Falcon: Visual analysis of large, irregularly sampled, and multivariate time series data in additive manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Steed, Chad A.; Halsey, William; Dehoff, Ryan

Flexible visual analysis of long, high-resolution, and irregularly sampled time series data from multiple sensor streams is a challenge in several domains. In the field of additive manufacturing, this capability is critical for realizing the full potential of large-scale 3D printers. Here, we propose a visual analytics approach that helps additive manufacturing researchers acquire a deep understanding of patterns in log and imagery data collected by 3D printers. Our specific goals include discovering patterns related to defects and system performance issues, optimizing build configurations to avoid defects, and increasing production efficiency. We introduce Falcon, a new visual analytics system thatmore » allows users to interactively explore large, time-oriented data sets from multiple linked perspectives. Falcon provides overviews, detailed views, and unique segmented time series visualizations, all with adjustable scale options. To illustrate the effectiveness of Falcon at providing thorough and efficient knowledge discovery, we present a practical case study involving experts in additive manufacturing and data from a large-scale 3D printer. The techniques described are applicable to the analysis of any quantitative time series, though the focus of this paper is on additive manufacturing.« less

Utility of Big Area Additive Manufacturing (BAAM) For The Rapid Manufacture of Customized Electric Vehicles

DOE Office of Scientific and Technical Information (OSTI.GOV)

Love, Lonnie J.

This Oak Ridge National Laboratory (ORNL) Manufacturing Development Facility (MDF) technical collaboration project was conducted in two phases as a CRADA with Local Motors Inc. Phase 1 was previously reported as Advanced Manufacturing of Complex Cyber Mechanical Devices through Community Engagement and Micro-manufacturing and demonstrated the integration of components onto a prototype body part for a vehicle. Phase 2 was reported as Utility of Big Area Additive Manufacturing (BAAM) for the Rapid Manufacture of Customized Electric Vehicles and demonstrated the high profile live printing of an all-electric vehicle using ONRL s Big Area Additive Manufacturing (BAAM) technology. This demonstration generatedmore » considerable national attention and successfully demonstrated the capabilities of the BAAM system as developed by ORNL and Cincinnati, Inc. and the feasibility of additive manufacturing of a full scale electric vehicle as envisioned by the CRADA partner Local Motors, Inc.« less

OTEC riser cable model and prototype testing

NASA Astrophysics Data System (ADS)

Kurt, J. P.; Schultz, J. A.; Roblee, L. H. S.

1981-12-01

Two different OTEC riser cables have been developed to span the distance between a floating OTEC power plant and the ocean floor. The major design concerns for a riser cable in the dynamic OTEC environment are fatigue, corrosion, and electrical/mechanical aging of the cable components. The basic properties of the cable materials were studied through tests on model cables and on samples of cable materials. Full-scale prototype cables were manufactured and were tested to measure their electrical and mechanical properties and performance. The full-scale testing was culminated by the electrical/mechanical fatigue test, which exposes full-scale cables to simultaneous tension, bending and electrical loads, all in a natural seawater environment.

Design and development of pressure and repressurization purge system for reusable space shuttle multilayer insulation system

NASA Technical Reports Server (NTRS)

1972-01-01

The experimental determination of purge bag materials properties, development of purge bag manufacturing techniques, experimental evaluation of a subscale purge bag under simulated operating conditions and the experimental evaluation of the purge pin concept for MLI purging are discussed. The basic purge bag material, epoxy fiberglass bounded by skins of FEP Teflon, showed no significant permeability to helium flow under normal operating conditions. Purge bag small scale manufacturing tests were conducted to develop tooling and fabrication techniques for use in full scale bag manufacture. A purge bag material layup technique was developed whereby the two plys of epoxy fiberglass enclosed between skins of FEP Teflon are vacuum bag cured in an oven in a single operation. The material is cured on a tool with the shape of a purge bag half. Plastic tooling was selected for use in bag fabrication. A model purge bag 0.6 m in diameter was fabricated and subjected to a series of structural and environmental tests simulating various flight type environments. Pressure cycling tests at high (450 K) and low (200 K) temperature as well as acoustic loading tests were performed. The purge bag concept proved to be structurally sound and was used for the full scale bag detailed design model.

Summary of the Manufacture, Testing and Model Validation of a Full-Scale Radiator for Fission Surface Power Applications

NASA Technical Reports Server (NTRS)

Ellis, David L.; Calder, James; Siamidis, John

2011-01-01

A full-scale radiator for a lunar fission surface power application was manufactured by Material innovations, Inc., for the NASA Glenn Research Center. The radiator was designed to reject 6 kWt with an inlet water temperature of 400 K and a water mass flow rate of 0.5 kg/s. While not flight hardware, the radiator incorporated many potential design features and manufacturing techniques for future flight hardware. The radiator was tested at NASA Glenn Research Center for heat rejection performance. The results showed that the radiator design was capable of rejecting over 6 kWt when operating at the design conditions. The actual performance of the radiator as a function of operational manifolds, inlet water temperature and facility sink temperature was compared to the predictive model developed by NASA Glenn Research Center. The results showed excellent agreement with the model with the actual average face sheet temperature being within 1% of the predicted value. The results will be used in the design and production of NASA s next generation fission power heat rejection systems. The NASA Glenn Research Center s Technology Demonstration Unit will be the first project to take advantage of the newly developed manufacturing techniques and analytical models.

Integrated Composite Stiffener Structure (ICoSS) Concept for Planetary Entry Vehicles

NASA Technical Reports Server (NTRS)

Kellas, Sotiris

2016-01-01

Results from the design, manufacturing, and testing of a lightweight Integrated Composite Stiffened Structure (ICoSS) concept, intended for multi-mission planetary entry vehicles are presented. Tests from both component and full-scale tests for a typical Earth Entry Vehicle forward shell manufactured using the ICoSS concept are presented and advantages of the concept for the particular application of passive Earth Entry Vehicles over other structural concepts are discussed.

Development of Experimental Icing Simulation Capability for Full-Scale Swept Wings: Hybrid Design Process, Years 1 and 2

NASA Technical Reports Server (NTRS)

Fujiwara, Gustavo; Bragg, Mike; Triphahn, Chris; Wiberg, Brock; Woodard, Brian; Loth, Eric; Malone, Adam; Paul, Bernard; Pitera, David; Wilcox, Pete;

Materials and Process Activities for NASA's Composite Crew Module

NASA Technical Reports Server (NTRS)

Polis, Daniel L.

2012-01-01

In January 2007, the NASA Administrator and Associate Administrator for the Exploration Systems Mission Directorate chartered the NASA Engineering and Safety Center (NESC) to design, build, and test a full-scale Composite Crew Module (CCM). The overall goal of the CCM project was to develop a team from the NASA family with hands-on experience in composite design, manufacturing, and testing in anticipation of future space exploration systems being made of composite materials. The CCM project was planned to run concurrently with the Orion project s baseline metallic design within the Constellation Program so that features could be compared and discussed without inducing risk to the overall Program. The materials and process activities were prioritized based on a rapid prototype approach. This approach focused developmental activities on design details with greater risk and uncertainty, such as out-of-autoclave joining, over some of the more traditional lamina and laminate building block levels. While process development and associated building block testing were performed, several anomalies were still observed at the full-scale level due to interactions between process robustness and manufacturing scale-up. This paper describes the process anomalies that were encountered during the CCM development and the subsequent root cause investigations that led to the final design solutions. These investigations highlight the importance of full-scale developmental work early in the schedule of a complex composite design/build project.

Sceening, down selection, and implementation of environmentally compliant cleaning and insulation bonding for MNASA

NASA Astrophysics Data System (ADS)

Keen, Jill M.; Hutchens, D. E.; Smith, G. M.; Dillard, T. W.

1994-06-01

MNASA, a quarter-scale space shuttle solid rocket motor, has historically been processed using environmentally and physiologically harmful chemicals. This program draws from previous testing done in support of full-scale manufacturing and examines the synergy and interdependency between environmentally acceptable materials for Solid Rocket Motor insulation applications, bonding, corrosion inhibiting, painting, priming and cleaning; and then implements new materials and processes in sub-scale motors. Tests have been conducted to eliminate or minimize hazardous chemicals used in the manufacture of MNASA components and identify alternate materials and/or processes following NASA Operational Environment Team (NOET) priorities. This presentation describes implementation of high pressure water refurbishment cleaning, aqueous precision cleaning using both Brulin 815 GD and Jettacin and insulation case bonding using ODC compliant primers and adhesives.

Developing Materials Processing to Performance Modeling Capabilities and the Need for Exascale Computing Architectures (and Beyond)

DOE Office of Scientific and Technical Information (OSTI.GOV)

Schraad, Mark William; Luscher, Darby Jon

Additive Manufacturing techniques are presenting the Department of Energy and the NNSA Laboratories with new opportunities to consider novel component production and repair processes, and to manufacture materials with tailored response and optimized performance characteristics. Additive Manufacturing technologies already are being applied to primary NNSA mission areas, including Nuclear Weapons. These mission areas are adapting to these new manufacturing methods, because of potential advantages, such as smaller manufacturing footprints, reduced needs for specialized tooling, an ability to embed sensing, novel part repair options, an ability to accommodate complex geometries, and lighter weight materials. To realize the full potential of Additivemore » Manufacturing as a game-changing technology for the NNSA’s national security missions; however, significant progress must be made in several key technical areas. In addition to advances in engineering design, process optimization and automation, and accelerated feedstock design and manufacture, significant progress must be made in modeling and simulation. First and foremost, a more mature understanding of the process-structure-property-performance relationships must be developed. Because Additive Manufacturing processes change the nature of a material’s structure below the engineering scale, new models are required to predict materials response across the spectrum of relevant length scales, from the atomistic to the continuum. New diagnostics will be required to characterize materials response across these scales. And not just models, but advanced algorithms, next-generation codes, and advanced computer architectures will be required to complement the associated modeling activities. Based on preliminary work in each of these areas, a strong argument for the need for Exascale computing architectures can be made, if a legitimate predictive capability is to be developed.« less

Manufacturing process scale-up of optical grade transparent spinel ceramic at ArmorLine Corporation

NASA Astrophysics Data System (ADS)

Spilman, Joseph; Voyles, John; Nick, Joseph; Shaffer, Lawrence

2013-06-01

While transparent Spinel ceramic's mechanical and optical characteristics are ideal for many Ultraviolet (UV), visible, Short-Wave Infrared (SWIR), Mid-Wave Infrared (MWIR), and multispectral sensor window applications, commercial adoption of the material has been hampered because the material has historically been available in relatively small sizes (one square foot per window or less), low volumes, unreliable supply, and with unreliable quality. Recent efforts, most notably by Technology Assessment and Transfer (TA and T), have scaled-up manufacturing processes and demonstrated the capability to produce larger windows on the order of two square feet, but with limited output not suitable for production type programs. ArmorLine Corporation licensed the hot-pressed Spinel manufacturing know-how of TA and T in 2009 with the goal of building the world's first dedicated full-scale Spinel production facility, enabling the supply of a reliable and sufficient volume of large Transparent Armor and Optical Grade Spinel plates. With over $20 million of private investment by J.F. Lehman and Company, ArmorLine has installed and commissioned the largest vacuum hot press in the world, the largest high-temperature/high-pressure hot isostatic press in the world, and supporting manufacturing processes within 75,000 square feet of manufacturing space. ArmorLine's equipment is capable of producing window blanks as large as 50" x 30" and the facility is capable of producing substantial volumes of material with its Lean configuration and 24/7 operation. Initial production capability was achieved in 2012. ArmorLine will discuss the challenges that were encountered during scale-up of the manufacturing processes, ArmorLine Optical Grade Spinel optical performance, and provide an overview of the facility and its capabilities.

Advanced Thermoplastic Polymers and Additive Manufacturing Applied to ISS Columbus Toolbox: Lessons Learnt and Results

NASA Astrophysics Data System (ADS)

Ferrino, Marinella; Secondo, Ottaviano; Sabbagh, Amir; Della Sala, Emilio

2014-06-01

In the frame of the International Space Station (ISS) Exploitation Program a new toolbox has been realized by TAS-I to accommodate the tools currently in use on the ISS Columbus Module utilizing full-scale prototypes obtained with 3D rapid prototyping. The manufacturing of the flight hardware by means of advanced thermoplastic polymer UL TEM 9085 and additive manufacturing Fused Deposition Modelling (FDM) technology represent innovative elements. In this paper, the results achieved and the lessons learned are analyzed to promote future technology know-how. The acquired experience confirmed that the additive manufacturing process allows to save time/cost and to realize new shapes/features to introduce innovation in products and future design processes for space applications.

Newly invented biobased materials from low-carbon, diverted waste fibers: research methods, testing, and full-scale application in a case study structure

Treesearch

Julee A Herdt; John Hunt; Kellen Schauermann

2016-01-01

This project demonstrates newly invented, biobased construction materials developed by applying lowcarbon, biomass waste sources through the Authors’ engineered fiber processes and technology. If manufactured and applied large-scale the project inventions can divert large volumes of cellulose waste into high-performance, low embodied energy, environmental construction...

Passenger car crippling end-load test and analyses

DOT National Transportation Integrated Search

2017-09-01

The Transportation Technology Center, Inc. (TTCI) performed a series of full-scale tests and a finite element analysis (FEA) in a case study that may become a model for manufacturers seeking to use the waiver process of Tier I crashworthiness and occ...

Quality cell therapy manufacturing by design.

PubMed

Lipsitz, Yonatan Y; Timmins, Nicholas E; Zandstra, Peter W

2016-04-01

Transplantation of live cells as therapeutic agents is poised to offer new treatment options for a wide range of acute and chronic diseases. However, the biological complexity of cells has hampered the translation of laboratory-scale experiments into industrial processes for reliable, cost-effective manufacturing of cell-based therapies. We argue here that a solution to this challenge is to design cell manufacturing processes according to quality-by-design (QbD) principles. QbD integrates scientific knowledge and risk analysis into manufacturing process development and is already being adopted by the biopharmaceutical industry. Many opportunities to incorporate QbD into cell therapy manufacturing exist, although further technology development is required for full implementation. Linking measurable molecular and cellular characteristics of a cell population to final product quality through QbD is a crucial step in realizing the potential for cell therapies to transform healthcare.

Development and manufacture of reactive-transfer-printed CIGS photovoltaic modules

NASA Astrophysics Data System (ADS)

Eldada, Louay; Sang, Baosheng; Lu, Dingyuan; Stanbery, Billy J.

2010-09-01

In recent years, thin-film photovoltaic (PV) companies started realizing their low manufacturing cost potential, and grabbing an increasingly larger market share from multicrystalline silicon companies. Copper Indium Gallium Selenide (CIGS) is the most promising thin-film PV material, having demonstrated the highest energy conversion efficiency in both cells and modules. However, most CIGS manufacturers still face the challenge of delivering a reliable and rapid manufacturing process that can scale effectively and deliver on the promise of this material system. HelioVolt has developed a reactive transfer process for CIGS absorber formation that has the benefits of good compositional control, high-quality CIGS grains, and a fast reaction. The reactive transfer process is a two stage CIGS fabrication method. Precursor films are deposited onto substrates and reusable print plates in the first stage, while in the second stage, the CIGS layer is formed by rapid heating with Se confinement. High quality CIGS films with large grains were produced on a full-scale manufacturing line, and resulted in high-efficiency large-form-factor modules. With 14% cell efficiency and 12% module efficiency, HelioVolt started to commercialize the process on its first production line with 20 MW nameplate capacity.

Full-Scale Incineration System Trial Burns at the Naval Construction Battalion Center, Gulfport, Mississippi. Volume 2, Part 2

DTIC Science & Technology

1991-07-01

The prime mover for the MWP-2000 is a single steam powered jet venturi scrubber that was manufactured by Hydrosonics, Inc. to develop a negative...orime mover for the MWP-2000 is a single steam powered jet venturi scrubber that was manufactured by Hydrosonics, inc. to develop a negative pressure...packed tower and the scrubber during the trial burn or opening of the TRV, you should include these AWISOs since these shut offs would normally be

Using PAT to accelerate the transition to continuous API manufacturing.

PubMed

Gouveia, Francisca F; Rahbek, Jesper P; Mortensen, Asmus R; Pedersen, Mette T; Felizardo, Pedro M; Bro, Rasmus; Mealy, Michael J

2017-01-01

Significant improvements can be realized by converting conventional batch processes into continuous ones. The main drivers include reduction of cost and waste, increased safety, and simpler scale-up and tech transfer activities. Re-designing the process layout offers the opportunity to incorporate a set of process analytical technologies (PAT) embraced in the Quality-by-Design (QbD) framework. These tools are used for process state estimation, providing enhanced understanding of the underlying variability in the process impacting quality and yield. This work describes a road map for identifying the best technology to speed-up the development of continuous processes while providing the basis for developing analytical methods for monitoring and controlling the continuous full-scale reaction. The suitability of in-line Raman, FT-infrared (FT-IR), and near-infrared (NIR) spectroscopy for real-time process monitoring was investigated in the production of 1-bromo-2-iodobenzene. The synthesis consists of three consecutive reaction steps including the formation of an unstable diazonium salt intermediate, which is critical to secure high yield and avoid formation of by-products. All spectroscopic methods were able to capture critical information related to the accumulation of the intermediate with very similar accuracy. NIR spectroscopy proved to be satisfactory in terms of performance, ease of installation, full-scale transferability, and stability to very adverse process conditions. As such, in-line NIR was selected to monitor the continuous full-scale production. The quantitative method was developed against theoretical concentration values of the intermediate since representative sampling for off-line reference analysis cannot be achieved. The rapid and reliable analytical system allowed the following: speeding up the design of the continuous process and a better understanding of the manufacturing requirements to ensure optimal yield and avoid unreacted raw materials and by-products in the continuous reactor effluent. Graphical Abstract Using PAT to accelerate the transition to continuous API manufacturing.

DOE Office of Scientific and Technical Information (OSTI.GOV)

McGrath, M.S.; Nieuwland, J.C.; Lith, C. van

Holzindustie Bruchsal (HIB) was required to treat moderate levels of styrene emissions from their plastic dashboard manufacturing process. After evaluating many types of control technologies, HIB decided to install a Bioton biofiltration system from Monsanto Enviro-Chem Systems Inc. (MEC). After the installation of the Bioton biofilter, HIB and MEC learned that large amounts of butylacetate were also present in the off-gas stream. The presence of butylacetate was found to have inhibitory effects on the removal of styrene. Therefore, MEC performed a series of pilot and laboratory studies to determine if a bacteria strain could be identified that would be capablemore » of removing styrene in the presence of butylacetate. It was found that a specific bacteria strain was capable of achieving high levels of styrene removal without inhibition from butylacetate in laboratory and pilot testing. This strain was inoculated into the full scale system. After acclimation, the full scale inoculation produced a consortium of bacteria that biologically removed the styrene from the dashboard manufacturing process in the presence of butylacetate.« less

Impact of 50% Synthesized Iso-Paraffins (SIP) on F-76 Fuel Coalescence

DTIC Science & Technology

2013-12-16

petroleum JP-5 and Synthesized Iso-Paraffins (SIP). SIP fuels are made from direct fermentation of sugar into olefinic hydrocarbons. The olefinic...manufactured scaled down filter/coalescer and separator to simulate the performance of a full-scale filter separator system. This test is designed to predict...5 and Synthesized Iso-Paraffins (SIP). SIP fuels are made from direct fermentation of sugar into olefinic hydrocarbons. The olefinic hydrocarbons

36 CFR 2.18 - Snowmobiles.

Code of Federal Regulations, 2011 CFR

2011-07-01

... that makes excessive noise. Excessive noise for snowmobiles manufactured after July 1, 1975 is a level of total snowmobile noise that exceeds 78 decibels measured on the A-weighted scale measured at 50... on snowmobile operation at or near full throttle. (2) Operating a snowmobile without a lighted white...

36 CFR 2.18 - Snowmobiles.

Code of Federal Regulations, 2010 CFR

2010-07-01

... that makes excessive noise. Excessive noise for snowmobiles manufactured after July 1, 1975 is a level of total snowmobile noise that exceeds 78 decibels measured on the A-weighted scale measured at 50... on snowmobile operation at or near full throttle. (2) Operating a snowmobile without a lighted white...

Design, qualification, manufacturing and integration of IXV Ablative Thermal Protection System

NASA Astrophysics Data System (ADS)

Cioeta, Mario; Di Vita, Gandolfo; Signorelli Maria, Teresa; Bianco, Gianluca; Cutroni, Maurizio; Damiani, Francesco; Ferretti, Viviana; Rotondo, Adriano

2016-07-01

In the present paper, all the activities carried out by Avio S.p.A in order to define, qualify, manufacture and integrate the IXV Ablative TPS will be presented. In particular the extensive numerical simulation in both small and full scale testing activities will be overviewed. Wide-ranging testing activity has been carried out in order to verify, confirm and correlate the numerical models used for TPS sizing. Tests ranged from classical thermo-mechanical characterization traction specimens to tests in plasma wind tunnels on dedicated prototypes. Finally manufacturing and integration activities will be described emphasizing technological aspects solved in order to meet the stringent requirements in terms of shape accuracy and integration tolerances.

Space shuttle orbit maneuvering engine

NASA Technical Reports Server (NTRS)

Pauckert, R. P.

1975-01-01

Data on the performance, stability, and thermal characteristics of an OME operating with an alternate injector configuration and with alternate propellants was obtained. The design, manufacturing, and operating characteristics of an electroformed, regeneratively cooled thrust chamber were also derived. Subscale and full scale tests provide data relating to off-design and transient operation.

Cells as advanced therapeutics: State-of-the-art, challenges, and opportunities in large scale biomanufacturing of high-quality cells for adoptive immunotherapies.

