incorporate square arrays of superconducting-transition-edge bolometers with optically reflective backshorts are being developed for use in image sensors in the spectral range from far infrared to millimeter wavelengths. To maximize the optical efficiency (and, thus,...

Honeycomb structures are commonly employed as load- and force-bearing structures as they are structurally strong and lightweight. These structures include many aircraft and spacecraft surfaces, including aircraft wings and fuselages, spacecraft pressure vessels, and...

A procedure was developed to inject thermal filler material (a paste-like substance) inside the power wire bundle coming from solar arrays. This substance fills in voids between wires, which enhances the heat path and reduces wire temperature. This leads...

Carbon nanotube (CNT)-based sensors for structural health monitoring (SHM) can be embedded in structures of all geometries to monitor conditions both inside and at the surface of the structure to continuously sense changes. These CNTs can be manipulated into specific orientations to create...