PubMed

Dwarshuis, Nate J; Parratt, Kirsten; Santiago-Miranda, Adriana; Roy, Krishnendu

2017-05-15

Therapeutic cells hold tremendous promise in treating currently incurable, chronic diseases since they perform multiple, integrated, complex functions in vivo compared to traditional small-molecule drugs or biologics. However, they also pose significant challenges as therapeutic products because (a) their complex mechanisms of actions are difficult to understand and (b) low-cost bioprocesses for large-scale, reproducible manufacturing of cells have yet to be developed. Immunotherapies using T cells and dendritic cells (DCs) have already shown great promise in treating several types of cancers, and human mesenchymal stromal cells (hMSCs) are now extensively being evaluated in clinical trials as immune-modulatory cells. Despite these exciting developments, the full potential of cell-based therapeutics cannot be realized unless new engineering technologies enable cost-effective, consistent manufacturing of high-quality therapeutic cells at large-scale. Here we review cell-based immunotherapy concepts focused on the state-of-the-art in manufacturing processes including cell sourcing, isolation, expansion, modification, quality control (QC), and culture media requirements. We also offer insights into how current technologies could be significantly improved and augmented by new technologies, and how disciplines must converge to meet the long-term needs for large-scale production of cell-based immunotherapies. Copyright © 2017 Elsevier B.V. All rights reserved.

Application of damage tolerance methodology in certification of the Piaggio P-180 Avanti

NASA Technical Reports Server (NTRS)

Johnson, Jerry

1992-01-01

The Piaggio P-180 Avanti, a twin pusher-prop engine nine-passenger business aircraft was certified in 1990, to the requirements of FAR Part 23 and Associated Special Conditions for Composite Structure. Certification included the application of a damage tolerant methodology to the design of the composite forward wing and empennage (vertical fin, horizontal stabilizer, tailcone, and rudder) structure. This methodology included an extensive analytical evaluation coupled with sub-component and full-scale testing of the structure. The work from the Damage Tolerance Analysis Assessment was incorporated into the full-scale testing. Damage representing hazards such as dropped tools, ground equipment, handling, and runway debris, was applied to the test articles. Additional substantiation included allowing manufacturing discrepancies to exist unrepaired on the full-scale articles and simulated bondline failures in critical elements. The importance of full-scale testing in the critical environmental conditions and the application of critical damage are addressed. The implication of damage tolerance on static and fatigue testing is discussed. Good correlation between finite element solutions and experimental test data was observed.

Algorithmic design for 3D printing at building scale

DOE PAGES

Guerguis, Maged; Eikevik, Leif; Obendorf, Andrew; ...

2017-01-01

Here, this paper addresses the use of algorithmic design paired with additive manufacturing and their potential impact on architectural design and fabrication of a full-sized building, as demonstrated with the AMIE project. AMIE (Additive Manufacturing and Integrated Energy) was collaboration to 3d print a building and vehicle. Both the car and building were designed to generate, store and share energy in an effort to reduce or eliminate reliability on the power grid. This paper is intended to outline our methodology in successfully designing for these innovative strategies, with a focus on the use of computational design tools as a catalystmore » for design optimization, integrated project delivery, rapid prototyping and fabrication of building elements using additive manufacturing.« less

Algorithmic design for 3D printing at building scale

DOE Office of Scientific and Technical Information (OSTI.GOV)

Guerguis, Maged; Eikevik, Leif; Obendorf, Andrew

Here, this paper addresses the use of algorithmic design paired with additive manufacturing and their potential impact on architectural design and fabrication of a full-sized building, as demonstrated with the AMIE project. AMIE (Additive Manufacturing and Integrated Energy) was collaboration to 3d print a building and vehicle. Both the car and building were designed to generate, store and share energy in an effort to reduce or eliminate reliability on the power grid. This paper is intended to outline our methodology in successfully designing for these innovative strategies, with a focus on the use of computational design tools as a catalystmore » for design optimization, integrated project delivery, rapid prototyping and fabrication of building elements using additive manufacturing.« less

An Ice Protection and Detection Systems Manufacturer's Perspective

NASA Technical Reports Server (NTRS)

Sweet, Dave

2009-01-01

Accomplishments include: World Class Aircraft Icing Research Center and Facility. Primary Sponsor/Partner - Aircraft Icing Consortia/Meetings. Icing Research Tunnel. Icing Test Aircraft. Icing Codes - LEWICE/Scaling, et al. Development of New Technologies (SBIR, STTR, et al). Example: Look Ahead Ice Detection. Pilot Training Materials. Full Cooperation with Academia, Government and Industry.

Manned remote work station development article

NASA Technical Reports Server (NTRS)

1978-01-01

The two prime objectives of the Manned Remote Work Station (MRWS) Development Article Study are to first, evaluate the MRWS flight article roles and associated design concepts for fundamental requirements and embody key technology developments into a simulation program; and to provide detail manufacturing drawings and schedules for a simulator development test article. An approach is outlined which establishes flight article requirements based on past studies of Solar Power Satellite, orbital construction support equipments, construction bases and near term shuttle operations. Simulation objectives are established for those technology issues that can best be addressed on a simulator. Concepts for full-scale and sub-scale simulators are then studied to establish an overall approach to studying MRWS requirements. Emphasis then shifts to design and specification of a full-scale development test article.

Structural Testing at the NWTC Helps Improve Blade Design and Increase System Reliability; NREL (National Renewable Energy Laboratory)

DOE Office of Scientific and Technical Information (OSTI.GOV)

None

2015-08-01

Since 1990, the National Renewable Energy Laboratory’s (NREL's) National Wind Technology Center (NWTC) has tested more than 150 wind turbine blades. NWTC researchers can test full-scale and subcomponent articles, conduct data analyses, and provide engineering expertise on best design practices. Structural testing of wind turbine blades enables designers, manufacturers, and owners to validate designs and assess structural performance to specific load conditions. Rigorous structural testing can reveal design and manufacturing problems at an early stage of development that can lead to overall improvements in design and increase system reliability.

A Modular Aerospike Engine Design Using Additive Manufacturing

NASA Technical Reports Server (NTRS)

Peugeot, John; Garcia, Chance; Burkhardt, Wendel

2014-01-01

A modular aerospike engine concept has been developed with the objective of demonstrating the viability of the aerospike design using additive manufacturing techniques. The aerospike system is a self-compensating design that allows for optimal performance over the entire flight regime and allows for the lowest possible mass vehicle designs. At low altitudes, improvements in Isp can be traded against chamber pressure, staging, and payload. In upper stage applications, expansion ratio and engine envelope can be traded against nozzle efficiency. These features provide flexibility to the System Designer optimizing a complete vehicle stage. The aerospike concept is a good example of a component that has demonstrated improved performance capability, but traditionally has manufacturing requirements that are too expensive and complex to use in a production vehicle. In recent years, additive manufacturing has emerged as a potential method for improving the speed and cost of building geometrically complex components in rocket engines. It offers a reduction in tooling overhead and significant improvements in the integration of the designer and manufacturing method. In addition, the modularity of the engine design provides the ability to perform full scale testing on the combustion devices outside of the full engine configuration. The proposed design uses a hydrocarbon based gas-generator cycle, with plans to take advantage of existing powerhead hardware while focusing DDT&E resources on manufacturing and sub-system testing of the combustion devices. The major risks for the modular aerospike concept lie in the performance of the propellant feed system, the structural integrity of the additive manufactured components, and the aerodynamic efficiency of the exhaust flow.

Room temperature stretch forming of scale space shuttle external tank dome gores. Volume 1: Technical

NASA Technical Reports Server (NTRS)

Blunck, R. D.; Krantz, D. E.

1974-01-01

An account of activities and data gathered in the Room Temperature Stretch Forming of One-third Scale External Tank Bulkhead Gores for space shuttle study, and a tooling design and production cost study are reported. The following study phases are described: (1) the stretch forming of three approximately one-third scale external tank dome gores from single sheets of 2219-T37 aluminum alloy; (2) the designing of a full scale production die, including a determination of tooling requirements; and (3) the determination of cost per gore at the required production rates, including manufacturing, packaging, and shipping.

On the aero-elastic design of the DTU 10MW wind turbine blade for the LIFES50+ wind tunnel scale model

NASA Astrophysics Data System (ADS)

Bayati, I.; Belloli, M.; Bernini, L.; Mikkelsen, R.; Zasso, A.

2016-09-01

This paper illustrates the aero-elastic optimal design, the realization and the verification of the wind tunnel scale model blades for the DTU 10 MW wind turbine model, within LIFES50+ project. The aerodynamic design was focused on the minimization of the difference, in terms of thrust coefficient, with respect to the full scale reference. From the Selig low Reynolds database airfoils, the SD7032 was chosen for this purpose and a proper constant section wing was tested at DTU red wind tunnel, providing force and distributed pressure coefficients for the design, in the Reynolds range 30-250 E3 and for different angles of attack. The aero-elastic design algorithm was set to define the optimal spanwise thickness over chord ratio (t/c), the chord length and the twist to match the first flapwise scaled natural frequency. An aluminium mould for the carbon fibre was CNC manufactured based on B-Splines CAD definition of the external geometry. Then the wind tunnel tests at Politecnico di Milano confirmed successful design and manufacturing approaches.

Structural Integrity of an Electron Beam Melted Titanium Alloy.

PubMed

Lancaster, Robert; Davies, Gareth; Illsley, Henry; Jeffs, Spencer; Baxter, Gavin

2016-06-14

Advanced manufacturing encompasses the wide range of processes that consist of "3D printing" of metallic materials. One such method is Electron Beam Melting (EBM), a modern build technology that offers significant potential for lean manufacture and a capability to produce fully dense near-net shaped components. However, the manufacture of intricate geometries will result in variable thermal cycles and thus a transient microstructure throughout, leading to a highly textured structure. As such, successful implementation of these technologies requires a comprehensive assessment of the relationships of the key process variables, geometries, resultant microstructures and mechanical properties. The nature of this process suggests that it is often difficult to produce representative test specimens necessary to achieve a full mechanical property characterisation. Therefore, the use of small scale test techniques may be exploited, specifically the small punch (SP) test. The SP test offers a capability for sampling miniaturised test specimens from various discrete locations in a thin-walled component, allowing a full characterisation across a complex geometry. This paper provides support in working towards development and validation strategies in order for advanced manufactured components to be safely implemented into future gas turbine applications. This has been achieved by applying the SP test to a series of Ti-6Al-4V variants that have been manufactured through a variety of processing routes including EBM and investigating the structural integrity of each material and how this controls the mechanical response.

Wide band design on the scaled absorbing material filled with flaky CIPs

NASA Astrophysics Data System (ADS)

Xu, Yonggang; Yuan, Liming; Gao, Wei; Wang, Xiaobing; Liang, Zichang; Liao, Yi

2018-02-01

The scaled target measurement is an important method to get the target characteristic. Radar absorbing materials are widely used in the low detectable target, considering the absorbing material frequency dispersion characteristics, it makes designing and manufacturing scaled radar absorbing materials on the scaled target very difficult. This paper proposed a wide band design method on the scaled absorbing material of the thin absorption coating with added carbonyl iron particles. According to the theoretical radar cross section (RCS) of the plate, the reflection loss determined by the permittivity and permeability was chosen as the main design factor. Then, the parameters of the scaled absorbing materials were designed using the effective medium theory, and the scaled absorbing material was constructed. Finally, the full-size coating plate and scaled coating plates (under three different scale factors) were simulated; the RCSs of the coating plates were numerically calculated and measured at 4 GHz and a scale factor of 2. The results showed that the compensated RCS of the scaled coating plate was close to that of the full-size coating plate, that is, the mean deviation was less than 0.5 dB, and the design method for the scaled material was very effective.

The Use of Additive Manufacturing for Fabrication of Multi-Function Small Satellite Structures

DOE Office of Scientific and Technical Information (OSTI.GOV)

Horais, Brian J; Love, Lonnie J; Dehoff, Ryan R

2013-01-01

The use of small satellites in constellations is limited only by the growing functionality of smallsats themselves. Additive manufacturing provides exciting new design opportunities for development of multifunction CubeSat structures that integrate such functions as propulsion and thermal control into the satellite structures themselves. Manufacturing of these complex multifunction structures is now possible in lightweight, high strength, materials such as titanium by using existing electron beam melting additive manufacturing processes. However, the use of today's additive manufacturing capabilities is often cost-prohibitive for small companies due to the large capital investments required. To alleviate this impediment the U.S. Department of Energymore » has established a Manufacturing Demonstration Facility (MDF) at their Oak Ridge National Laboratory (ORNL) in Tennessee that provides industry access to a broad range of energy-efficient additive manufacturing equipment for collaborative use by both small and large organizations. This paper presents a notional CubeSat multifunction design that integrates the propulsion system into a three-unit (3U) CubeSat structure. The full-scale structure has been designed and fabricated at the ORNL MDF. The use of additive manufacturing for spacecraft fabrication is opening up many new possibilities in design and fabrication capabilities for what had previously been impossible structures to fabricate.« less

Manufacturing Cost Levelization Model – A User’s Guide

DOE Office of Scientific and Technical Information (OSTI.GOV)

Morrow, William R.; Shehabi, Arman; Smith, Sarah Josephine

The Manufacturing Cost Levelization Model is a cost-performance techno-economic model that estimates total large-scale manufacturing costs for necessary to produce a given product. It is designed to provide production cost estimates for technology researchers to help guide technology research and development towards an eventual cost-effective product. The model presented in this user’s guide is generic and can be tailored to the manufacturing of any product, including the generation of electricity (as a product). This flexibility, however, requires the user to develop the processes and process efficiencies that represents a full-scale manufacturing facility. The generic model is comprised of several modulesmore » that estimate variable costs (material, labor, and operating), fixed costs (capital & maintenance), financing structures (debt and equity financing), and tax implications (taxable income after equipment and building depreciation, debt interest payments, and expenses) of a notional manufacturing plant. A cash-flow method is used to estimate a selling price necessary for the manufacturing plant to recover its total cost of production. A levelized unit sales price ($ per unit of product) is determined by dividing the net-present value of the manufacturing plant’s expenses ($) by the net present value of its product output. A user defined production schedule drives the cash-flow method that determines the levelized unit price. In addition, an analyst can increase the levelized unit price to include a gross profit margin to estimate a product sales price. This model allows an analyst to understand the effect that any input variables could have on the cost of manufacturing a product. In addition, the tool is able to perform sensitivity analysis, which can be used to identify the key variables and assumptions that have the greatest influence on the levelized costs. This component is intended to help technology researchers focus their research attention on tasks that offer the greatest opportunities for cost reduction early in the research and development stages of technology invention.« less

Additive Manufacturing of Porous Metal

DOE Office of Scientific and Technical Information (OSTI.GOV)

Dehoff, Ryan R.; Kirka, Michael M.

2017-06-01

Currently, helium is obtained through separation from natural gas. The current industrial process incurs significant costs and requires large energy resources to successfully achieve separation. Through utilizing Additive Manufacturing (AM) technologies it is possible to reduce both of these burdens when refining helium gas. The ability to engineer porosity levels within Inconel 718 discs for controlled separation of helium from natural gas was investigated. Arrays of samples fabricated using the electron beam melting process were analyzed for their relative porosity density. Based upon the measurements, full scale discs were fabricated, and subsequently tested to determine their effectiveness in separating heliummore » from liquefied natural gas.« less

Putting a price tag on novel autologous cellular therapies.

PubMed

Abou-El-Enein, Mohamed; Bauer, Gerhard; Medcalf, Nicholas; Volk, Hans-Dieter; Reinke, Petra

2016-08-01

Cell therapies, especially autologous therapies, pose significant challenges to researchers who wish to move from small, probably academic, methods of manufacture to full commercial scale. There is a dearth of reliable information about the costs of operation, and this makes it difficult to predict with confidence the investment needed to translate the innovations to the clinic, other than as small-scale, clinician-led prescriptions. Here, we provide an example of the results of a cost model that takes into account the fixed and variable costs of manufacture of one such therapy. We also highlight the different factors that influence the product final pricing strategy. Our findings illustrate the need for cooperative and collective action by the research community in pre-competitive research to generate the operational models that are much needed to increase confidence in process development for these advanced products. Copyright © 2016 International Society for Cellular Therapy. Published by Elsevier Inc. All rights reserved.

75 FR 72944 - Third Party Testing for Certain Children's Products; Mattresses, Mattress Pads, and/or Mattress...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-11-29

... Standard prescribes a full-scale test using a pair of T-shaped gas burners designed to represent burning... Group sought an additional one year for manufacturers to comply with the third party testing requirement... accredited by an ILAC-MRA member at the time of the test. For firewalled conformity assessment bodies, the...

Study of Strain-Stress Behavior of Non-Pressure Reinforced Concrete Pipes Used in Road Building

NASA Astrophysics Data System (ADS)

Rakitin, B. A.; Pogorelov, S. N.; Kolmogorova, A. O.

2017-11-01

The article contains the results of the full-scale tests performed for special road products - large-diameter non-pressure concrete pipes reinforced with a single space cylindrical frame manufactured with the technology of high-frequency vertical vibration molding with an immediate demolding. The authors studied the change in the strain-stress behavior of reinforced concrete pipes for underground pipeline laying depending on their laying depth in the trench and the transport load considering the properties of the surrounding ground mass. The strain-stress behavior of the reinforced concrete pipes was evaluated using the strain-gauge method based on the application of active resistance strain gauges. Based on the completed research, the authors made a conclusion on the applicability of a single space frame for reinforcement of large-diameter non-pressure concrete pipes instead of a double frame which allows one to significantly reduce the metal consumption for the production of one item. As a result of the full-scale tests of reinforced concrete pipes manufactured by vertical vibration molding, the authors obtained new data on the deformation of a pipeline cross-section depending on the placement of the transport load with regard to the axis.

Fully Coupled Simulation of Lithium Ion Battery Cell Performance

DOE Office of Scientific and Technical Information (OSTI.GOV)

Trembacki, Bradley L.; Murthy, Jayathi Y.; Roberts, Scott Alan

Lithium-ion battery particle-scale (non-porous electrode) simulations applied to resolved electrode geometries predict localized phenomena and can lead to better informed decisions on electrode design and manufacturing. This work develops and implements a fully-coupled finite volume methodology for the simulation of the electrochemical equations in a lithium-ion battery cell. The model implementation is used to investigate 3D battery electrode architectures that offer potential energy density and power density improvements over traditional layer-by-layer particle bed battery geometries. Advancement of micro-scale additive manufacturing techniques has made it possible to fabricate these 3D electrode microarchitectures. A variety of 3D battery electrode geometries are simulatedmore » and compared across various battery discharge rates and length scales in order to quantify performance trends and investigate geometrical factors that improve battery performance. The energy density and power density of the 3D battery microstructures are compared in several ways, including a uniform surface area to volume ratio comparison as well as a comparison requiring a minimum manufacturable feature size. Significant performance improvements over traditional particle bed electrode designs are observed, and electrode microarchitectures derived from minimal surfaces are shown to be superior. A reduced-order volume-averaged porous electrode theory formulation for these unique 3D batteries is also developed, allowing simulations on the full-battery scale. Electrode concentration gradients are modeled using the diffusion length method, and results for plate and cylinder electrode geometries are compared to particle-scale simulation results. Additionally, effective diffusion lengths that minimize error with respect to particle-scale results for gyroid and Schwarz P electrode microstructures are determined.« less

DOE Office of Scientific and Technical Information (OSTI.GOV)

Wheeler, D.; Ulsh, M.

In 2008, the National Renewable Energy Laboratory (NREL), under contract to the US Department of Energy (DOE), conducted a manufacturing readiness assessment (MRA) of fuel cell systems and fuel cell stacks for back-up power and material handling applications (MHE). To facilitate the MRA, manufacturing readiness levels (MRL) were defined that were based on the Technology Readiness Levels previously established by the US Department of Energy (DOE). NREL assessed the extensive existing hierarchy of MRLs developed by Department of Defense (DoD) and other Federal entities, and developed a MRL scale adapted to the needs of the Fuel Cell Technologies Program (FCTP)more » and to the status of the fuel cell industry. The MRL ranking of a fuel cell manufacturing facility increases as the manufacturing capability transitions from laboratory prototype development through Low Rate Initial Production to Full Rate Production. DOE can use MRLs to address the economic and institutional risks associated with a ramp-up in polymer electrolyte membrane (PEM) fuel cell production. In 2010, NREL updated this assessment, including additional manufacturers, an assessment of market developments since the original report, and a comparison of MRLs between 2008 and 2010.« less

Structural Integrity of an Electron Beam Melted Titanium Alloy

PubMed Central

Lancaster, Robert; Davies, Gareth; Illsley, Henry; Jeffs, Spencer; Baxter, Gavin

2016-01-01

Advanced manufacturing encompasses the wide range of processes that consist of “3D printing” of metallic materials. One such method is Electron Beam Melting (EBM), a modern build technology that offers significant potential for lean manufacture and a capability to produce fully dense near-net shaped components. However, the manufacture of intricate geometries will result in variable thermal cycles and thus a transient microstructure throughout, leading to a highly textured structure. As such, successful implementation of these technologies requires a comprehensive assessment of the relationships of the key process variables, geometries, resultant microstructures and mechanical properties. The nature of this process suggests that it is often difficult to produce representative test specimens necessary to achieve a full mechanical property characterisation. Therefore, the use of small scale test techniques may be exploited, specifically the small punch (SP) test. The SP test offers a capability for sampling miniaturised test specimens from various discrete locations in a thin-walled component, allowing a full characterisation across a complex geometry. This paper provides support in working towards development and validation strategies in order for advanced manufactured components to be safely implemented into future gas turbine applications. This has been achieved by applying the SP test to a series of Ti-6Al-4V variants that have been manufactured through a variety of processing routes including EBM and investigating the structural integrity of each material and how this controls the mechanical response. PMID:28773590

Space Shuttle Flight Support Motor no. 1 (FSM-1)

NASA Technical Reports Server (NTRS)

Hughes, Phil D.

1990-01-01

Space Shuttle Flight Support Motor No. 1 (FSM-1) was static test fired on 15 Aug. 1990 at the Thiokol Corporation Static Test Bay T-24. FSM-1 was a full-scale, full-duration static test fire of a redesigned solid rocket motor. FSM-1 was the first of seven flight support motors which will be static test fired. The Flight Support Motor program validates components, materials, and manufacturing processes. In addition, FSM-1 was the full-scale motor for qualification of Western Electrochemical Corporation ammonium perchlorate. This motor was subjected to all controls and documentation requirements CTP-0171, Revision A. Inspection and instrumentation data indicate that the FSM-1 static test firing was successful. The ambient temperature during the test was 87 F and the propellant mean bulk temperature was 82 F. Ballistics performance values were within the specified requirements. The overall performance of the FSM-1 components and test equipment was nominal.

Africa's largest long-lasting insecticide-treated net producer: lessons from A to Z Textiles.

PubMed

Masum, Hassan; Shah, Ronak; Schroeder, Karl; Daar, Abdallah S; Singer, Peter A

2010-12-13

Field trials have demonstrated the efficacy of insecticide-treated nets, and the WHO has recently endorsed a shift toward Long-Lasting Insecticide Treated nets (LLINs) due to factors such as reduced distribution costs. However, the need for LLINs poses several challenges. Is it possible to manufacture LLINs in large quantities in the African continent, where malaria is most endemic? When production is located in low-income countries, what role is played by local funding and employment, scaling up manufacturing, and partnerships? What factors influence availability and pricing? A case study of A to Z Textiles was undertaken to answer the question of how large-scale production of LLINs can occur in a low income setting. One of the largest sources of bed nets for Africa, A to Z Textiles is Africa-based, and its Tanzanian operations have a production capacity of 30 million LLINs per year, along with full WHO recommendation for its nets. Our analysis is based on semi-structured interviews with key informants familiar with A to Z, site visits in Tanzania, and literature reviews.This paper discusses the history and current status of A to Z Textiles, identifies the factors that led to its success, and suggests policy considerations that could support similar initiatives in the future. Local funding, scaling up manufacturing, technology transfer, and partnerships all played important roles in A to Z's ascent, as did perceived benefits of local employment and capacity-building. Regulatory issues and procurement rules acted as barriers. A to Z cost-effectively manufactures high-quality LLINs where malaria is most endemic. With a production capacity of 30 million LLINs per year, and full WHOPES (WHO Pesticide Evaluation Scheme) certification, A to Z Textiles demonstrates how key health goods can be successfully produced in the low-income countries that use them. Its example may be instructive and of high interest to readers in the malaria community, especially in developing countries, and to those who wish to support or partner with efforts by developing countries to build their health innovation capacity.

Africa's largest long-lasting insecticide-treated net producer: lessons from A to Z Textiles

PubMed Central

2010-01-01

Background Field trials have demonstrated the efficacy of insecticide-treated nets, and the WHO has recently endorsed a shift toward Long-Lasting Insecticide Treated nets (LLINs) due to factors such as reduced distribution costs. However, the need for LLINs poses several challenges. Is it possible to manufacture LLINs in large quantities in the African continent, where malaria is most endemic? When production is located in low-income countries, what role is played by local funding and employment, scaling up manufacturing, and partnerships? What factors influence availability and pricing? Discussion A case study of A to Z Textiles was undertaken to answer the question of how large-scale production of LLINs can occur in a low income setting. One of the largest sources of bed nets for Africa, A to Z Textiles is Africa-based, and its Tanzanian operations have a production capacity of 30 million LLINs per year, along with full WHO recommendation for its nets. Our analysis is based on semi-structured interviews with key informants familiar with A to Z, site visits in Tanzania, and literature reviews. This paper discusses the history and current status of A to Z Textiles, identifies the factors that led to its success, and suggests policy considerations that could support similar initiatives in the future. Local funding, scaling up manufacturing, technology transfer, and partnerships all played important roles in A to Z’s ascent, as did perceived benefits of local employment and capacity-building. Regulatory issues and procurement rules acted as barriers. A to Z cost-effectively manufactures high-quality LLINs where malaria is most endemic. Summary With a production capacity of 30 million LLINs per year, and full WHOPES (WHO Pesticide Evaluation Scheme) certification, A to Z Textiles demonstrates how key health goods can be successfully produced in the low-income countries that use them. Its example may be instructive and of high interest to readers in the malaria community, especially in developing countries, and to those who wish to support or partner with efforts by developing countries to build their health innovation capacity. PMID:21144077

Advanced manufacturing development of a composite empennage component for L-1011 aircraft. Phase 4: Full scale ground test

NASA Technical Reports Server (NTRS)

Jackson, A. C.; Dorwald, F.

1982-01-01

The ground tests conducted on the advanced composite vertical fin (ACVF) program are described. The design and fabrication of the test fixture and the transition structure, static test of Ground Test Article (GTA) No. 1, rework of GTA No. 2, and static, damage tolerance, fail-safe and residual strength tests of GTA No. 2 are described.

Electronic Stability Control

DTIC Science & Technology

2013-12-05

pressure (see Section 2.3) - Optional 1 percent Tire pressure 0.7 kilopascals (kPa) (0.1 pounds per square inch (psi)) Brake pedal application...d. Load cell to monitor brake pedal force with a range of 0 to 136 kg (0 to 300 lb) and accuracy + 1.0 percent full scale. While brake pedal ...sideslip, brake pedal application force and document the manufacturer, identification (serial number, part number, etc.), calibration information

Large-scale Advanced Prop-fan (LAP) technology assessment report

NASA Technical Reports Server (NTRS)

Degeorge, C. L.

1988-01-01

The technologically significant findings and accomplishments of the Large Scale Advanced Prop-Fan (LAP) program in the areas of aerodynamics, aeroelasticity, acoustics and materials and fabrication are described. The extent to which the program goals related to these disciplines were achieved is discussed, and recommendations for additional research are presented. The LAP program consisted of the design, manufacture and testing of a near full-scale Prop-Fan or advanced turboprop capable of operating efficiently at speeds to Mach .8. An aeroelastically scaled model of the LAP was also designed and fabricated. The goal of the program was to acquire data on Prop-Fan performance that would indicate the technology readiness of Prop-Fans for practical applications in commercial and military aviation.

Evaluation of Operating Time and Patient Perception Using Conventional Impression Taking and Intraoral Scanning for Crown Manufacture: A Split-mouth, Randomized Clinical Study.

PubMed

Haddadi, Yasser; Bahrami, Golnosh; Isidor, Flemming

To compare operating time and patient perception of conventional impression (CI) taking and intraoral scanning (IOS) for manufacture of a tooth-supported crown. A total of 19 patients needing indirect full-coverage restorations fitting the requirements for a split-mouth design were recruited. Each patient received two lithium disilicate crowns, one manufactured from CI taking and one from IOS. Both teeth were prepared following the manufacturers' recommendations. For both impression techniques, two retraction cords soaked in 15% ferric sulphate were used for tissue management. CIs were taken in a full-arch metallic tray using one-step, two-viscosity technique with polyvinyl siloxane silicone. The operating time for each step of the two impression methods was registered. Patient perception associated with each method was scored using a 100-mm visual analog scale (VAS), with 100 indicating maximum discomfort. Median total operating time for CI taking was 15:47 minutes (interquartile range [IQR] 15:18 to 17:30), and for IOS was 5:05 minutes (IQR 4:35 to 5:23). The median VAS score for patient perception was 73 (IQR 16 to 89) for CI taking and 6 (IQR 2 to 9) for IOS. The differences between the two groups were statistically significant (P < .05) for both parameters. IOS was less time consuming than CI taking, and patient perception was in favor of IOS.

Update on Risk Reduction Activities for a Liquid Advanced Booster for NASA's Space Launch System

NASA Technical Reports Server (NTRS)

Crocker, Andy; Graham, Bart

2016-01-01

Dynetics has designed innovative structure assemblies; manufactured them using Friction Stir Welding (FSW) to leverage NASA investments in tools, facilities, and processes; conducted proof and burst testing, demonstrating viability of design/build processes Dynetics/AR has applied state-of-the-art manufacturing and processing techniques to the heritage F-1, reducing risk for engine development Dynetics/AR has also made progress on technology demonstrations for ORSC cycle engine, which offers affordability and performance for both NASA and other launch vehicles Full-scale integrated oxidizer-rich test article. Testing will evaluate performance and combustion stability characteristics. Contributes to technology maturation for ox-rich staged combustion engines.

Additive manufacturing of materials: Opportunities and challenges

DOE Office of Scientific and Technical Information (OSTI.GOV)

Babu, Sudarsanam Suresh; Love, Lonnie J.; Dehoff, Ryan R.

Additive manufacturing (also known as 3D printing) is considered a disruptive technology for producing components with topologically optimized complex geometries as well as functionalities that are not achievable by traditional methods. The realization of the full potential of 3D printing is stifled by a lack of computational design tools, generic material feedstocks, techniques for monitoring thermomechanical processes under in situ conditions, and especially methods for minimizing anisotropic static and dynamic properties brought about by microstructural heterogeneity. In this paper, we discuss the role of interdisciplinary research involving robotics and automation, process control, multiscale characterization of microstructure and properties, and high-performancemore » computational tools to address each of these challenges. In addition, emerging pathways to scale up additive manufacturing of structural materials to large sizes (>1 m) and higher productivities (5–20 kg/h) while maintaining mechanical performance and geometrical flexibility are also discussed.« less

Additive manufacturing of materials: Opportunities and challenges

DOE PAGES

Babu, Sudarsanam Suresh; Love, Lonnie J.; Dehoff, Ryan R.; ...

2015-11-01

Additive manufacturing (also known as 3D printing) is considered a disruptive technology for producing components with topologically optimized complex geometries as well as functionalities that are not achievable by traditional methods. The realization of the full potential of 3D printing is stifled by a lack of computational design tools, generic material feedstocks, techniques for monitoring thermomechanical processes under in situ conditions, and especially methods for minimizing anisotropic static and dynamic properties brought about by microstructural heterogeneity. In this paper, we discuss the role of interdisciplinary research involving robotics and automation, process control, multiscale characterization of microstructure and properties, and high-performancemore » computational tools to address each of these challenges. In addition, emerging pathways to scale up additive manufacturing of structural materials to large sizes (>1 m) and higher productivities (5–20 kg/h) while maintaining mechanical performance and geometrical flexibility are also discussed.« less

Investigation into the influence of build parameters on failure of 3D printed parts

NASA Astrophysics Data System (ADS)

Fornasini, Giacomo

Additive manufacturing, including fused deposition modeling (FDM), is transforming the built world and engineering education. Deep understanding of parts created through FDM technology has lagged behind its adoption in home, work, and academic environments. Properties of parts created from bulk materials through traditional manufacturing are understood well enough to accurately predict their behavior through analytical models. Unfortunately, Additive Manufacturing (AM) process parameters create anisotropy on a scale that fundamentally affects the part properties. Understanding AM process parameters (implemented by program algorithms called slicers) is necessary to predict part behavior. Investigating algorithms controlling print parameters (slicers) revealed stark differences between the generation of part layers. In this work, tensile testing experiments, including a full factorial design, determined that three key factors, width, thickness, infill density, and their interactions, significantly affect the tensile properties of 3D printed test samples.

The NASA modern technology rotors program

NASA Technical Reports Server (NTRS)

Watts, M. E.; Cross, J. L.

1986-01-01

Existing data bases regarding helicopters are based on work conducted on 'old-technology' rotor systems. The Modern Technology Rotors (MTR) Program is to provide extensive data bases on rotor systems using present and emerging technology. The MTR is concerned with modern, four-bladed, rotor systems presently being manufactured or under development. Aspects of MTR philosophy are considered along with instrumentation, the MTR test program, the BV 360 Rotor, and the UH-60 Black Hawk. The program phases include computer modelling, shake test, model-scale test, minimally instrumented flight test, extensively pressure-instrumented-blade flight test, and full-scale wind tunnel test.

Advances in the Lightweight Air-Liquid Composite Heat Exchanger Development for Space Exploration Applications

NASA Technical Reports Server (NTRS)

Shin, E. Eugene; Johnston, J. Chris; Haas, Daniel

2011-01-01

An advanced, lightweight composite modular Air/Liquid (A/L) Heat Exchanger (HX) Prototype for potential space exploration thermal management applications was successfully designed, manufactured, and tested. This full-scale Prototype consisting of 19 modules, based on recommendations from its predecessor Engineering Development unit (EDU) but with improved thermal characteristics and manufacturability, was 11.2 % lighter than the EDU and achieves potentially a 42.7% weight reduction from the existing state-of-the-art metallic HX demonstrator. However, its higher pressure drop (0.58 psid vs. 0.16 psid of the metal HX) has to be mitigated by foam material optimizations and design modifications including a more systematic air channel design. Scalability of the Prototype design was validated experimentally by comparing manufacturability and performance between the 2-module coupon and the 19-module Prototype. The Prototype utilized the thermally conductive open-cell carbon foam material but with lower density and adopted a novel high-efficiency cooling system with significantly increased heat transfer contact surface areas, improved fabricability and manufacturability compared to the EDU. Even though the Prototype was required to meet both the thermal and the structural specifications, accomplishing the thermal requirement was a higher priority goal for this first version. Overall, the Prototype outperformed both the EDU and the corresponding metal HX, particularly in terms of specific heat transfer, but achieved 93.4% of the target. The next generation Prototype to achieve the specification target, 3,450W would need 24 core modules based on the simple scaling factor. The scale-up Prototype will weigh about 14.7 Kg vs. 21.6 Kg for the metal counterpart. The advancement of this lightweight composite HX development from the original feasibility test coupons to EDU to Prototype is discussed in this paper.

Opaque Nuclear Strategy

DTIC Science & Technology

2017-12-01

enrichment facility); 3. The acquisition of the technology and know-how to design, assemble, and manufacture the bomb ; 4. A full-scale nuclear test...14 Scott D. Sagan, “Why Do States Build Nuclear Weapons?: Three Models in Search of a Bomb ,” International...15 Sagan, “Why Do States Build Nuclear Weapons?: Three Models in Search of a Bomb ,” 57–59. 16 Lewis A. Dunn and Herman Kahn, Trends in Nuclear

Friction Stir Welding Development

NASA Technical Reports Server (NTRS)

Romine, Peter L.

1998-01-01

The research of this summer was a continuation of work started during the previous summer faculty fellowship period. The Friction Stir Welding process (FSW) patented by The Welding Institute (TWI), in Great Britain, has become a popular topic at the Marshall Space Flight Center over the past year. Last year it was considered a novel approach to welding but few people took it very seriously as a near term solution. However, due to continued problems with cracks in the new aluminum-lithium space shuttle external tank (ET), the friction stir process is being mobilized at full speed in an effort to mature this process for the potential manufacture of flight hardware. It is now the goal of NASA and Lockheed-Martin Corporation (LMC) to demonstrate a full-scale friction stir welding system capable of welding ET size barrel sections. The objectives this summer were: (1) Implementation and validation of the rotating dynamometer on the MSFC FSW system; (2) Collection of data for FSW process modeling efforts; (3) Specification development for FSW implementation on the vertical weld tool; (4) Controls and user interface development for the adjustable pin tool; and (5) Development of an instrumentation system for the planishing process. The projects started this summer will lead to a full scale friction stir welding system that is expected to produce a friction stir welded shuttle external tank type barrel section. The success of this could lead to the implementation of the friction stir process for manufacturing future shuttle external tanks.

Rapid prototyping of multi-scale biomedical microdevices by combining additive manufacturing technologies.

PubMed

Hengsbach, Stefan; Lantada, Andrés Díaz

2014-08-01

The possibility of designing and manufacturing biomedical microdevices with multiple length-scale geometries can help to promote special interactions both with their environment and with surrounding biological systems. These interactions aim to enhance biocompatibility and overall performance by using biomimetic approaches. In this paper, we present a design and manufacturing procedure for obtaining multi-scale biomedical microsystems based on the combination of two additive manufacturing processes: a conventional laser writer to manufacture the overall device structure, and a direct-laser writer based on two-photon polymerization to yield finer details. The process excels for its versatility, accuracy and manufacturing speed and allows for the manufacture of microsystems and implants with overall sizes up to several millimeters and with details down to sub-micrometric structures. As an application example we have focused on manufacturing a biomedical microsystem to analyze the impact of microtextured surfaces on cell motility. This process yielded a relevant increase in precision and manufacturing speed when compared with more conventional rapid prototyping procedures.

Atomic and close-to-atomic scale manufacturing—A trend in manufacturing development

NASA Astrophysics Data System (ADS)

Fang, Fengzhou

2016-12-01

Manufacturing is the foundation of a nation's economy. It is the primary industry to promote economic and social development. To accelerate and upgrade China's manufacturing sector from "precision manufacturing" to "high-performance and high-quality manufacturing", a new breakthrough should be found in terms of achieving a "leap-frog development". Unlike conventional manufacturing, the fundamental theory of "Manufacturing 3.0" is beyond the scope of conventional theory; rather, it is based on new principles and theories at the atomic and/or closeto- atomic scale. Obtaining a dominant role at the international level is a strategic move for China's progress.

Design Study for the Asteroid Redirect Vehicle (ARV) Composite Primary Bulkhead

NASA Technical Reports Server (NTRS)

Cressman, Thomas O.; Paddock, David A.

2017-01-01

A design study was undertaken of a carbon fiber primary bulkhead for a large solar electric propulsion (SEP) spacecraft. The bulkhead design, supporting up to 16 t of xenon propellant, progressed from one consisting of many simple parts with many complex joints, to one consisting of a few complex parts with a few simple joints. The unique capabilities of composites led to a topology that transitioned loads from bending to in-plane tension and shear, with low part count. This significantly improved bulkhead manufacturability, cost, and mass. The stiffness-driven structure utilized high-modulus M55J fiber unidirectional prepregs. A full-scale engineering demonstration unit (EDU) of the concept was used to demonstrate manufacturability of the concept. Actual labor data was obtained, which could be extrapolated to a full bulkhead. The effort demonstrated the practicality of using high-modulus fiber (HMF) composites for unique shape topologies that minimize mass and cost. The lessons are applicable to primary and secondary aerospace structures that are stiffness driven.

The LHC magnet system and its status of development

NASA Technical Reports Server (NTRS)

Bona, Maurizio; Perin, Romeo; Vlogaert, Jos

1995-01-01

CERN is preparing for the construction of a new high energy accelerator/collider, the Large Hadron Collider (LHC). This new facility will mainly consist of two superconducting magnetic beam channels, 27 km long, to be installed in the existing LEP tunnel. The magnetic system comprises about 1200 twin-aperture dipoles, 13.145 m long, with an operational field of 8.65 T, about 600 quadrupoles, 3 m long, and a very large number of other superconducting magnetic components. A general description of the system is given together with the main features of the design of the regular lattice magnets. The paper also describes the present state of the magnet R & D program. Results from short model work, as well as from full scale prototypes will be presented, including the recently tested 10 m long full-scale prototype dipole manufactured in industry.

Implementation of environmentally compliant cleaning and insulation bonding for MNASA

NASA Technical Reports Server (NTRS)

Hutchens, Dale E.; Keen, Jill M.; Smith, Gary M.; Dillard, Terry W.; Deweese, C. Darrell; Lawson, Seth W.

1995-01-01

Historically, many subscale and full-scale rocket motors have employed environmentally and physiologically harmful chemicals during the manufacturing process. This program examines the synergy and interdependency between environmentally acceptable materials for solid rocket motor insulation applications, bonding, corrosion inhibiting, painting, priming, and cleaning, and then implements new materials and processes in subscale motors. Tests have been conducted to eliminate or minimize hazardous chemicals used in the manufacture of modified-NASA materials test motor (MNASA) components and identify alternate materials and/or processes following NASA Operational Environmental Team (NOET) priorities. This presentation describes implementation of high pressure water refurbishment cleaning, aqueous precision cleaning using both Brulin 815 GD and Jettacin, and insulation case bonding using ozone depleting chemical (ODC) compliant primers and adhesives.

One-step volumetric additive manufacturing of complex polymer structures

PubMed Central

Shusteff, Maxim; Browar, Allison E. M.; Kelly, Brett E.; Henriksson, Johannes; Weisgraber, Todd H.; Panas, Robert M.; Fang, Nicholas X.; Spadaccini, Christopher M.

2017-01-01

Two limitations of additive manufacturing methods that arise from layer-based fabrication are slow speed and geometric constraints (which include poor surface quality). Both limitations are overcome in the work reported here, introducing a new volumetric additive fabrication paradigm that produces photopolymer structures with complex nonperiodic three-dimensional geometries on a time scale of seconds. We implement this approach using holographic patterning of light fields, demonstrate the fabrication of a variety of structures, and study the properties of the light patterns and photosensitive resins required for this fabrication approach. The results indicate that low-absorbing resins containing ~0.1% photoinitiator, illuminated at modest powers (~10 to 100 mW), may be successfully used to build full structures in ~1 to 10 s. PMID:29230437

One-step volumetric additive manufacturing of complex polymer structures.

PubMed

Shusteff, Maxim; Browar, Allison E M; Kelly, Brett E; Henriksson, Johannes; Weisgraber, Todd H; Panas, Robert M; Fang, Nicholas X; Spadaccini, Christopher M

2017-12-01

Two limitations of additive manufacturing methods that arise from layer-based fabrication are slow speed and geometric constraints (which include poor surface quality). Both limitations are overcome in the work reported here, introducing a new volumetric additive fabrication paradigm that produces photopolymer structures with complex nonperiodic three-dimensional geometries on a time scale of seconds. We implement this approach using holographic patterning of light fields, demonstrate the fabrication of a variety of structures, and study the properties of the light patterns and photosensitive resins required for this fabrication approach. The results indicate that low-absorbing resins containing ~0.1% photoinitiator, illuminated at modest powers (~10 to 100 mW), may be successfully used to build full structures in ~1 to 10 s.

Continued Water-Based Phase Change Material Heat Exchanger Development

NASA Technical Reports Server (NTRS)

Hansen, Scott; Poynot, Joe

2014-01-01

In a cyclical heat load environment such as low Lunar orbit, a spacecraft's radiators are not sized to reject the full heat load requirement. Traditionally, a supplemental heat rejection device (SHReD) such as an evaporator or sublimator is used to act as a "topper" to meet the additional heat rejection demands. Utilizing a Phase Change Material (PCM) heat exchanger (HX) as a SHReD provides an attractive alternative to evaporators and sublimators as PCM HXs do not use a consumable, thereby leading to reduced launch mass and volume requirements. In continued pursuit of water PCM HX development two full-scale, Orion sized water-based PCM HX's were constructed by Mezzo Technologies. These HX's were designed by applying prior research and experimentation to the full scale design. Design options considered included bladder restraint and clamping mechanisms, bladder manufacturing, tube patterns, fill/drain methods, manifold dimensions, weight optimization, and midplate designs. Design and construction of these HX's led to successful testing of both PCM HX's.

Estimating Animal Abundance in Ground Beef Batches Assayed with Molecular Markers

PubMed Central

Hu, Xin-Sheng; Simila, Janika; Platz, Sindey Schueler; Moore, Stephen S.; Plastow, Graham; Meghen, Ciaran N.

2012-01-01

Estimating animal abundance in industrial scale batches of ground meat is important for mapping meat products through the manufacturing process and for effectively tracing the finished product during a food safety recall. The processing of ground beef involves a potentially large number of animals from diverse sources in a single product batch, which produces a high heterogeneity in capture probability. In order to estimate animal abundance through DNA profiling of ground beef constituents, two parameter-based statistical models were developed for incidence data. Simulations were applied to evaluate the maximum likelihood estimate (MLE) of a joint likelihood function from multiple surveys, showing superiority in the presence of high capture heterogeneity with small sample sizes, or comparable estimation in the presence of low capture heterogeneity with a large sample size when compared to other existing models. Our model employs the full information on the pattern of the capture-recapture frequencies from multiple samples. We applied the proposed models to estimate animal abundance in six manufacturing beef batches, genotyped using 30 single nucleotide polymorphism (SNP) markers, from a large scale beef grinding facility. Results show that between 411∼1367 animals were present in six manufacturing beef batches. These estimates are informative as a reference for improving recall processes and tracing finished meat products back to source. PMID:22479559

Sub-scale Inverse Wind Turbine Blade Design Using Bound Circulation

NASA Astrophysics Data System (ADS)

Kelley, Christopher; Berg, Jonathan

2014-11-01

A goal of the National Rotor Testbed project at Sandia is to design a sub-scale wind turbine blade that has similitude to a modern, commercial size blade. However, a smaller diameter wind turbine operating at the same tip-speed-ratio exhibits a different range of operating Reynolds numbers across the blade span, thus changing the local lift and drag coefficients. Differences to load distribution also affect the wake dynamics and stability. An inverse wind turbine blade design tool has been implemented which uses a target, dimensionless circulation distribution from a full-scale blade to find the chord and twist along a sub-scale blade. In addition, airfoil polar data are interpolated from a few specified span stations leading to a smooth, manufacturable blade. The iterative process perturbs chord and twist, after running a blade element momentum theory code, to reduce the residual sum of the squares between the modeled sub-scale circulation and the target full-scale circulation. It is shown that the converged sub-scale design also leads to performance similarity in thrust and power coefficients. Sandia National Laboratories is a multi-program laboratory managed and operated by Sandia Corporation, a wholly owned subsidiary of Lockheed Martin Corporation, for the U.S. Department of Energy under Contract DE-AC04-94AL85000.

Amyris, Inc. Integrated Biorefinery Project Summary Final Report - Public Version

DOE Office of Scientific and Technical Information (OSTI.GOV)

Gray, David; Sato, Suzanne; Garcia, Fernando

The Amyris pilot-scale Integrated Biorefinery (IBR) leveraged Amyris synthetic biology and process technology experience to upgrade Amyris’s existing Emeryville, California pilot plant and fermentation labs to enable development of US-based production capabilities for renewable diesel fuel and alternative chemical products. These products were derived semi-synthetically from high-impact biomass feedstocks via microbial fermentation to the 15-carbon intermediate farnesene, with subsequent chemical finishing to farnesane. The Amyris IBR team tested and provided methods for production of diesel and alternative chemical products from sweet sorghum, and other high-impact lignocellulosic feedstocks, at pilot scale. This enabled robust techno-economic analysis (TEA), regulatory approvals, and amore » basis for full-scale manufacturing processes and facility design.« less

Large-scale manufacture and characterization of a lentiviral vector produced for clinical ex vivo gene therapy application.

PubMed

Merten, Otto-Wilhelm; Charrier, Sabine; Laroudie, Nicolas; Fauchille, Sylvain; Dugué, Céline; Jenny, Christine; Audit, Muriel; Zanta-Boussif, Maria-Antonietta; Chautard, Hélène; Radrizzani, Marina; Vallanti, Giuliana; Naldini, Luigi; Noguiez-Hellin, Patricia; Galy, Anne

2011-03-01

From the perspective of a pilot clinical gene therapy trial for Wiskott-Aldrich syndrome (WAS), we implemented a process to produce a lentiviral vector under good manufacturing practices (GMP). The process is based on the transient transfection of 293T cells in Cell Factory stacks, scaled up to harvest 50 liters of viral stock per batch, followed by purification of the vesicular stomatitis virus glycoprotein-pseudotyped particles through several membrane-based and chromatographic steps. The process leads to a 200-fold volume concentration and an approximately 3-log reduction in protein and DNA contaminants. An average yield of 13% of infectious particles was obtained in six full-scale preparations. The final product contained low levels of contaminants such as simian virus 40 large T antigen or E1A sequences originating from producer cells. Titers as high as 2 × 10(9) infectious particles per milliliter were obtained, generating up to 6 × 10(11) infectious particles per batch. The purified WAS vector was biologically active, efficiently expressing the genetic insert in WAS protein-deficient B cell lines and transducing CD34(+) cells. The vector introduced 0.3-1 vector copy per cell on average in CD34(+) cells when used at the concentration of 10(8) infectious particles per milliliter, which is comparable to preclinical preparations. There was no evidence of cellular toxicity. These results show the implementation of large-scale GMP production, purification, and control of advanced HIV-1-derived lentiviral technology. Results obtained with the WAS vector provide the initial manufacturing and quality control benchmarking that should be helpful to further development and clinical applications.

Continued Water-Based Phase Change Material Heat Exchanger Development

NASA Technical Reports Server (NTRS)

Hansen, Scott W.; Sheth, Rubik B.; Poynot, Joe; Giglio, Tony; Ungar, Gene K.

2015-01-01

In a cyclical heat load environment such as low Lunar orbit, a spacecraft's radiators are not sized to meet the full heat rejection demands. Traditionally, a supplemental heat rejection device (SHReD) such as an evaporator or sublimator is used to act as a "topper" to meet the additional heat rejection demands. Utilizing a Phase Change Material (PCM) heat exchanger (HX) as a SHReD provides an attractive alternative to evaporators and sublimators as PCM HX's do not use a consumable, thereby leading to reduced launch mass and volume requirements. In continued pursuit of water PCM HX development two full-scale, Orion sized water-based PCM HX's were constructed by Mezzo Technologies. These HX's were designed by applying prior research on freeze front propagation to a full-scale design. Design options considered included bladder restraint and clamping mechanisms, bladder manufacturing, tube patterns, fill/drain methods, manifold dimensions, weight optimization, and midplate designs. Two units, Units A and B, were constructed and differed only in their midplate design. Both units failed multiple times during testing. This report highlights learning outcomes from these tests and are applied to a final sub-scale PCM HX which is slated to be tested on the ISS in early 2017.

Ultra Barrier Topsheet Film for Flexible Photovoltaics with 3M Company

DOE Office of Scientific and Technical Information (OSTI.GOV)

Funkenbusch, Arnie; Ruth, Charles

2014-12-30

In this DOE sponsored program, 3M achieved the critical UBT features to enable durable flexible high efficiency modules to be produced by a range of customers who have now certified the 3M UBT and are actively developing said flexible modules. The specific objectives and accomplishments of the work under this program were; Scale-up the current Generation-1 UBT from 12” width, as made on 3M’s pilot line, to 1+meter width full-scale manufacturing, while maintaining baseline performance metrics (see table below); This objective was fully met; Validate service life of Generation-1 UBT for the 25+ year lifetime demanded by the photovoltaic market;more » Aggressive testing revealed potential failure modes in the Gen 1 UBT. Deficiencies were identified and corrective action taken in the Gen 2 UBT; Develop a Generation-2 UBT on the pilot line, targeting improved performance relative to baseline, including higher %T (percent transmission), lower water vapor transmission rate (WVTR) with targets based on what the technology needs for 25 year lifetime, proven lifetime of 25 years in solar module construction in the field, and lower cost; Testing of UBT Gen 2 under a wide range of conditions presented in this report failed to reveal any failure mode. Therefore UBT Gen 2 is known to be highly durable. 3M will continue to test towards statistically validating a 25 year lifetime under 3M funding; Transfer Generation-2 UBT from the pilot line to the full-scale manufacturing line within three years; and This objective was fully met.« less

Production of recombinant antigens and antibodies in Nicotiana benthamiana using 'magnifection' technology: GMP-compliant facilities for small- and large-scale manufacturing.

PubMed

Klimyuk, Victor; Pogue, Gregory; Herz, Stefan; Butler, John; Haydon, Hugh

2014-01-01

This review describes the adaptation of the plant virus-based transient expression system, magnICON(®) for the at-scale manufacturing of pharmaceutical proteins. The system utilizes so-called "deconstructed" viral vectors that rely on Agrobacterium-mediated systemic delivery into the plant cells for recombinant protein production. The system is also suitable for production of hetero-oligomeric proteins like immunoglobulins. By taking advantage of well established R&D tools for optimizing the expression of protein of interest using this system, product concepts can reach the manufacturing stage in highly competitive time periods. At the manufacturing stage, the system offers many remarkable features including rapid production cycles, high product yield, virtually unlimited scale-up potential, and flexibility for different manufacturing schemes. The magnICON system has been successfully adaptated to very different logistical manufacturing formats: (1) speedy production of multiple small batches of individualized pharmaceuticals proteins (e.g. antigens comprising individualized vaccines to treat NonHodgkin's Lymphoma patients) and (2) large-scale production of other pharmaceutical proteins such as therapeutic antibodies. General descriptions of the prototype GMP-compliant manufacturing processes and facilities for the product formats that are in preclinical and clinical testing are provided.

Delivering Value In A Global Aerospace Manufacturer Through The Effective Use Of Numerical Process Simulation

NASA Astrophysics Data System (ADS)

Ward, M. J.; Walløe, S. J.

2004-06-01

Numerical models are used extensively in the aerospace sector to identify appropriate manufacturing parameters, and to minimize the risk associated with new product introduction and manufacturing change. This usage is equally prevalent in original equipment manufacturers (OEMs), and in their supply chains. The wide range of manufacturing processes and production environments involved, coupled with the varying degrees of technology maturity associated with numerical models of different processes leads to a situation of significant complexity from the OEM perspective. In addition, the intended use of simulation technology can vary considerably between applications, from simple geometric assessment of die shape at one extreme, to full process design or development at the other. Consequently there is an increasing trend towards multi-scale modelling, i.e. the use of several different model types, with differing attributes in terms of accuracy and speed to support a range of different new product introduction decisions. This makes the allocation of appropriate levels of activity to the research and implementation of new capabilities a difficult problem. This paper uses a number of industrial cases studies to illustrate a framework for making such allocation decisions such that value to the OEM is maximized, and investigates how such a framework is likely to shift over the next few years based on technological developments.

Analysis of Stress Distributions Under Lightweight Wheeled Vehicles

DTIC Science & Technology

2013-10-09

For a balanced analysis it is important at examine the full scale error ε f . Sinkage error, although large in a relative sense is typically on the...director of the Edgerton Center at MIT, to Thuan Doan, and to Meccanotecnica Riesi SRL for collaborating on manufacturing the custom sensing array...a pulling/braking force at the vehicle axle. Fx = T −Rc (33) The importance of drawbar force is obvious, since a positive drawbar force implies that

Demonstration of a Full-Scale Fluidized Bed Bioreactor for the Treatment of Perchlorate at Low Concentrations in Groundwater

DTIC Science & Technology

2009-01-01

these experiments, samples were collected to determine the presence of volatile organic compounds (VOCs) and n- 99 nitrosodimethylamine ( NDMA ). On...presence of NDMA was also measured and not detected (ɘ.004 µg/L) in the Trimite multimedia filter effluent water. Since only one sample was obtained for... NDMA analysis in the effluent water of the Trimite multimedia filter, limited conclusions can be made. However, per the manufacturer, the

NIF optical materials and fabrication technologies: an overview

NASA Astrophysics Data System (ADS)

Campbell, John H.; Hawley-Fedder, Ruth A.; Stolz, Christopher J.; Menapace, Joseph A.; Borden, Michael R.; Whitman, Pamela K.; Yu, June; Runkel, Michael J.; Riley, Michael O.; Feit, Michael D.; Hackel, Richard P.

2004-05-01

The high-energy/high-power section of the NIF laser system contains 7360 meter-scale optics. Advanced optical materials and fabrication technologies needed to manufacture the NIF optics have been developed and put into production at key vendor sites. Production rates are up to 20 times faster and per-optic costs 5 times lower than could be achieved prior to the NIF. In addition, the optics manufactured for NIF are better than specification giving laser performance better than the design. A suite of custom metrology tools have been designed, built and installed at the vendor sites to verify compliance with NIF optical specifications. A brief description of the NIF optical wavefront specifications for the glass and crystal optics is presented. The wavefront specifications span a continuous range of spatial scale-lengths from 10 μm to 0.5 m (full aperture). We have continued our multi-year research effort to improve the lifetime (i.e. damage resistance) of bulk optical materials, finished optical surfaces and multi-layer dielectric coatings. New methods for post-processing the completed optic to improve the damage resistance have been developed and made operational. This includes laser conditioning of coatings, glass surfaces and bulk KDP and DKDP and well as raster and full aperture defect mapping systems. Research on damage mechanisms continues to drive the development of even better optical materials.

Development of a scaled-down aerobic fermentation model for scale-up in recombinant protein vaccine manufacturing.

PubMed

Farrell, Patrick; Sun, Jacob; Gao, Meg; Sun, Hong; Pattara, Ben; Zeiser, Arno; D'Amore, Tony

2012-08-17

A simple approach to the development of an aerobic scaled-down fermentation model is presented to obtain more consistent process performance during the scale-up of recombinant protein manufacture. Using a constant volumetric oxygen mass transfer coefficient (k(L)a) for the criterion of a scale-down process, the scaled-down model can be "tuned" to match the k(L)a of any larger-scale target by varying the impeller rotational speed. This approach is demonstrated for a protein vaccine candidate expressed in recombinant Escherichia coli, where process performance is shown to be consistent among 2-L, 20-L, and 200-L scales. An empirical correlation for k(L)a has also been employed to extrapolate to larger manufacturing scales. Copyright © 2012 Elsevier Ltd. All rights reserved.

Polyhydroxyalkanoates (PHA) production using wastewater as carbon source and activated sludge as microorganisms.

PubMed

Yan, S; Tyagi, R D; Surampalli, R Y

2006-01-01

Activated sludge from different full-scale wastewater treatment plants (municipal, pulp and paper industry, starch manufacturing and cheese manufacturing wastewaters) was used as a source of microorganisms to produce biodegradable plastics in shake flask experiments. Acetate, glucose and different wastewaters were used as carbon sources. Pulp and paper wastewater sludge was found to accumulate maximum concentration (43% of dry weight of suspended solids) of polyhydroxy alkanoates (PHA) with acetate as carbon source. Among the different wastewaters tested as a source of carbon, pulp and paper industry and starch industry wastewaters were found to be the best source of carbon while employing pulp and paper activated sludge for maximum accumulation of PHA. High concentration of volatile fatty acids in these wastewaters was the probable reason.

Manufacturing Laboratory | Energy Systems Integration Facility | NREL

Science.gov Websites

Manufacturing Laboratory Manufacturing Laboratory Researchers in the Energy Systems Integration Facility's Manufacturing Laboratory develop methods and technologies to scale up renewable energy technology manufacturing capabilities. Photo of researchers and equipment in the Manufacturing Laboratory. Capability Hubs

Assessment of impact damage of composite rocket motor cases

NASA Technical Reports Server (NTRS)

Paris, Henry G.

1994-01-01

This contract reviewed the available literature on mechanisms of low velocity impact damage in filament wound rocket motor cases, MDE methods to quantify damage, critical coupon level test methods, manufacturing and material process variables and empirical and analytical modeling off impact damage. The critical design properties for rocket motor cases are biaxial hoop and axial tensile strength. Low velocity impact damage is insidious because it can create serious nonvisible damage at very low impact velocities. In thick rocket motor cases the prevalent low velocity impact damage is fiber fracture and matrix cracking adjacent to the front face. In contrast, low velocity loading of thin wall cylinders induces flexure, depending on span length and the flexure induces delamination and tensile cracking on the back face wall opposed to impact occurs due to flexural stresses imposed by impact loading. Important NDE methods for rocket motor cases are non-contacting methods that allow inspection from one side. Among these are vibrothermography, and pulse-echo methods based on acoustic-ultrasonic methods. High resolution techniques such as x-ray computed tomography appear to have merit for accurate geometrical characterization of local damage to support development of analytical models of micromechanics. The challenge of coupon level testing is to reproduce the biaxial stress state that the full scale article experiences, and to determine how to scale the composite structure to model full sized behavior. Biaxial tensile testing has been performed by uniaxially tensile loading internally pressurized cylinders. This is experimentally difficult due to gripping problems and pressure containment. Much prior work focused on uniaxial tensile testing of model filament wound cylinders. Interpretation of the results of some studies is complicated by the fact that the fabrication process did not duplicate full scale manufacturing. It is difficult to scale results from testing subscale cylinders since there are significant differences in out time of the resins relative to full scale cylinder fabrication, differences in hoop fiber tensioning and unsatisfactory coupon configurations. It appears that development of a new test method for subscale cylinders is merited. Damage tolerance may be improved by material optimization that uses fiber treatments and matrix modifications to control the fiber matrix interface bonding. It is difficult to develop process optimization in subscale cylinders without also modeling the longer out times resins experience in full scale testing. A major breakthrough in characterizing the effect of impact damage on residual strength, and understanding how to scale results of subscale evaluations, will be a sound micromechanical model that described progressive failure of the composite. Such models will utilize a three dimensional stress analysis due to the complex nature of low velocity impact stresses in thick composites. When these models are coupled with non-contact NDE methods that geometrically characterize the damage and acoustic methods that characterize the effective local elastic properties, accurate assessment of residual strength from impact damage may be possible. Directions for further development are suggested.

Assessment of impact damage of composite rocket motor cases

NASA Astrophysics Data System (ADS)

Paris, Henry G.

1994-02-01

This contract reviewed the available literature on mechanisms of low velocity impact damage in filament wound rocket motor cases, MDE methods to quantify damage, critical coupon level test methods, manufacturing and material process variables and empirical and analytical modeling off impact damage. The critical design properties for rocket motor cases are biaxial hoop and axial tensile strength. Low velocity impact damage is insidious because it can create serious nonvisible damage at very low impact velocities. In thick rocket motor cases the prevalent low velocity impact damage is fiber fracture and matrix cracking adjacent to the front face. In contrast, low velocity loading of thin wall cylinders induces flexure, depending on span length and the flexure induces delamination and tensile cracking on the back face wall opposed to impact occurs due to flexural stresses imposed by impact loading. Important NDE methods for rocket motor cases are non-contacting methods that allow inspection from one side. Among these are vibrothermography, and pulse-echo methods based on acoustic-ultrasonic methods. High resolution techniques such as x-ray computed tomography appear to have merit for accurate geometrical characterization of local damage to support development of analytical models of micromechanics. The challenge of coupon level testing is to reproduce the biaxial stress state that the full scale article experiences, and to determine how to scale the composite structure to model full sized behavior. Biaxial tensile testing has been performed by uniaxially tensile loading internally pressurized cylinders. This is experimentally difficult due to gripping problems and pressure containment. Much prior work focused on uniaxial tensile testing of model filament wound cylinders. Interpretation of the results of some studies is complicated by the fact that the fabrication process did not duplicate full scale manufacturing. It is difficult to scale results from testing subscale cylinders since there are significant differences in out time of the resins relative to full scale cylinder fabrication, differences in hoop fiber tensioning and unsatisfactory coupon configurations. It appears that development of a new test method for subscale cylinders is merited. Damage tolerance may be improved by material optimization that uses fiber treatments and matrix modifications to control the fiber matrix interface bonding. It is difficult to develop process optimization in subscale cylinders without also modeling the longer out times resins experience in full scale testing. A major breakthrough in characterizing the effect of impact damage on residual strength, and understanding how to scale results of subscale evaluations, will be a sound micromechanical model that described progressive failure of the composite.

Low-Cost Opportunity for Small-Scale Manufacture of Hardwood Blanks

Treesearch

Bruce G. Hansen; Philip A. Araman

1985-01-01

We analyzed the manufacture of standard-size hardwood blanks from lumber on a relatively small scale by conventional processing. Requiring an investment of just over $200,000, the conventional mill can process 500 M bf (thousand board feet) of kiln-dried lumber annually. The study focused on the economics associated with manufacture of blanks from four species -...

Novel method to construct large-scale design space in lubrication process utilizing Bayesian estimation based on a small-scale design-of-experiment and small sets of large-scale manufacturing data.

PubMed

Maeda, Jin; Suzuki, Tatsuya; Takayama, Kozo

2012-12-01

A large-scale design space was constructed using a Bayesian estimation method with a small-scale design of experiments (DoE) and small sets of large-scale manufacturing data without enforcing a large-scale DoE. The small-scale DoE was conducted using various Froude numbers (X(1)) and blending times (X(2)) in the lubricant blending process for theophylline tablets. The response surfaces, design space, and their reliability of the compression rate of the powder mixture (Y(1)), tablet hardness (Y(2)), and dissolution rate (Y(3)) on a small scale were calculated using multivariate spline interpolation, a bootstrap resampling technique, and self-organizing map clustering. The constant Froude number was applied as a scale-up rule. Three experiments under an optimal condition and two experiments under other conditions were performed on a large scale. The response surfaces on the small scale were corrected to those on a large scale by Bayesian estimation using the large-scale results. Large-scale experiments under three additional sets of conditions showed that the corrected design space was more reliable than that on the small scale, even if there was some discrepancy in the pharmaceutical quality between the manufacturing scales. This approach is useful for setting up a design space in pharmaceutical development when a DoE cannot be performed at a commercial large manufacturing scale.

Test Plan. GCPS Task 4, subtask 4.2 thrust structure development

NASA Astrophysics Data System (ADS)

Greenberg, H. S.

1994-09-01

The Single Stage To Orbit (SSTO) vehicle is designed to lift off from a vertical position, go into orbit, return to earth for a horizontal landing, and be reusable for the next mission. (NASA baseline only) In order to meet its performance goals, the SSTO relies on light weight structure and the use of 8 tri-propellant engines. These engines are mounted to the thrust structure. This test plan addresses selection of the material for this structure, and the integrity of the design through testing of elements and a full-scale subcomponent. This test plan supports the development of the design for an advanced composite thrust structure for a Single Stage to Orbit manned, heavy launch vehicle. The thrust structure is designed to transmit very high thrust loads from the engines to the rest of the vehicle (see Figure 1 ). The thrust structure will also be used for primary attachment of the twin vertical tails and possibly act as the aft attach point for the wing. The combination of high loading, high vibration, long service life and high acoustic environments will need to be evaluated by tests. To minimize design risk, a building block approach will be used. We will first screen materials to determine which materials show the most promise for this application. Factors in this screening will be the suitability of these materials for chosen design concepts, particularly concerning specific strength, environmental compatibility and applicability to fabrication processes. Next we will characterize two material systems that will be used in the design; the characterization will allow us to generate preliminary design data that will be used for the analysis. Element testing will be performed to evaluate critical structural locations under load. Final testing on the full scale test article will be performed to verify the design and to demonstrate predictability of the analysis. Additionally, risks associated with fabricating full scale thrust structures will be reduced through testing activities. One of the major concerns that stems from full scale fabrication is the realities of size and the associated complexities of handling, manufacturing, and assembly. The need exists to fabricate, assemble and test_representative joint specimens to achieve_confidence in the design and manufacturing technologies being proposed.

Test Plan. GCPS Task 4, subtask 4.2 thrust structure development

NASA Technical Reports Server (NTRS)

Greenberg, H. S.

1994-01-01

The Single Stage To Orbit (SSTO) vehicle is designed to lift off from a vertical position, go into orbit, return to earth for a horizontal landing, and be reusable for the next mission. (NASA baseline only) In order to meet its performance goals, the SSTO relies on light weight structure and the use of 8 tri-propellant engines. These engines are mounted to the thrust structure. This test plan addresses selection of the material for this structure, and the integrity of the design through testing of elements and a full-scale subcomponent. This test plan supports the development of the design for an advanced composite thrust structure for a Single Stage to Orbit manned, heavy launch vehicle. The thrust structure is designed to transmit very high thrust loads from the engines to the rest of the vehicle (see Figure 1 ). The thrust structure will also be used for primary attachment of the twin vertical tails and possibly act as the aft attach point for the wing. The combination of high loading, high vibration, long service life and high acoustic environments will need to be evaluated by tests. To minimize design risk, a building block approach will be used. We will first screen materials to determine which materials show the most promise for this application. Factors in this screening will be the suitability of these materials for chosen design concepts, particularly concerning specific strength, environmental compatibility and applicability to fabrication processes. Next we will characterize two material systems that will be used in the design; the characterization will allow us to generate preliminary design data that will be used for the analysis. Element testing will be performed to evaluate critical structural locations under load. Final testing on the full scale test article will be performed to verify the design and to demonstrate predictability of the analysis. Additionally, risks associated with fabricating full scale thrust structures will be reduced through testing activities. One of the major concerns that stems from full scale fabrication is the realities of size and the associated complexities of handling, manufacturing, and assembly. The need exists to fabricate, assemble and test_representative joint specimens to achieve_confidence in the design and manufacturing technologies being proposed.

Transcriptomics as a tool for assessing the scalability of mammalian cell perfusion systems.

PubMed

Jayapal, Karthik P; Goudar, Chetan T

2014-01-01

DNA microarray-based transcriptomics have been used to determine the time course of laboratory and manufacturing-scale perfusion bioreactors in an attempt to characterize cell physiological state at these two bioreactor scales. Given the limited availability of genomic data for baby hamster kidney (BHK) cells, a Chinese hamster ovary (CHO)-based microarray was used following a feasibility assessment of cross-species hybridization. A heat shock experiment was performed using both BHK and CHO cells and resulting DNA microarray data were analyzed using a filtering criteria of perfect match (PM)/single base mismatch (MM) > 1.5 and PM-MM > 50 to exclude probes with low specificity or sensitivity for cross-species hybridizations. For BHK cells, 8910 probe sets (39 %) passed the cutoff criteria, whereas 12,961 probe sets (56 %) passed the cutoff criteria for CHO cells. Yet, the data from BHK cells allowed distinct clustering of heat shock and control samples as well as identification of biologically relevant genes as being differentially expressed, indicating the utility of cross-species hybridization. Subsequently, DNA microarray analysis was performed on time course samples from laboratory- and manufacturing-scale perfusion bioreactors that were operated under the same conditions. A majority of the variability (37 %) was associated with the first principal component (PC-1). Although PC-1 changed monotonically with culture duration, the trends were very similar in both the laboratory and manufacturing-scale bioreactors. Therefore, despite time-related changes to the cell physiological state, transcriptomic fingerprints were similar across the two bioreactor scales at any given instance in culture. Multiple genes were identified with time-course expression profiles that were very highly correlated (> 0.9) with bioprocess variables of interest. Although the current incomplete annotation limits the biological interpretation of these observations, their full potential may be realized in due course when richer genomic data become available. By taking a pragmatic approach of transcriptome fingerprinting, we have demonstrated the utility of systems biology to support the comparability of laboratory and manufacturing-scale perfusion systems. Scale-down model qualification is the first step in process characterization and hence is an integral component of robust regulatory filings. Augmenting the current paradigm, which relies primarily on cell culture and product quality information, with gene expression data can help make a substantially stronger case for similarity. With continued advances in systems biology approaches, we expect them to be seamlessly integrated into bioprocess development, which can translate into more robust and high yielding processes that can ultimately reduce cost of care for patients.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Cobb, Corie Lynn

The development of mass markets for large-format batteries, including electric vehicles (EVs) and grid support, depends on both cost reductions and performance enhancements to improve their economic viability. Palo Alto Research Center (PARC) has developed a multi-material, advanced manufacturing process called co-extrusion (CoEx) to remove multiple steps in a conventional battery coating process with the potential to simultaneously increase battery energy and power density. CoEx can revolutionize battery manufacturing across most chemistries, significantly lowering end-product cost and shifting the underlying economics to make EVs and other battery applications a reality. PARC’s scale-up of CoEx for electric vehicle (EV) batteries buildsmore » on a solid base of experience in applying CoEx to solar cell manufacturing, deposition of viscous ceramic pastes, and Li-ion battery chemistries. In the solar application, CoEx has been deployed commercially at production scale where multi-channel CoEx printheads are used to print viscous silver gridline pastes at full production speeds (>40 ft/min). This operational scale-up provided invaluable experience with the nuances of speed, yield, and maintenance inherent in taking a new technology to the factory floor. PARC has leveraged this experience, adapting the CoEx process for Lithium-ion (Li-ion) battery manufacturing. To date, PARC has worked with Li-ion battery materials and structured cathodes with high-density Li-ion regions and low-density conduction regions, documenting both energy and power performance. Modeling results for a CoEx cathode show a path towards a 10-20% improvement in capacity for an EV pouch cell. Experimentally, we have realized a co-extruded battery structure with a Lithium Nickel Manganese Cobalt (NMC) cathode at print speeds equivalent to conventional roll coating processes. The heterogeneous CoEx cathode enables improved capacity in thick electrodes at higher C-rates. The proof-of-principle coin cells demonstrate the feasibility of the CoEx technology and a path towards higher energy and higher power EV pouch cells.« less

Test-bed and Full-Scale Demonstration of Plasma Flow Control for Wind Turbines. Phase 1

DTIC Science & Technology

2013-07-15

the actuators was prohibitive. This led to the decision to mount the step-up transformers on the hub of the turbine , reducing the slip ring voltage...facility as it is manufactured as one piece and must be installed during assembly of the turbine . Figure 73 shows the slip ring after installation on...the turbine . The anti- rotation pin can be seen extending up past the brake disc at the top of the ring . Navatek, Ltd. Plasma Flow Control for Wind

Fatigue qualification of high thickness composite rotor components

NASA Astrophysics Data System (ADS)

Raggi, M.; Mariani, U.; Zaffaroni, G.

Fatigue qualification aspects of composite rotor components are presented according with the safe life procedure usually applied by helicopter manufacturers. Test activities are identified at three levels of specimen complexity: coupon, structural element and full scale component. Particular attention is given to high thickness laminates qualification as far as environmental exposure is concerned. A practical approach for an accelerated conditioning procedure is described. The application to a main rotor tension link is presented showing the negligible effect of the moisture absorption on its fatigue strength.

Fastrac Nozzle Design, Performance and Development

NASA Technical Reports Server (NTRS)

Peters, Warren; Rogers, Pat; Lawrence, Tim; Davis, Darrell; DAgostino, Mark; Brown, Andy

2000-01-01

With the goal of lowering the cost of payload to orbit, NASA/MSFC (Marshall Space Flight Center) researched ways to decrease the complexity and cost of an engine system and its components for a small two-stage booster vehicle. The composite nozzle for this Fastrac Engine was designed, built and tested by MSFC with fabrication support and engineering from Thiokol-SEHO (Science and Engineering Huntsville Operation). The Fastrac nozzle uses materials, fabrication processes and design features that are inexpensive, simple and easily manufactured. As the low cost nozzle (and injector) design matured through the subscale tests and into full scale hot fire testing, X-34 chose the Fastrac engine for the propulsion plant for the X-34. Modifications were made to nozzle design in order to meet the new flight requirements. The nozzle design has evolved through subscale testing and manufacturing demonstrations to full CFD (Computational Fluid Dynamics), thermal, thermomechanical and dynamic analysis and the required component and engine system tests to validate the design. The Fastrac nozzle is now in final development hot fire testing and has successfully accumulated 66 hot fire tests and 1804 seconds on 18 different nozzles.

Structural evaluation of curved stiffened composite panels fabricated using a THERM-Xsm process

NASA Technical Reports Server (NTRS)

Kassapoglou, Christos; Dinicola, Albert J.; Chou, Jack C.; Deaton, Jerry W.

1991-01-01

The use of composites in aircraft structures is often limited by material and manufacturing costs which, for some designs and applications, are prohibitively high. To increase the frequency of application of composites in primary airframe components alternative manufacturing processes are sought that reduce cost and/or enhance structural efficiency. One alternative process involves the use of THERM-Xsm as the pressure transfer medium during autoclave curing. THERM-Xsm, a silicon-based flow able polymer which behaves like a liquid under autoclave presssure, transmits quasi-hydrostatic pressure to all contacting surfaces of the part to be cured. Once the autoclave pressure is relieved, THERM-Xsm reverts back to the powdery solid state and can be reused many times. The THERM-Xsm process to be evaluated is depicted and consists of (1) enclosing the tool and part to be cured by a set of frames that create a box, (2) pouring THERM-Xsm powder onto the part and filling the box, and (3) placing a vacuum bag over the box assembly. In this program, a separating non-porous film (Teflon) was placed between the part to be cured and THERM-Xsm powder to avoid any contamination. The use of THERM-Xsm has two significant advantages over conventional manufacturing procedures. First, it eliminates complicated hard tooling since it guarantees uniform pressure transfer and thus, good compaction at complex structural details (such as frame-stiffener intersections and corners). Second, it greatly simplifies vacuum bagging, since once the part to be cured is covered by THERM-Xsm powder, the vacuum bag need only conform to a relatively flat shape reducing significantly the number of pleats required. A program is on-going at Sikorsky Aircraft to evaluate the structural performance of complex composite fuselage structures made with this THERM-Xsm process and to quantify the impact of THERM-Xsm on manufacturing labor hours and cost. The program involves fuselage panel optimization analysis, a building block test program where structural details representative of the full-scale article are analyzed and tested, and static and fatigue test/analysis of the full-scale test articles. The main results of this program are reported.

Wash Solution Bath Life Extension for the Space Shuttle Rocket Motor Aqueous Cleaning System

NASA Technical Reports Server (NTRS)

Saunders, Chad; Evans, Kurt; Sagers, Neil

1999-01-01

A spray-in-air aqueous cleaning system, which replaced 1,1,1 trichloroethane (TCA) vapor degreasing, is used for critical cleaning of Space Shuttle Redesigned Solid Rocket Motor (RSRM) metal parts. Small-scale testing demonstrated that the alkaline-based wash solution possesses adequate soil loading and cleaning properties. However, full-scale testing exhibited unexpected depletion of some primary components of the wash solution. Specifically, there was a significant decrease in the concentration of sodium metasilicate which forced change-out of the wash solution after eight days. Extension of wash solution bath life was necessary to ease the burden of frequent change-out on manufacturing. A laboratory study supports a depletion mechanism that is initiated by the hydrolysis of sodium tripolyphosphate (STPP) lowering the pH of the solution. The decrease in pH causes polymerization and subsequent precipitation of sodium metasilicate (SM). Further investigation showed that maintaining the pH was the key to preventing the precipitation of the sodium metasilicate. Implementation to the full scale operation demonstrated that periodic additions of potassium hydroxide (KOH) extended the useful bath life to more than four months.

Alternating phase-shifted mask for logic gate levels, design, and mask manufacturing

NASA Astrophysics Data System (ADS)

Liebmann, Lars W.; Graur, Ioana C.; Leipold, William C.; Oberschmidt, James M.; O'Grady, David S.; Regaill, Denis

1999-07-01

While the benefits of alternating phase shifted masks in improving lithographic process windows at increased resolution are well known throughout the lithography community, broad implementation of this potentially powerful technique has been slow due to the inherent complexity of the layout design and mask manufacturing process. This paper will review a project undertaken at IBM's Semiconductor Research and Development Center and Mask Manufacturing and Development facility to understand the technical and logistical issues associated with the application of alternating phase shifted mask technology to the gate level of a full microprocessor chip. The work presented here depicts an important milestone toward integration of alternating phase shifted masks into the manufacturing process by demonstrating an automated design solution and yielding a functional alternating phase shifted mask. The design conversion of the microprocessor gate level to a conjugate twin shifter alternating phase shift layout was accomplished with IBM's internal design system that automatically scaled the design, added required phase regions, and resolved phase conflicts. The subsequent fabrication of a nearly defect free phase shifted mask, as verified by SEM based die to die inspection, highlights the maturity of the alternating phase shifted mask manufacturing process in IBM's internal mask facility. Well defined and recognized challenges in mask inspection and repair remain and the layout of alternating phase shifted masks present a design and data preparation overhead, but the data presented here demonstrate the feasibility of designing and building manufacturing quality alternating phase shifted masks for the gate level of a microprocessor.

Impact of marketing, information system, modularity, and low-cost solution on the implementation of CIM in SMEs

NASA Astrophysics Data System (ADS)

Marri, Hussain B.; McGaughey, Ronald; Gunasekaran, Angappa

2000-10-01

Globalization can have a dramatic impact on manufacturing sector due to the fact that the majority of establishments in this industry are small to medium manufacturing companies. The role of Small and Medium Enterprises (SMEs) in the national economy has been emphasized all over the world, considering their contribution to the total manufacturing output and employment opportunities. The lack of marketing forces to regulate the operation of SMEs has been a fundamental cause of low efficiency for a long time. Computer Integrated Manufacturing (CIM) is emerging as one of the most promising opportunities for shrinking the time delays in information transfer and reducing manufacturing costs. CIM is the architecture for integrating the engineering, marketing and manufacturing functions through information system technologies. SMEs in general have not made full use of new technologies although their investments in CIM technology tended to be wider in scale and scope. Most of the SMEs only focus on the short-term benefit, but overlook a long- term and fundamental development on applications of new technologies. With the help of suitable information systems, modularity and low cost solutions, SMEs can compete in the global market. Considering the importance of marketing, information system, modularity and low cost solutions in the implementation of CIM in SMEs, a model has been developed and studied with the help of an empirical study conducted with British SMEs to facilitate the adoption of CIM. Finally, a summary of findings and recommendations are presented.

Case Study: Commercialization of sweet sorghum juice clarification for large-scale syrup manufacture

USDA-ARS?s Scientific Manuscript database

The precipitation and burning of insoluble granules of starch from sweet sorghum juice on heating coils prevented the large scale manufacture of syrup at a new industrial plant in Missouri, USA. To remove insoluble starch granules, a series of small and large-scale experiments were conducted at the...

ODC-Free Solvent Implementation Issues for Vulcanized Rubber and Bond Systems

NASA Technical Reports Server (NTRS)

Hodgson, James R.; McCool, Alex (Technical Monitor)

2001-01-01

Thiokol Propulsion has worked extensively to replace 1,1,1-trichloroethane (TCA) with ozone depleting chemicals (ODC)-free solvents for use in the manufacture of the Reusable Solid Rocket Motor (RSRM) for the Space Shuttle Program. As Thiokol has transitioned from sub-scale to full-scale testing and implementation of these new solvents, issues have been discovered which have required special attention. The original intent of Thiokol's solvent replacement strategy was to replace TCA with a single drop-in solvent for all equivalent applications. We have learned that a single candidate does not exist for replacing TCA. Solvent incompatibility with process materials has caused us to seek for niche solvents and/or processing changes that provide an ODC-free solution for special applications. This paper addresses some of the solvent incompatibilities, which have lead to processes changes and possible niche solvent usage. These incompatibilities were discovered during full-scale testing of ODC-free solvents and relate to vulcanized rubber and bond systems in the RSRM. Specifically, the following items are presented: (1) Cure effects of d-limonene based solvents on Silica Filled Ethylene Propylene Diene Monomer (SF-EPDM) rubber. During full-scale test operations, Thiokol discovered that d-limonene (terpene) based solvents inhibit the cure of EPDM rubber. Subsequent testing showed the same issue with Nitrile Butadiene Rubber (NBR). Also discussed are efforts to minimize uncured rubber exposure to solvents; and (2) Cured bond system sensitivity to ODC-free solvents. During full scale testing it was discovered that a natural rubber to steel vulcanized bond could degrade after prolonged exposure to ODC-free solvents. Follow on testing showed that low vapor pressure and residence time seemed to be most likely cause for failure.

[Application of risk-based approach for determination of critical factors in technology transfer of production of medicinal products].

PubMed

Beregovykh, V V; Spitskiy, O R

2014-01-01

Risk-based approach is used for examination of impact of different factors on quality of medicinal products in technology transfer. A general diagram is offered for risk analysis execution in technology transfer from pharmaceutical development to production. When transferring technology to full- scale commercial production it is necessary to investigate and simulate production process application beforehand in new real conditions. The manufacturing process is the core factorfor risk analysis having the most impact on quality attributes of a medicinal product. Further importantfactors are linked to materials and products to be handled and manufacturing environmental conditions such as premises, equipment and personnel. Usage of risk-based approach in designing of multipurpose production facility of medicinal products is shown where quantitative risk analysis tool RAMM (Risk Analysis and Mitigation Matrix) was applied.

Nanomanufacturing-related programs at NSF

NASA Astrophysics Data System (ADS)

Cooper, Khershed P.

2015-08-01

The National Science Foundation is meeting the challenge of transitioning lab-scale nanoscience and technology to commercial-scale through several nanomanufacturing-related research programs. The goal of the core Nanomanufacturing (NM) and the inter-disciplinary Scalable Nanomanufacturing (SNM) programs is to meet the barriers to manufacturability at the nano-scale by developing the fundamental principles for the manufacture of nanomaterials, nanostructures, nanodevices, and engineered nanosystems. These programs address issues such as scalability, reliability, quality, performance, yield, metrics, and cost, among others. The NM and SNM programs seek nano-scale manufacturing ideas that are transformative, that will be widely applicable and that will have far-reaching technological and societal impacts. It is envisioned that the results from these basic research programs will provide the knowledge base for larger programs such as the manufacturing Nanotechnology Science and Engineering Centers (NSECs) and the Nanosystems Engineering Research Centers (NERCs). Besides brief descriptions of these different programs, this paper will include discussions on novel

Assessment of safety and immunogenicity of two different lots of diphtheria, tetanus, pertussis, hepatitis B and Haemophilus influenzae type b vaccine manufactured using small and large scale manufacturing process.

PubMed

Sharma, Hitt J; Patil, Vishwanath D; Lalwani, Sanjay K; Manglani, Mamta V; Ravichandran, Latha; Kapre, Subhash V; Jadhav, Suresh S; Parekh, Sameer S; Ashtagi, Girija; Malshe, Nandini; Palkar, Sonali; Wade, Minal; Arunprasath, T K; Kumar, Dinesh; Shewale, Sunil D

2012-01-11

Hib vaccine can be easily incorporated in EPI vaccination schedule as the immunization schedule of Hib is similar to that of DTP vaccine. To meet the global demand of Hib vaccine, SIIL scaled up the Hib conjugate manufacturing process. This study was conducted in Indian infants to assess and compare the immunogenicity and safety of DTwP-HB+Hib (Pentavac(®)) vaccine of SIIL manufactured at large scale with the 'same vaccine' manufactured at a smaller scale. 720 infants aged 6-8 weeks were randomized (2:1 ratio) to receive 0.5 ml of Pentavac(®) vaccine from two different lots one produced at scaled up process and the other at a small scale process. Serum samples obtained before and at one month after the 3rd dose of vaccine from both the groups were tested for IgG antibody response by ELISA and compared to assess non-inferiority. Neither immunological interference nor increased reactogenicity was observed in either of the vaccine groups. All infants developed protective antibody titres to diphtheria, tetanus and Hib disease. For hepatitis B antigen, one child from each group remained sero-negative. The response to pertussis was 88% in large scale group vis-à-vis 87% in small scale group. Non-inferiority was concluded for all five components of the vaccine. No serious adverse event was reported in the study. The scale up vaccine achieved comparable response in terms of the safety and immunogenicity to small scale vaccine and therefore can be easily incorporated in the routine childhood vaccination programme. Copyright © 2011 Elsevier Ltd. All rights reserved.

Lightning protection guidelines and test data for adhesively bonded aircraft structures

NASA Technical Reports Server (NTRS)

Pryzby, J. E.; Plumer, J. A.

1984-01-01

The highly competitive marketplace and increasing cost of energy has motivated manufacturers of general aviation aircraft to utilize composite materials and metal-to-metal bonding in place of conventional fasteners and rivets to reduce weight, obtain smoother outside surfaces and reduce drag. The purpose of this program is protection of these new structures from hazardous lightning effects. The program began with a survey of advance-technology materials and fabrication methods under consideration for future designs. Sub-element specimens were subjected to simulated lightning voltages and currents. Measurements of bond line voltages, electrical sparking, and mechanical strength degradation were made to comprise a data base of electrical properties for new technology materials and basic structural configurations. The second hase of the program involved tests on full scale wing structures which contained integral fuel tanks and which were representative of examples of new technology structures and fuel systems. The purpose of these tests was to provide a comparison between full scale structural measurements and those obtained from the sub-element specimens.

Additive Manufacturing for Cost Efficient Production of Compact Ceramic Heat Exchangers and Recuperators

DOE Office of Scientific and Technical Information (OSTI.GOV)

Shulman, Holly; Ross, Nicole

2015-10-30

An additive manufacture technique known as laminated object manufacturing (LOM) was used to fabricate compact ceramic heat exchanger prototypes. LOM uses precision CO2 laser cutting of ceramic green tapes, which are then precision stacked to build a 3D object with fine internal features. Modeling was used to develop prototype designs and predict the thermal response, stress, and efficiency in the ceramic heat exchangers. Build testing and materials analyses were used to provide feedback for the design selection. During this development process, laminated object manufacturing protocols were established. This included laser optimization, strategies for fine feature integrity, lamination fluid control, greenmore » handling, and firing profile. Three full size prototypes were fabricated using two different designs. One prototype was selected for performance testing. During testing, cross talk leakage prevented the application of a high pressure differential, however, the prototype was successful at withstanding the high temperature operating conditions (1300 °F). In addition, analysis showed that the bulk of the part did not have cracks or leakage issues. This led to the development of a module method for next generation LOM heat exchangers. A scale-up cost analysis showed that given a purpose built LOM system, these ceramic heat exchangers would be affordable for the applications.« less

75 FR 30781 - Manufacturing Council

Federal Register 2010, 2011, 2012, 2013, 2014

2010-06-02

... . Please visit the Manufacturing Council Web site at: http://www.manufacturing.gov/council/index.asp?dName... broader applicant pool to reflect the full diversity of the U.S. manufacturing industry in terms of... the diversity of American manufacturing by representing a balanced cross-section of the U.S...

Enabling Microfluidics: From Clean Rooms to Makerspaces

DTIC Science & Technology

2016-09-30

anyone can make 133 and rapidly scale to bulk manufacturing . To enable others to take part in this type of product 134 design and development, we...cost molds for a fee; however, the 77 design process is slowed down waiting for molds to be manufactured and shipped. While 78 PDMS devices may be...finished prototype into a commercial product . An example of a rapid 101 prototyping method amenable to scaled-up manufacturing is laser cutting. Figure

Best Practices: DOD Can Achieve Better Outcomes by Standardizing the Way Manufacturing Risks are Managed

DTIC Science & Technology

2010-04-01

scale needed can be proven. As an example, GE Healthcare’s Gemstone scintillator underwent years of laboratory development on a small scale until GE...GE Healthcare provides another example of proving out manufacturing processes prior to production in their development of the Gemstone scintillator...including the development and manufacturing of their Gemstone scintillator for use on advanced CT scanners. • Honeywell Aerospace, a global provider

Workshop Report on Additive Manufacturing for Large-Scale Metal Components - Development and Deployment of Metal Big-Area-Additive-Manufacturing (Large-Scale Metals AM) System

DOE Office of Scientific and Technical Information (OSTI.GOV)

Babu, Sudarsanam Suresh; Love, Lonnie J.; Peter, William H.

Additive manufacturing (AM) is considered an emerging technology that is expected to transform the way industry can make low-volume, high value complex structures. This disruptive technology promises to replace legacy manufacturing methods for the fabrication of existing components in addition to bringing new innovation for new components with increased functional and mechanical properties. This report outlines the outcome of a workshop on large-scale metal additive manufacturing held at Oak Ridge National Laboratory (ORNL) on March 11, 2016. The charter for the workshop was outlined by the Department of Energy (DOE) Advanced Manufacturing Office program manager. The status and impact ofmore » the Big Area Additive Manufacturing (BAAM) for polymer matrix composites was presented as the background motivation for the workshop. Following, the extension of underlying technology to low-cost metals was proposed with the following goals: (i) High deposition rates (approaching 100 lbs/h); (ii) Low cost (<$10/lbs) for steel, iron, aluminum, nickel, as well as, higher cost titanium, (iii) large components (major axis greater than 6 ft) and (iv) compliance of property requirements. The above concept was discussed in depth by representatives from different industrial sectors including welding, metal fabrication machinery, energy, construction, aerospace and heavy manufacturing. In addition, DOE’s newly launched High Performance Computing for Manufacturing (HPC4MFG) program was reviewed. This program will apply thermo-mechanical models to elucidate deeper understanding of the interactions between design, process, and materials during additive manufacturing. Following these presentations, all the attendees took part in a brainstorming session where everyone identified the top 10 challenges in large-scale metal AM from their own perspective. The feedback was analyzed and grouped in different categories including, (i) CAD to PART software, (ii) selection of energy source, (iii) systems development, (iv) material feedstock, (v) process planning, (vi) residual stress & distortion, (vii) post-processing, (viii) qualification of parts, (ix) supply chain and (x) business case. Furthermore, an open innovation network methodology was proposed to accelerate the development and deployment of new large-scale metal additive manufacturing technology with the goal of creating a new generation of high deposition rate equipment, affordable feed stocks, and large metallic components to enhance America’s economic competitiveness.« less

Bearings working group

NASA Technical Reports Server (NTRS)

1985-01-01

The service life of the Space Shuttle Main Engine (SSME) turbomachinery bearings was a predominant factor in engine durability and maintenance problems. Recent data has indicated that bearing life is about one order of magnitude lower than the goal of seven and one-half hours particularly those in the High Pressure Oxidizer Turbopump (HPOTP). Bearing technology, primarily cryogenic turbomachinery bearing technology, is expanded by exploring the life and performance effects of design changes; design concept changes; materials changes; manufacturing technique changes; and lubrication system changes. Each variation is assessed against the current bearing design in full scale cryogenic tests.

Packaging of silicon photonic devices: from prototypes to production

NASA Astrophysics Data System (ADS)

Morrissey, Padraic E.; Gradkowski, Kamil; Carroll, Lee; O'Brien, Peter

2018-02-01

The challenges associated with the photonic packaging of silicon devices is often underestimated and remains technically challenging. In this paper, we review some key enabling technologies that will allow us to overcome the current bottleneck in silicon photonic packaging; while also describing the recent developments in standardisation, including the establishment of PIXAPP as the worlds first open-access PIC packaging and assembly Pilot Line. These developments will allow the community to move from low volume prototype photonic packaged devices to large scale volume manufacturing, where the full commercialisation of PIC technology can be realised.

Evaluation of Two Guralp Preamplifiers for GS13 Seismometer Application.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Merchant, Bion J.

Sandia National Laboratories has tested and evaluated a new preamplifier, the Guralp Preamplifier for GS13, manufactured by Guralp. These preamplifiers are used to interface between Guralp digitizers and Geotech GS13 Seismometers. The purpose of the preamplifier evaluation was to measure the performance characteristics in such areas as power consumption, input impedance, sensitivity, full scale, self-noise, dynamic range, system noise, response, passband, and timing. The Guralp GS13 Preamplifiers are being evaluated for potential use in the International Monitoring System (IMS) of the Comprehensive Nuclear Test-Ban-Treaty Organization (CTBTO).

X-33 Injector Ignition Single Cell Test

NASA Technical Reports Server (NTRS)

1997-01-01

The X-33 injector ignition single cell was tested at the Marshall Space Flight Center test stand 116. The X-33 was a sub-scale technology demonstrator prototype of a Reusable Launch Vehicle (RLV) manufactured and named by Lockheed Martin as the Venture Star. The goal of the program was to demonstrate the technologies needed for a full size, single-stage-to-orbit RLV, thus enabling private industry to build and operate the RLV in the first decade of the 21st century. The X-33 program was cancelled in 2001.

Design, Development and Hotfire Testing of Monolithic Copper and Bimetallic Additively Manufactured Combustion Chambers

NASA Technical Reports Server (NTRS)

Gradl, Paul; Barnett, Greg; Brandsmeier, Will; Greene, Sandy Elam; Protz, Chris

2016-01-01

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM) otherwise commonly referred to as additive manufacturing. The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for the GRCop-84 copper-alloy commensurate with powder bed additive manufacturing, evaluate bimetallic deposition and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. As a direct spin off of this program, NASA is working with industry partners to further develop the printing process for the GRCop-84 material in addition to the C-18150 (CuCrZr) material. To advance the process further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic additively manufactured chambers. A 1.2k sized thrust-chamber was designed and developed to compare the printing process of the GRCop-84 and C-18150 SLM materials. A series of similar MCC liners also completed development with an Inconel 625 jacket bonded to the GRcop-84 liner evaluating direct metal deposition (DMD) laser and arc-based techniques. This paper describes the design, development, manufacturing and testing of these combustion chambers and associated lessons learned throughout the design and development process.

Development and Validation of a Safety Climate Scale for Manufacturing Industry

PubMed Central

Ghahramani, Abolfazl; Khalkhali, Hamid R.

2015-01-01

Background This paper describes the development of a scale for measuring safety climate. Methods This study was conducted in six manufacturing companies in Iran. The scale developed through conducting a literature review about the safety climate and constructing a question pool. The number of items was reduced to 71 after performing a screening process. Results The result of content validity analysis showed that 59 items had excellent item content validity index (≥ 0.78) and content validity ratio (> 0.38). The exploratory factor analysis resulted in eight safety climate dimensions. The reliability value for the final 45-item scale was 0.96. The result of confirmatory factor analysis showed that the safety climate model is satisfactory. Conclusion This study produced a valid and reliable scale for measuring safety climate in manufacturing companies. PMID:26106508

DOE Office of Scientific and Technical Information (OSTI.GOV)

Valery, N.

The calorific values of the fuels being studied were compared. Petrol is the most efficient, followed by methane in the form of LGN, then methanol and liquid hydrogen. Hydrogen is attractive only on a weight basis, but the storage problems are serious for its liquefied state. Liquid methane requires the same costly storage equipment as hydrogen, making it prohibitive for road vehicles. Methanol is a clean burning fuel and manufacturing processes are being developed. Tests are being sponsored by the Office of Coal Research and the American Gas Association and large-scale commercial plants could be capable of being onstream bymore » 1978. Synthetic crude oil has been manufactured in Sasol, South Africa since 1955. The technique is based on the Fischer-Tropsch process for synthesizing oil from coal, not only making synthetic petrol from coal but also the full range of products normally derived from crude oil. (MCW)« less

A new large-scale manufacturing platform for complex biopharmaceuticals.

PubMed

Vogel, Jens H; Nguyen, Huong; Giovannini, Roberto; Ignowski, Jolene; Garger, Steve; Salgotra, Anil; Tom, Jennifer

2012-12-01

Complex biopharmaceuticals, such as recombinant blood coagulation factors, are addressing critical medical needs and represent a growing multibillion-dollar market. For commercial manufacturing of such, sometimes inherently unstable, molecules it is important to minimize product residence time in non-ideal milieu in order to obtain acceptable yields and consistently high product quality. Continuous perfusion cell culture allows minimization of residence time in the bioreactor, but also brings unique challenges in product recovery, which requires innovative solutions. In order to maximize yield, process efficiency, facility and equipment utilization, we have developed, scaled-up and successfully implemented a new integrated manufacturing platform in commercial scale. This platform consists of a (semi-)continuous cell separation process based on a disposable flow path and integrated with the upstream perfusion operation, followed by membrane chromatography on large-scale adsorber capsules in rapid cycling mode. Implementation of the platform at commercial scale for a new product candidate led to a yield improvement of 40% compared to the conventional process technology, while product quality has been shown to be more consistently high. Over 1,000,000 L of cell culture harvest have been processed with 100% success rate to date, demonstrating the robustness of the new platform process in GMP manufacturing. While membrane chromatography is well established for polishing in flow-through mode, this is its first commercial-scale application for bind/elute chromatography in the biopharmaceutical industry and demonstrates its potential in particular for manufacturing of potent, low-dose biopharmaceuticals. Copyright © 2012 Wiley Periodicals, Inc.

Commercial-scale biotherapeutics manufacturing facility for plant-made pharmaceuticals.

PubMed

Holtz, Barry R; Berquist, Brian R; Bennett, Lindsay D; Kommineni, Vally J M; Munigunti, Ranjith K; White, Earl L; Wilkerson, Don C; Wong, Kah-Yat I; Ly, Lan H; Marcel, Sylvain

2015-10-01

Rapid, large-scale manufacture of medical countermeasures can be uniquely met by the plant-made-pharmaceutical platform technology. As a participant in the Defense Advanced Research Projects Agency (DARPA) Blue Angel project, the Caliber Biotherapeutics facility was designed, constructed, commissioned and released a therapeutic target (H1N1 influenza subunit vaccine) in <18 months from groundbreaking. As of 2015, this facility was one of the world's largest plant-based manufacturing facilities, with the capacity to process over 3500 kg of plant biomass per week in an automated multilevel growing environment using proprietary LED lighting. The facility can commission additional plant grow rooms that are already built to double this capacity. In addition to the commercial-scale manufacturing facility, a pilot production facility was designed based on the large-scale manufacturing specifications as a way to integrate product development and technology transfer. The primary research, development and manufacturing system employs vacuum-infiltrated Nicotiana benthamiana plants grown in a fully contained, hydroponic system for transient expression of recombinant proteins. This expression platform has been linked to a downstream process system, analytical characterization, and assessment of biological activity. This integrated approach has demonstrated rapid, high-quality production of therapeutic monoclonal antibody targets, including a panel of rituximab biosimilar/biobetter molecules and antiviral antibodies against influenza and dengue fever. © 2015 Society for Experimental Biology, Association of Applied Biologists and John Wiley & Sons Ltd.

Large-Scale Noniridescent Structural Color Printing Enabled by Infiltration-Driven Nonequilibrium Colloidal Assembly.

PubMed

Bai, Ling; Mai, Van Cuong; Lim, Yun; Hou, Shuai; Möhwald, Helmuth; Duan, Hongwei

2018-03-01

Structural colors originating from interaction of light with intricately arranged micro-/nanostructures have stimulated considerable interest because of their inherent photostability and energy efficiency. In particular, noniridescent structural color with wide viewing angle has been receiving increasing attention recently. However, no method is yet available for rapid and large-scale fabrication of full-spectrum structural color patterns with wide viewing angles. Here, infiltration-driven nonequilibrium assembly of colloidal particles on liquid-permeable and particle-excluding substrates is demonstrated to direct the particles to form amorphous colloidal arrays (ACAs) within milliseconds. The infiltration-assisted (IFAST) colloidal assembly opens new possibilities for rapid manufacture of noniridescent structural colors of ACAs and straightforward structural color mixing. Full-spectrum noniridescent structural colors are successfully produced by mixing primary structural colors of red, blue, and yellow using a commercial office inkjet printer. Rapid fabrication of large-scale structural color patterns with sophisticated color combination/layout by IFAST printing is realized. The IFAST technology is versatile for developing structural color patterns with wide viewing angles, as colloidal particles, inks, and substrates are flexibly designable for diverse applications. © 2018 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Bioaugmentation for treatment of full-scale diethylene glycol monobutyl ether (DGBE) wastewater by Serratia sp. BDG-2.

PubMed

Chen, Maoxia; Fan, Rong; Zou, Wenhui; Zhou, Houzhen; Tan, Zhouliang; Li, Xudong

2016-05-15

A novel bacterial strain BDG-2 was isolated and used to augment the treatment of silicon plate manufacturing wastewater that primarily contains diethylene glycol monobutyl ether (DGBE). BDG-2 was identified as a Serratia sp. Under the optimal conditions of 30 °C, pH 9 and DGBE concentration of 2000 mg L(-1), the bioaugmented system achieved 96.92% COD removal after 39.9h. Laboratory-scale technological matching results indicated that, in a biofilm process with the addition of 100 mg L(-1) ammonia and 5 mg L(-1) total phosphorus (TP), 70.61% COD removal efficiency could be obtained in 46 h. Addition of polyaluminium chloride (PAC) to the reactors during the suspension process enhanced the settleability of the BDG-2 culture. Subsequently, successful start-up and stable operation of a full-scale bioaugmented treatment facilities were accomplished, and the volumetric organic load in the plug-flow aeration tank was 2.17 ± 0.81 kg m(-3) d(-1). The effluent COD of the facilities was stable and always below 100 mg L(-1). Copyright © 2016 Elsevier B.V. All rights reserved.

Achieving continuous manufacturing: technologies and approaches for synthesis, workup, and isolation of drug substance. May 20-21, 2014 Continuous Manufacturing Symposium.

PubMed

Baxendale, Ian R; Braatz, Richard D; Hodnett, Benjamin K; Jensen, Klavs F; Johnson, Martin D; Sharratt, Paul; Sherlock, Jon-Paul; Florence, Alastair J

2015-03-01

This whitepaper highlights current challenges and opportunities associated with continuous synthesis, workup, and crystallization of active pharmaceutical ingredients (drug substances). We describe the technologies and requirements at each stage and emphasize the different considerations for developing continuous processes compared with batch. In addition to the specific sequence of operations required to deliver the necessary chemical and physical transformations for continuous drug substance manufacture, consideration is also given to how adoption of continuous technologies may impact different manufacturing stages in development from discovery, process development, through scale-up and into full scale production. The impact of continuous manufacture on drug substance quality and the associated challenges for control and for process safety are also emphasized. In addition to the technology and operational considerations necessary for the adoption of continuous manufacturing (CM), this whitepaper also addresses the cultural, as well as skills and training, challenges that will need to be met by support from organizations in order to accommodate the new work flows. Specific action items for industry leaders are: Develop flow chemistry toolboxes, exploiting the advantages of flow processing and including highly selective chemistries that allow use of simple and effective continuous workup technologies. Availability of modular or plug and play type equipment especially for workup to assist in straightforward deployment in the laboratory. As with learning from other industries, standardization is highly desirable and will require cooperation across industry and academia to develop and implement. Implement and exploit process analytical technologies (PAT) for real-time dynamic control of continuous processes. Develop modeling and simulation techniques to support continuous process development and control. Progress is required in multiphase systems such as crystallization. Involve all parts of the organization from discovery, research and development, and manufacturing in the implementation of CM. Engage with academia to develop the training provision to support the skills base for CM, particularly in flow chemistry, physical chemistry, and chemical engineering skills at the chemistry-process interface. Promote and encourage publication and dissemination of examples of CM across the sector to demonstrate capability, engage with regulatory comment, and establish benchmarks for performance and highlight challenges. Develop the economic case for CM of drug substance. This will involve various stakeholders at project and business level, however establishing the critical economic drivers is critical to driving the transformation in manufacturing. © 2014 Wiley Periodicals, Inc. and the American Pharmacists Association.

Design and additive manufacture for flow chemistry.

PubMed

Capel, Andrew J; Edmondson, Steve; Christie, Steven D R; Goodridge, Ruth D; Bibb, Richard J; Thurstans, Matthew

2013-12-07

We review the use of additive manufacturing (AM) as a novel manufacturing technique for the production of milli-scale reactor systems. Five well-developed additive manufacturing techniques: stereolithography (SL), multi-jet modelling (MJM), selective laser melting (SLM), laser sintering (LS) and fused deposition modelling (FDM) were used to manufacture a number of miniaturised reactors which were tested using a range of organic and inorganic reactions.

Concentrating Solar Power Central Receiver Panel Component Fabrication and Testing FINAL REPORT

DOE Office of Scientific and Technical Information (OSTI.GOV)

McDowell, Michael W; Miner, Kris

The objective of this project is to complete a design of an advanced concentrated solar panel and demonstrate the manufacturability of key components. Then confirm the operation of the key components under prototypic solar flux conditions. This work is an important step in reducing the levelized cost of energy (LCOE) from a central receiver solar power plant. The key technical risk to building larger power towers is building the larger receiver systems. Therefore, this proposed technology project includes the design of an advanced molten salt prototypic sub-scale receiver panel that can be utilized into a large receiver system. Then completemore » the fabrication and testing of key components of the receive design that will be used to validate the design. This project shall have a significant impact on solar thermal power plant design. Receiver panels of suitable size for utility scale plants are a key element to a solar power tower plant. Many subtle and complex manufacturing processes are involved in producing a reliable, robust receiver panel. Given the substantial size difference between receiver panels manufactured in the past and those needed for large plant designs, the manufacture and demonstration on prototype receiver panel components with representative features of a full-sized panel will be important to improving the build process for commercial success. Given the thermal flux limitations of the test facility, the panel components cannot be rendered full size. Significance changes occurred in the projects technical strategies from project initiation to the accomplishments described herein. The initial strategy was to define cost improvements for the receiver, design and build a scale prototype receiver and test, on sun, with a molten salt heat transport system. DOE had committed to constructing a molten salt heat transport loop to support receiver testing at the top of the NSTTF tower. Because of funding constraints this did not happen. A subsequent plan to test scale prototype receiver, off sun but at temperature, at a molten salt loop at ground level adjacent to the tower also had to be abandoned. Thus, no test facility existed for a molten salt receiver test. As a result, PWR completed the prototype receiver design and then fabricated key components for testing instead of fabricating the complete prototype receiver. A number of innovative design ideas have been developed. Key features of the receiver panel have been identified. This evaluation includes input from Solar 2, personal experience of people working on these programs and meetings with Sandia. Key components of the receiver design and key processes used to fabricate a receiver have been selected for further evaluation. The Test Plan, Concentrated Solar Power Receiver In Cooperation with the Department of Energy and Sandia National Laboratory was written to define the scope of the testing to be completed as well as to provide details related to the hardware, instrumentation, and data acquisition. The document contains a list of test objectives, a test matrix, and an associated test box showing the operating points to be tested. Test Objectives: 1. Demonstrate low-cost manufacturability 2. Demonstrate robustness of two different tube base materials 3. Collect temperature data during on sun operation 4. Demonstrate long term repeated daily operation of heat shields 5. Complete pinhole tube weld repairs 6. Anchor thermal models This report discusses the tests performed, the results, and implications for design improvements and LCOE reduction.« less

Manufacturing Process Developments for Regeneratively-Cooled Channel Wall Rocket Nozzles

NASA Technical Reports Server (NTRS)

Gradl, Paul; Brandsmeier, Will

2016-01-01

Regeneratively cooled channel wall nozzles incorporate a series of integral coolant channels to contain the coolant to maintain adequate wall temperatures and expand hot gas providing engine thrust and specific impulse. NASA has been evaluating manufacturing techniques targeting large scale channel wall nozzles to support affordability of current and future liquid rocket engine nozzles and thrust chamber assemblies. The development of these large scale manufacturing techniques focus on the liner formation, channel slotting with advanced abrasive water-jet milling techniques and closeout of the coolant channels to replace or augment other cost reduction techniques being evaluated for nozzles. NASA is developing a series of channel closeout techniques including large scale additive manufacturing laser deposition and explosively bonded closeouts. A series of subscale nozzles were completed evaluating these processes. Fabrication of mechanical test and metallography samples, in addition to subscale hardware has focused on Inconel 625, 300 series stainless, aluminum alloys as well as other candidate materials. Evaluations of these techniques are demonstrating potential for significant cost reductions for large scale nozzles and chambers. Hot fire testing is planned using these techniques in the future.

Fabrication methods for mesoscopic flying vehicle

NASA Astrophysics Data System (ADS)

Cheng, Yih-Lin

2001-10-01

Small-scale flying vehicles are attractive tools for atmospheric science research. A centimeter-size mesoscopic electric helicopter, the mesicopter, has been developed at Stanford University for these applications. The mesoscopic scale implies a design with critical features between tens of microns and several millimeters. Three major parts in the mesicopter are challenging to manufacture. Rotors require smooth 3D surfaces and a blade thickness of less than 100 mum. Components in the DC micro-motor must be made of engineering materials, which is difficult on the mesoscopic scale. Airframe fabrication has to integrate complex 3D geometry into one single structure at this scale. In this research, material selection and manufacturing approaches have been investigated and implemented. In rotor fabrication, high-strength polymers manufactured by the Shape Deposition Manufacturing (SDM) technique were the top choice. Aluminum alloys were only considered as the second choice because the fabrication process is more involved. Lift tests showed that the 4-blade polymer and aluminum rotors could deliver about 90% of the expected lift (4g). To explain the rotor performance, structural analyses of spinning rotors were performed and the fabricated geometry was investigated. The bending deflections and the torsional twists were found to be too small to degrade aerodynamic performance. The rotor geometry was verified by laser scanning and by cross-section observations. Commercially available motors are used in the prototypes but a smaller DC micro-motor was designed for future use. Components of the DC micro-motors were fabricated by the Mesoscopic Additive/Subtractive Material Processing technique, which is capable of shaping engineering materials on the mesoscopic scale. The approaches are described in this thesis. The airframe was manufactured using the SDM process, which is capable of building complex parts without assembly. Castable polymers were chosen and mixed with glass microspheres to reduce their density. The finished airframe (65.5 mm x 65.5 mm) weighed only 1.5g. Two mesicopter prototypes, weighing 3g and 17g, have illustrated that powered flight at this scale is feasible. This research provides solutions to manufacture the challenging parts for the mesicopter. The manufacturing approaches discussed here are applicable to other small flying vehicles in similar and even smaller size regimes.

Hot isostatically pressed manufacture of high strength MERL 76 disk and seal shapes

NASA Technical Reports Server (NTRS)

Eng, R. D.; Evans, D. J.

1982-01-01

The feasibility of using MERL 76, an advanced high strength direct hot isostatic pressed powder metallurgy superalloy, as a full scale component in a high technology, long life, commercial turbine engine were demonstrated. The component was a JT9D first stage turbine disk. The JT9D disk rim temperature capability was increased by at least 22 C and the weight of JT9D high pressure turbine rotating components was reduced by at least 35 pounds by replacement of forged Superwaspaloy components with hot isostatic pressed (HIP) MERL 76 components. The process control plan and acceptance criteria for manufacture of MERL 76 HIP consolidated components were generated. Disk components were manufactured for spin/burst rig test, experimental engine tests, and design data generation, which established lower design properties including tensile, stress-rupture, 0.2% creep and notched (Kt = 2.5) low cycle fatigue properties, Sonntag, fatigue crack propagation, and low cycle fatigue crack threshold data. Direct HIP MERL 76, when compared to conventionally forged Superwaspaloy, is demonstrated to be superior in mechanical properties, increased rim temperature capability, reduced component weight, and reduced material cost by at least 30% based on 1980 costs.

Structural Testing of the Blade Reliability Collaborative Effect of Defect Wind Turbine Blades

DOE Office of Scientific and Technical Information (OSTI.GOV)

Desmond, M.; Hughes, S.; Paquette, J.

Two 8.3-meter (m) wind turbine blades intentionally constructed with manufacturing flaws were tested to failure at the National Wind Technology Center (NWTC) at the National Renewable Energy Laboratory (NREL) south of Boulder, Colorado. Two blades were tested; one blade was manufactured with a fiberglass spar cap and the second blade was manufactured with a carbon fiber spar cap. Test loading primarily consisted of flap fatigue loading of the blades, with one quasi-static ultimate load case applied to the carbon fiber spar cap blade. Results of the test program were intended to provide the full-scale test data needed for validation ofmore » model and coupon test results of the effect of defects in wind turbine blade composite materials. Testing was part of the Blade Reliability Collaborative (BRC) led by Sandia National Laboratories (SNL). The BRC seeks to develop a deeper understanding of the causes of unexpected blade failures (Paquette 2012), and to develop methods to enable blades to survive to their expected operational lifetime. Recent work in the BRC includes examining and characterizing flaws and defects known to exist in wind turbine blades from manufacturing processes (Riddle et al. 2011). Recent results from reliability databases show that wind turbine rotor blades continue to be a leading contributor to turbine downtime (Paquette 2012).« less

Summary of Liquid Oxygen/Hydrogen, Direct Metal Laser Sintering Injector Testing and Evaluation Effort at Marshall Space Flight Center

NASA Technical Reports Server (NTRS)

Barnett, Gregory; Bullard, David B.

2015-01-01

The last several years have witnessed a significant advancement in the area of additive manufacturing technology. One area that has seen substantial expansion in application has been laser sintering (or melting) in a powder bed. This technology is often termed 3D printing or various acronyms that may be industry, process, or company specific. Components manufactured via 3D printing have the potential to significantly reduce development and fabrication time and cost. The usefulness of 3D printed components is influenced by several factors such as material properties and surface roughness. This paper details three injectors that were designed, fabricated, and tested in order to evaluate the utility of 3D printed components for rocket engine applications. The three injectors were tested in a hot-fire environment with chamber pressures of approximately 1400 psia. One injector was a 28 element design printed by Directed Manufacturing. The other two injectors were identical 40 element designs printed by Directed Manufacturing and Solid Concepts. All the injectors were swirl-coaxial designs and were subscale versions of a full-scale injector currently in fabrication. The test and evaluation programs for the 28 element and 40 element injectors provided a substantial amount of data that confirms the feasibility of 3D printed parts for future applications. The operating conditions of previously tested, conventionally manufactured injectors were reproduced in the 28 and 40 element programs in order to contrast the performance of each. Overall, the 3D printed injectors demonstrated comparable performance to the conventionally manufactured units. The design features of the aforementioned injectors can readily be implemented in future applications with a high degree of confidence.

Aeroelastic characteristics of a rapid prototype multi-material wind tunnel model of a mechanically deployable aerodynamic decelerator

NASA Astrophysics Data System (ADS)

Raskin, Boris

Scaled wind tunnel models are necessary for the development of aircraft and spacecraft to simulate aerodynamic behavior. This allows for testing multiple iterations of a design before more expensive full-scale aircraft and spacecraft are built. However, the cost of building wind tunnel models can still be high because they normally require costly subtractive manufacturing processes, such as machining, which can be time consuming and laborious due to the complex surfaces of aerodynamic models. Rapid prototyping, commonly known as 3D printing, can be utilized to save on wind tunnel model manufacturing costs. A rapid prototype multi-material wind tunnel model was manufactured for this thesis to investigate the possibility of using PolyJet 3D printing to create a model that exhibits aeroelastic behavior. The model is of NASA's Adaptable Deployable entry and Placement (ADEPT) aerodynamic decelerator, used to decelerate a spacecraft during reentry into a planet's atmosphere. It is a 60° cone with a spherically blunted nose that consists of a 12 flexible panels supported by a rigid structure of nose, ribs, and rim. The novel rapid prototype multi-material model was instrumented and tested in two flow conditions. Quantitative comparisons were made of the average forces and dynamic forces on the model, demonstrating that the model matched expected behavior for average drag, but not Strouhal number, indicating that there was no aeroelastic behavior in this particular case. It was also noted that the dynamic properties (e.g., resonant frequency) associated with the mounting scheme are very important and may dominate the measured dynamic response.

Analysis of labor productivity using large-scale data of firm's financial statements

NASA Astrophysics Data System (ADS)

Ikeda, Y.; Souma, W.; Aoyama, H.; Fujiwara, Y.; Iyetomi, H.

2010-08-01

We investigated labor productivity distribution by analyzing large-scale financial statement data consisting of listed and unlisted Japanese firms to clarify the characteristics of the Japanese labor market. Both high and low productivity sides of the labor productivity distribution follows the power-law distribution. Large inequality in the low productivity side was observed only for the manufacturing sectors in Japan fiscal year (JFY) 1999 and observed for both the manufacturing and non-manufacturing sectors in JFY 2002. The decline in the Japanese GDP in JFY 1999 and JFY 2002 were coincided with the large inequality in the low productivity side of the distribution. A lower peak was found for all non-manufacturing sectors. This might be the origin of the low productivity of the non-manufacturing sectors reported in recent economic studies.

Tip-Based Nanofabrication for Scalable Manufacturing

DOE PAGES

Hu, Huan; Kim, Hoe; Somnath, Suhas

2017-03-16

Tip-based nanofabrication (TBN) is a family of emerging nanofabrication techniques that use a nanometer scale tip to fabricate nanostructures. Here in this review, we first introduce the history of the TBN and the technology development. We then briefly review various TBN techniques that use different physical or chemical mechanisms to fabricate features and discuss some of the state-of-the-art techniques. Subsequently, we focus on those TBN methods that have demonstrated potential to scale up the manufacturing throughput. Finally, we discuss several research directions that are essential for making TBN a scalable nano-manufacturing technology.

Tip-Based Nanofabrication for Scalable Manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hu, Huan; Kim, Hoe; Somnath, Suhas

Tip-based nanofabrication (TBN) is a family of emerging nanofabrication techniques that use a nanometer scale tip to fabricate nanostructures. Here in this review, we first introduce the history of the TBN and the technology development. We then briefly review various TBN techniques that use different physical or chemical mechanisms to fabricate features and discuss some of the state-of-the-art techniques. Subsequently, we focus on those TBN methods that have demonstrated potential to scale up the manufacturing throughput. Finally, we discuss several research directions that are essential for making TBN a scalable nano-manufacturing technology.

Achieving continuous manufacturing for final dosage formation: challenges and how to meet them. May 20-21, 2014 Continuous Manufacturing Symposium.

PubMed

Byrn, Stephen; Futran, Maricio; Thomas, Hayden; Jayjock, Eric; Maron, Nicola; Meyer, Robert F; Myerson, Allan S; Thien, Michael P; Trout, Bernhardt L

2015-03-01

We describe the key issues and possibilities for continuous final dosage formation, otherwise known as downstream processing or drug product manufacturing. A distinction is made between heterogeneous processing and homogeneous processing, the latter of which is expected to add more value to continuous manufacturing. We also give the key motivations for moving to continuous manufacturing, some of the exciting new technologies, and the barriers to implementation of continuous manufacturing. Continuous processing of heterogeneous blends is the natural first step in converting existing batch processes to continuous. In heterogeneous processing, there are discrete particles that can segregate, versus in homogeneous processing, components are blended and homogenized such that they do not segregate. Heterogeneous processing can incorporate technologies that are closer to existing technologies, where homogeneous processing necessitates the development and incorporation of new technologies. Homogeneous processing has the greatest potential for reaping the full rewards of continuous manufacturing, but it takes long-term vision and a more significant change in process development than heterogeneous processing. Heterogeneous processing has the detriment that, as the technologies are adopted rather than developed, there is a strong tendency to incorporate correction steps, what we call below "The Rube Goldberg Problem." Thus, although heterogeneous processing will likely play a major role in the near-term transformation of heterogeneous to continuous processing, it is expected that homogeneous processing is the next step that will follow. Specific action items for industry leaders are: Form precompetitive partnerships, including industry (pharmaceutical companies and equipment manufacturers), government, and universities. These precompetitive partnerships would develop case studies of continuous manufacturing and ideally perform joint-technology development, including development of small-scale equipment and processes. Develop ways to invest internally in continuous manufacturing. How best to do this will depend on the specifics of a given organization, in particular the current development projects. Upper managers will need to energize their process developers to incorporate continuous manufacturing in at least part of their processes to gain experience and demonstrate directly the benefits. Training of continuous manufacturing technologies, organizational approaches, and regulatory approaches is a key area that industrial leaders should pursue together. © 2014 Wiley Periodicals, Inc. and the American Pharmacists Association.

40 CFR 86.1824-01 - Durability demonstration procedures for evaporative emissions.

Code of Federal Regulations, 2013 CFR

2013-07-01

... over their full useful life. The manufacturer shall use good engineering judgment in determining this... actual use over its full useful life. The manufacturer shall use good engineering judgement in developing... hardware and software) must be installed and operating for the entire mileage accumulation period. (ii...

40 CFR 86.1824-01 - Durability demonstration procedures for evaporative emissions.

Code of Federal Regulations, 2012 CFR

2012-07-01

... over their full useful life. The manufacturer shall use good engineering judgment in determining this... actual use over its full useful life. The manufacturer shall use good engineering judgement in developing... hardware and software) must be installed and operating for the entire mileage accumulation period. (ii...

40 CFR 86.1824-01 - Durability demonstration procedures for evaporative emissions.

Code of Federal Regulations, 2014 CFR

2014-07-01

... their full useful life. The manufacturer shall use good engineering judgment in determining this process... actual use over its full useful life. The manufacturer shall use good engineering judgement in developing... hardware and software) must be installed and operating for the entire mileage accumulation period. (ii...

49 CFR 570.5 - Service brake system.

Code of Federal Regulations, 2010 CFR

2010-10-01

... CFR 571.105, on every new passenger car manufactured on or after January 1, 1968, and on other types... equipment manufacturer's specifications. Note the left to right brake force variance. (2) Road test. The..., inspecting front brake hoses through all wheel positions from full left to full right for conditions...

49 CFR 570.5 - Service brake system.

Code of Federal Regulations, 2011 CFR

2011-10-01

... CFR 571.105, on every new passenger car manufactured on or after January 1, 1968, and on other types... equipment manufacturer's specifications. Note the left to right brake force variance. (2) Road test. The..., inspecting front brake hoses through all wheel positions from full left to full right for conditions...

Anomaly Detection In Additively Manufactured Parts Using Laser Doppler Vibrometery

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hernandez, Carlos A.

Additively manufactured parts are susceptible to non-uniform structure caused by the unique manufacturing process. This can lead to structural weakness or catastrophic failure. Using laser Doppler vibrometry and frequency response analysis, non-contact detection of anomalies in additively manufactured parts may be possible. Preliminary tests show promise for small scale detection, but more future work is necessary.

Manufacturing Analysis | Energy Analysis | NREL

Science.gov Websites

, state, and community levels. Solar photovoltaic manufacturing cost analysis Examining the regional competitiveness of solar photovoltaic manufacturing points to access to capital as a critical component for scale of rare material-based photovoltaic PV technology deployment may influence the United States

Technology transfer and scale-up of the Flublok recombinant hemagglutinin (HA) influenza vaccine manufacturing process.

PubMed

Buckland, Barry; Boulanger, Robert; Fino, Mireli; Srivastava, Indresh; Holtz, Kathy; Khramtsov, Nikolai; McPherson, Clifton; Meghrous, Jamal; Kubera, Paul; Cox, Manon M J

2014-09-22

Multiple different hemagglutinin (HA) protein antigens have been reproducibly manufactured at the 650L scale by Protein Sciences Corporation (PSC) based on an insect cell culture with baculovirus infection. Significantly, these HA protein antigens were produced by the same Universal Manufacturing process as described in the biological license application (BLA) for the first recombinant influenza vaccine approved by the FDA (Flublok). The technology is uniquely designed so that a change in vaccine composition can be readily accommodated from one HA protein antigen to another one. Here we present a vaccine candidate to combat the recently emerged H7N9 virus as an example starting with the genetic sequence for the required HA, creation of the baculovirus and ending with purified protein antigen (or vaccine component) at the 10L scale accomplished within 38 days under GMP conditions. The same process performance is being achieved at the 2L, 10L, 100L, 650L and 2500L scale. An illustration is given of how the technology was transferred from the benchmark 650L scale facility to a retrofitted microbial facility at the 2500L scale within 100 days which includes the time for facility engineering changes. The successful development, technology transfer and scale-up of the Flublok process has major implications for being ready to make vaccine rapidly on a worldwide scale as a defense against pandemic influenza. The technology described does not have the same vulnerability to mutations in the egg adapted strain, and resulting loss in vaccine efficacy, faced by egg based manufacture. Copyright © 2014 Elsevier Ltd. All rights reserved.

The use of dissolved oxygen-controlled, fed-batch aerobic cultivation for recombinant protein subunit vaccine manufacturing.

PubMed

Farrell, Patrick; Sun, Jacob; Champagne, Paul-Philippe; Lau, Heron; Gao, Meg; Sun, Hong; Zeiser, Arno; D'Amore, Tony

2015-11-27

A simple "off-the-shelf" fed-batch approach to aerobic bacterial cultivation for recombinant protein subunit vaccine manufacturing is presented. In this approach, changes in the dissolved oxygen levels are used to adjust the nutrient feed rate (DO-stat), so that the desired dissolved oxygen level is maintained throughout cultivation. This enables high Escherichia coli cell densities and recombinant protein titers. When coupled to a kLa-matched scale-down model, process performance is shown to be consistent at the 2L, 20L, and 200L scales for two recombinant E. coli strains expressing different protein subunit vaccine candidates. Additionally, by mining historical DO-stat nutrient feeding data, a method to transition from DO-stat to a pre-determined feeding profile suitable for larger manufacturing scales without using feedback control is demonstrated at the 2L, 20L, and 200L scales. Copyright © 2015 Elsevier Ltd. All rights reserved.

Testing Starshade Manufacturing and Deployment Through NASA's Technology Development for Exoplanet Missions Program

NASA Astrophysics Data System (ADS)

Kasdin, N. J.; Shaklan, S.; Lisman, D.; Thomson, M.; Cady, E.; Lo, A.; Macintosh, B.

2014-01-01

An external occulter is a satellite employing a large screen, or starshade, that flies in formation with a spaceborne telescope to provide the starlight suppression needed for detecting and characterizing exoplanets. Among the advantages of using an occulter are the broadband allowed for characterization and the removal of light before entering the observatory, greatly relaxing the requirements on the telescope and instrument. In this poster we report on the results of our two Technology Development for Exoplanet Missions (TDEM) studies. In the first we examined the manufacturability and metrology of starshade petals, successfully constructing a full size petal from flight like materials and showing through precise edge shape measurements that an occulter made with petals consistent with the measured accuracy would achieve close to 10^-10 contrast. Our second TDEM tested the deployment precision of a roughly half-scale starshade. We demonstrated the deployment of an existing deployable truss outfitted with four sub-scale petals and a custom designed central hub. We showed that the system can be deployed multiple times with a repeatable positioning accuracy of the petals better than the requirement of 1.0 mm. The combined results of these two TDEM projects has significantly advanced the readiness level of occulter technology and moved the community closer to a realizable mission.

Validation of a pre-existing safety climate scale for the Turkish furniture manufacturing industry.

PubMed

Akyuz, Kadri Cemil; Yildirim, Ibrahim; Gungor, Celal

2018-03-22

Understanding the safety climate level is essential to implement a proactive safety program. The objective of this study is to explore the possibility of having a safety climate scale for the Turkish furniture manufacturing industry since there has not been any scale available. The questionnaire recruited 783 subjects. Confirmatory factor analysis (CFA) tested a pre-existing safety scale's fit to the industry. The CFA indicated that the structures of the model present a non-satisfactory fit with the data (χ 2  = 2033.4, df = 314, p ≤ 0.001; root mean square error of approximation = 0.08, normed fit index = 0.65, Tucker-Lewis index = 0.65, comparative fit index = 0.69, parsimony goodness-of-fit index = 0.68). The results suggest that a new scale should be developed and validated to measure the safety climate level in the Turkish furniture manufacturing industry. Due to the hierarchical structure of organizations, future studies should consider a multilevel approach in their exploratory factor analyses while developing a new scale.

French Sizing of Medical Devices is not Fit for Purpose

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kibriya, Nabil, E-mail: nabskib@yahoo.co.uk; Hall, Rebecca; Powell, Steven

PurposeThe purpose of the study is to quantify the variation in the metric equivalent of French size in a range of medical devices, from various manufacturers, used in interventional radiology.MethodsThe labelling of a range of catheters, introducers, drains, balloons, stents, and endografts was examined. Products were chosen to achieve a broad range of French sizes from several manufacturers. To assess manufacturing accuracy, eight devices were selected for measurement using a laser micrometer. The external diameters of three specimens of each device were measured at centimeter intervals along the length of the device to ensure uniformity.ResultsA total of 200 labels ofmore » interventional radiology equipment were scrutinized. The results demonstrate a wide variation in the metric equivalent of French sizing. Labelled products can vary in diameter across the product range by up to 0.79 mm.The devices selected for measurement with the non-contact laser micrometer demonstrate acceptable manufacturing consistency. The external diameter differed by 0.05 mm on average.ConclusionsOur results demonstrate wide variation in the interpretation of the French scale by different manufacturers of medical devices. This has the potential to lead to problems using coaxial systems especially when the products are from different manufacturers. It is recommended that standard labelling should be employed by all manufacturers conveying specific details of the equipment. Given the wide variation in the interpretation of the French scale, our opinion is that this scale either needs to be abandoned or be strictly defined and followed.« less

A Single-use Strategy to Enable Manufacturing of Affordable Biologics.

PubMed

Jacquemart, Renaud; Vandersluis, Melissa; Zhao, Mochao; Sukhija, Karan; Sidhu, Navneet; Stout, Jim

2016-01-01

The current processing paradigm of large manufacturing facilities dedicated to single product production is no longer an effective approach for best manufacturing practices. Increasing competition for new indications and the launch of biosimilars for the monoclonal antibody market have put pressure on manufacturers to produce at lower cost. Single-use technologies and continuous upstream processes have proven to be cost-efficient options to increase biomass production but as of today the adoption has been only minimal for the purification operations, partly due to concerns related to cost and scale-up. This review summarizes how a single-use holistic process and facility strategy can overcome scale limitations and enable cost-efficient manufacturing to support the growing demand for affordable biologics. Technologies enabling high productivity, right-sized, small footprint, continuous, and automated upstream and downstream operations are evaluated in order to propose a concept for the flexible facility of the future.

On-line application of near-infrared spectroscopy for monitoring water levels in parts per million in a manufacturing-scale distillation process.

PubMed

Lambertus, Gordon; Shi, Zhenqi; Forbes, Robert; Kramer, Timothy T; Doherty, Steven; Hermiller, James; Scully, Norma; Wong, Sze Wing; LaPack, Mark

2014-01-01

An on-line analytical method based on transmission near-infrared spectroscopy (NIRS) for the quantitative determination of water concentrations (in parts per million) was developed and applied to the manufacture of a pharmaceutical intermediate. Calibration models for water analysis, built at the development site and applied at the manufacturing site, were successfully demonstrated during six manufacturing runs at a 250-gallon scale. The water measurements will be used as a forward-processing control point following distillation of a toluene product solution prior to use in a Grignard reaction. The most significant impact of using this NIRS-based process analytical technology (PAT) to replace off-line measurements is the significant reduction in the risk of operator exposure through the elimination of sampling of a severely lachrymatory and mutagenic compound. The work described in this report illustrates the development effort from proof-of-concept phase to manufacturing implementation.

Impact Testing and Simulation of Composite Airframe Structures

NASA Technical Reports Server (NTRS)

Jackson, Karen E.; Littell, Justin D.; Horta, Lucas G.; Annett, Martin S.; Fasanella, Edwin L.; Seal, Michael D., II

2014-01-01

Dynamic tests were performed at NASA Langley Research Center on composite airframe structural components of increasing complexity to evaluate their energy absorption behavior when subjected to impact loading. A second objective was to assess the capabilities of predicting the dynamic response of composite airframe structures, including damage initiation and progression, using a state-of-the-art nonlinear, explicit transient dynamic finite element code, LS-DYNA. The test specimens were extracted from a previously tested composite prototype fuselage section developed and manufactured by Sikorsky Aircraft Corporation under the US Army's Survivable Affordable Repairable Airframe Program (SARAP). Laminate characterization testing was conducted in tension and compression. In addition, dynamic impact tests were performed on several components, including I-beams, T-sections, and cruciform sections. Finally, tests were conducted on two full-scale components including a subfloor section and a framed fuselage section. These tests included a modal vibration and longitudinal impact test of the subfloor section and a quasi-static, modal vibration, and vertical drop test of the framed fuselage section. Most of the test articles were manufactured of graphite unidirectional tape composite with a thermoplastic resin system. However, the framed fuselage section was constructed primarily of a plain weave graphite fabric material with a thermoset resin system. Test data were collected from instrumentation such as accelerometers and strain gages and from full-field photogrammetry.

The development of compact electroactive polymer actuators suitable for use in full page Braille displays

NASA Astrophysics Data System (ADS)

Gorny, Lee J.; Zellers, Brian C.; Lin, Minren; Liu, Sheng; Zhang, Qiming M.

2010-04-01

Piezoceramic actuators, presently used in commercial Braille displays, are limited by the material's relatively small strain and brittle nature. For this reason, it is a challenge to develop full page, compact, graphic Braille displays that are affordable. A newly developed material composed of P(VDF-TrFE-CFE) terpolymer blended with 5% P(VDF-CTFE) electrostrictive actuators exhibits large strains (~5% at 150V/μm), fast actuation (>5 mm/s), and has a relatively high elastic modulus (1.2 GPa). This material exhibits more than double the elastic energy density and a 50% higher modulus of the original electrostrictive terpolymer. Hence, the potential for viable actuators in compact, full page Braille displays is greater than ever, provided actuators can be manufactured reliably in quantity. This talk presents recent work in scaling production of such rolled actuators. Actuators extend .5 mm, are confined to the 2.5 mm grid spacing of conventional Braille text, generate >0.5 N force and operate at less than 200V, thus meeting the primary requirements for a commercialized Braille display. To manufacture these actuators, cast films are stretched using a roll-to-roll zone drawing machine that is capable of producing quantities of 2 μm thick film with high quality. What follows is a discussion of this machine, the roll-to-roll film stretching process and an assessment of the resulting stretched film for use as linear strain actuators, like those used in our Braille cell.

75 FR 47268 - Notice of Petitions by Firms for Determination of Eligibility To Apply for Trade Adjustment...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-08-05

.... Fixture Hardware Manufacturing 4116 First Avenue, 7/28/2010 Firm manufactures a full line of steel.../2010 MC2 designs and manufactures, hand made, MA 01230. precious jewelry using gold, platinum, diamonds and precious stones. MSW, Inc 7159 Country Road 200, 7/28/2010 MSW, Inc., designs and manufactures...

Thermal analysis of a prototype cryogenic polarization modulator for use in a space-borne CMB polarization experiment

NASA Astrophysics Data System (ADS)

Iida, T.; Sakurai, Y.; Matsumura, T.; Sugai, H.; Imada, H.; Kataza, H.; Ohsaki, H.; Hazumi, M.; Katayama, N.; Yamamoto, R.; Utsunomiya, S.; Terao, Y.

2017-12-01

We report a thermal analysis of a polarization modulator unit (PMU) for use in a space-borne cosmic microwave background (CMB) project. A measurement of the CMB polarization allows us to probe the physics of early universe, and that is the best method to test the cosmic inflation experimentally. One of the key instruments for this science is to use a halfwave plate (HWP) based polarization modulator. The HWP is required to rotate continuously at about 1 Hz below 10 K to minimize its own thermal emission to a detector system. The rotating HWP system at the cryogenic environment can be realized by using a superconducting magnetic bearing (SMB) without significant heat dissipation by mechanical friction. While the SMB achieves the smooth rotation due to the contactless bearing, an estimation of a levitating HWP temperature becomes a challenge. We manufactured a one-eighth scale prototype model of PMU and built a thermal model. We verified our thermal model with the experimental data. We forecasted the projected thermal performance of PMU for a full-scale model based on the thermal model. From this analysis, we discuss the design requirement toward constructing the full-scale model for use in a space environment such as a future CMB satellite mission, LiteBIRD.

Large Scale Composite Manufacturing for Heavy Lift Launch Vehicles

NASA Technical Reports Server (NTRS)

Stavana, Jacob; Cohen, Leslie J.; Houseal, Keth; Pelham, Larry; Lort, Richard; Zimmerman, Thomas; Sutter, James; Western, Mike; Harper, Robert; Stuart, Michael

2012-01-01

Risk reduction for the large scale composite manufacturing is an important goal to produce light weight components for heavy lift launch vehicles. NASA and an industry team successfully employed a building block approach using low-cost Automated Tape Layup (ATL) of autoclave and Out-of-Autoclave (OoA) prepregs. Several large, curved sandwich panels were fabricated at HITCO Carbon Composites. The aluminum honeycomb core sandwich panels are segments of a 1/16th arc from a 10 meter cylindrical barrel. Lessons learned highlight the manufacturing challenges required to produce light weight composite structures such as fairings for heavy lift launch vehicles.

A Perceptual Measure of the Degree of Development of Proprietary Equipment.

ERIC Educational Resources Information Center

Cua, Kristy O.; Junttila, Mikko A.; Schroeder, Roger G.

2002-01-01

Evaluated the psychometric properties of a perceptual measure of the extent to which manufacturing organizations develop proprietary equipment, the Proprietary Equipment Scale (developed by the World Class Manufacturing study). Analysis of data from 164 manufacturing plants in 5 countries indicates that although method effects are present, the…

A system approach for reducing the environmental impact of manufacturing and sustainability improvement of nano-scale manufacturing

NASA Astrophysics Data System (ADS)

Yuan, Yingchun

This dissertation develops an effective and economical system approach to reduce the environmental impact of manufacturing. The system approach is developed by using a process-based holistic method for upstream analysis and source reduction of the environmental impact of manufacturing. The system approach developed consists of three components of a manufacturing system: technology, energy and material, and is useful for sustainable manufacturing as it establishes a clear link between manufacturing system components and its overall sustainability performance, and provides a framework for environmental impact reductions. In this dissertation, the system approach developed is applied for environmental impact reduction of a semiconductor nano-scale manufacturing system, with three case scenarios analyzed in depth on manufacturing process improvement, clean energy supply, and toxic chemical material selection. The analysis on manufacturing process improvement is conducted on Atomic Layer Deposition of Al2O3 dielectric gate on semiconductor microelectronics devices. Sustainability performance and scale-up impact of the ALD technology in terms of environmental emissions, energy consumption, nano-waste generation and manufacturing productivity are systematically investigated and the ways to improve the sustainability of the ALD technology are successfully developed. The clean energy supply is studied using solar photovoltaic, wind, and fuel cells systems for electricity generation. Environmental savings from each clean energy supply over grid power are quantitatively analyzed, and costs for greenhouse gas reductions on each clean energy supply are comparatively studied. For toxic chemical material selection, an innovative schematic method is developed as a visual decision tool for characterizing and benchmarking the human health impact of toxic chemicals, with a case study conducted on six chemicals commonly used as solvents in semiconductor manufacturing. Reliability of the schematic method is validated by comparing its benchmark results on 104 chemicals with that from the conventional Human Toxicity Potential (HTP) method. This dissertation concludes with discussions on environmental impact assessment of nanotechnologies and sustainability management of nano-particles. As nano-manufacturing is emerging for wide industrial applications, improvement and expansion of the system approach would be valuable for use in the environmental management of nano-manufacturing and in the risk control of nano-particles in the interests of public health and the environment.

Large-Scale Advanced Prop-Fan (LAP)

NASA Technical Reports Server (NTRS)

Degeorge, C. L.

1988-01-01

In recent years, considerable attention has been directed toward improving aircraft fuel efficiency. Analytical studies and research with wind tunnel models have demonstrated that the high inherent efficiency of low speed turboprop propulsion systems may now be extended to the Mach .8 flight regime of today's commercial airliners. This can be accomplished with a propeller, employing a large number of thin highly swept blades. The term Prop-Fan has been coined to describe such a propulsion system. In 1983 the NASA-Lewis Research Center contracted with Hamilton Standard to design, build and test a near full scale Prop-Fan, designated the Large Scale Advanced Prop-Fan (LAP). This report provides a detailed description of the LAP program. The assumptions and analytical procedures used in the design of Prop-Fan system components are discussed in detail. The manufacturing techniques used in the fabrication of the Prop-Fan are presented. Each of the tests run during the course of the program are also discussed and the major conclusions derived from them stated.

Stall behavior of a scaled three-dimensional wind turbine blade

NASA Astrophysics Data System (ADS)

Mulleners, Karen; Melius, Matthew; Cal, Raul Bayoan

2014-11-01

The power generation of a wind turbine is influenced by many factors including the unsteady incoming flow characteristics, pitch regulation, and the geometry of the various turbine components. Within the framework of maximizing energy extraction, it is important to understand and tailor the aerodynamics of a wind turbine. In the interest of seeking further understanding into the complex flow over wind turbine blades, a three-dimensional scaled blade model has been designed and manufactured to be dynamically similar to a rotating full-scale NREL 5MW wind turbine blade. A wind tunnel experiment has been carried out in the 2.2 m × 1.8 m cross-section closed loop wind tunnel at DLR in Göttingen by means of time-resolved stereoscopic PIV. An extensive coherent structure analysis of the time-resolved velocity field over the suction side of the blade was performed to study stall characteristics under a geometrically induced pressure gradient. In particular, the radial extent and propagation of stalled flow regions were characterized for various static angles of attack.

Bio-inspired wooden actuators for large scale applications.

PubMed

Rüggeberg, Markus; Burgert, Ingo

2015-01-01

Implementing programmable actuation into materials and structures is a major topic in the field of smart materials. In particular the bilayer principle has been employed to develop actuators that respond to various kinds of stimuli. A multitude of small scale applications down to micrometer size have been developed, but up-scaling remains challenging due to either limitations in mechanical stiffness of the material or in the manufacturing processes. Here, we demonstrate the actuation of wooden bilayers in response to changes in relative humidity, making use of the high material stiffness and a good machinability to reach large scale actuation and application. Amplitude and response time of the actuation were measured and can be predicted and controlled by adapting the geometry and the constitution of the bilayers. Field tests in full weathering conditions revealed long-term stability of the actuation. The potential of the concept is shown by a first demonstrator. With the sensor and actuator intrinsically incorporated in the wooden bilayers, the daily change in relative humidity is exploited for an autonomous and solar powered movement of a tracker for solar modules.

Bio-Inspired Wooden Actuators for Large Scale Applications

PubMed Central

Rüggeberg, Markus; Burgert, Ingo

2015-01-01

Implementing programmable actuation into materials and structures is a major topic in the field of smart materials. In particular the bilayer principle has been employed to develop actuators that respond to various kinds of stimuli. A multitude of small scale applications down to micrometer size have been developed, but up-scaling remains challenging due to either limitations in mechanical stiffness of the material or in the manufacturing processes. Here, we demonstrate the actuation of wooden bilayers in response to changes in relative humidity, making use of the high material stiffness and a good machinability to reach large scale actuation and application. Amplitude and response time of the actuation were measured and can be predicted and controlled by adapting the geometry and the constitution of the bilayers. Field tests in full weathering conditions revealed long-term stability of the actuation. The potential of the concept is shown by a first demonstrator. With the sensor and actuator intrinsically incorporated in the wooden bilayers, the daily change in relative humidity is exploited for an autonomous and solar powered movement of a tracker for solar modules. PMID:25835386

Structural Similitude and Scaling Laws

NASA Technical Reports Server (NTRS)

Simitses, George J.

1998-01-01

Aircraft and spacecraft comprise the class of aerospace structures that require efficiency and wisdom in design, sophistication and accuracy in analysis and numerous and careful experimental evaluations of components and prototype, in order to achieve the necessary system reliability, performance and safety. Preliminary and/or concept design entails the assemblage of system mission requirements, system expected performance and identification of components and their connections as well as of manufacturing and system assembly techniques. This is accomplished through experience based on previous similar designs, and through the possible use of models to simulate the entire system characteristics. Detail design is heavily dependent on information and concepts derived from the previous steps. This information identifies critical design areas which need sophisticated analyses, and design and redesign procedures to achieve the expected component performance. This step may require several independent analysis models, which, in many instances, require component testing. The last step in the design process, before going to production, is the verification of the design. This step necessitates the production of large components and prototypes in order to test component and system analytical predictions and verify strength and performance requirements under the worst loading conditions that the system is expected to encounter in service. Clearly then, full-scale testing is in many cases necessary and always very expensive. In the aircraft industry, in addition to full-scale tests, certification and safety necessitate large component static and dynamic testing. Such tests are extremely difficult, time consuming and definitely absolutely necessary. Clearly, one should not expect that prototype testing will be totally eliminated in the aircraft industry. It is hoped, though, that we can reduce full-scale testing to a minimum. Full-scale large component testing is necessary in other industries as well, Ship building, automobile and railway car construction all rely heavily on testing. Regardless of the application, a scaled-down (by a large factor) model (scale model) which closely represents the structural behavior of the full-scale system (prototype) can prove to be an extremely beneficial tool. This possible development must be based on the existence of certain structural parameters that control the behavior of a structural system when acted upon by static and/or dynamic loads. If such structural parameters exist, a scaled-down replica can be built, which will duplicate the response of the full-scale system. The two systems are then said to be structurally similar. The term, then, that best describes this similarity is structural similitude. Similarity of systems requires that the relevant system parameters be identical and these systems be governed by a unique set of characteristic equations. Thus, if a relation or equation of variables is written for a system, it is valid for all systems which are similar to it. Each variable in a model is proportional to the corresponding variable of the prototype. This ratio, which plays an essential role in predicting the relationship between the model and its prototype, is called the scale factor.

Understanding and Controlling Sialylation in a CHO Fc-Fusion Process

PubMed Central

Lewis, Amanda M.; Croughan, William D.; Aranibar, Nelly; Lee, Alison G.; Warrack, Bethanne; Abu-Absi, Nicholas R.; Patel, Rutva; Drew, Barry; Borys, Michael C.; Reily, Michael D.; Li, Zheng Jian

2016-01-01

A Chinese hamster ovary (CHO) bioprocess, where the product is a sialylated Fc-fusion protein, was operated at pilot and manufacturing scale and significant variation of sialylation level was observed. In order to more tightly control glycosylation profiles, we sought to identify the cause of variability. Untargeted metabolomics and transcriptomics methods were applied to select samples from the large scale runs. Lower sialylation was correlated with elevated mannose levels, a shift in glucose metabolism, and increased oxidative stress response. Using a 5-L scale model operated with a reduced dissolved oxygen set point, we were able to reproduce the phenotypic profiles observed at manufacturing scale including lower sialylation, higher lactate and lower ammonia levels. Targeted transcriptomics and metabolomics confirmed that reduced oxygen levels resulted in increased mannose levels, a shift towards glycolysis, and increased oxidative stress response similar to the manufacturing scale. Finally, we propose a biological mechanism linking large scale operation and sialylation variation. Oxidative stress results from gas transfer limitations at large scale and the presence of oxygen dead-zones inducing upregulation of glycolysis and mannose biosynthesis, and downregulation of hexosamine biosynthesis and acetyl-CoA formation. The lower flux through the hexosamine pathway and reduced intracellular pools of acetyl-CoA led to reduced formation of N-acetylglucosamine and N-acetylneuraminic acid, both key building blocks of N-glycan structures. This study reports for the first time a link between oxidative stress and mammalian protein sialyation. In this study, process, analytical, metabolomic, and transcriptomic data at manufacturing, pilot, and laboratory scales were taken together to develop a systems level understanding of the process and identify oxygen limitation as the root cause of glycosylation variability. PMID:27310468

Manufacturing Road Map for Tissue Engineering and Regenerative Medicine Technologies

PubMed Central

Hunsberger, Joshua; Harrysson, Ola; Shirwaiker, Rohan; Starly, Binil; Wysk, Richard; Cohen, Paul; Allickson, Julie; Yoo, James

2015-01-01

Summary The Regenerative Medicine Foundation Annual Conference held on May 6 and 7, 2014, had a vision of assisting with translating tissue engineering and regenerative medicine (TERM)-based technologies closer to the clinic. This vision was achieved by assembling leaders in the field to cover critical areas. Some of these critical areas included regulatory pathways for regenerative medicine therapies, strategic partnerships, coordination of resources, developing standards for the field, government support, priorities for industry, biobanking, and new technologies. The final day of this conference featured focused sessions on manufacturing, during which expert speakers were invited from industry, government, and academia. The speakers identified and accessed roadblocks plaguing the field where improvements in advanced manufacturing offered many solutions. The manufacturing sessions included (a) product development toward commercialization in regenerative medicine, (b) process challenges to scale up manufacturing in regenerative medicine, and (c) infrastructure needs for manufacturing in regenerative medicine. Subsequent to this, industry was invited to participate in a survey to further elucidate the challenges to translation and scale-up. This perspective article will cover the lessons learned from these manufacturing sessions and early results from the survey. We also outline a road map for developing the manufacturing infrastructure, resources, standards, capabilities, education, training, and workforce development to realize the promise of TERM. PMID:25575525

Electrohydraulic Forming of Near-Net Shape Automotive Panels

DOE Office of Scientific and Technical Information (OSTI.GOV)

Golovaschenko, Sergey F.

2013-09-26

The objective of this project was to develop the electrohydraulic forming (EHF) process as a near-net shape automotive panel manufacturing technology that simultaneously reduces the energy embedded in vehicles and the energy consumed while producing automotive structures. Pulsed pressure is created via a shockwave generated by the discharge of high voltage capacitors through a pair of electrodes in a liquid-filled chamber. The shockwave in the liquid initiated by the expansion of the plasma channel formed between two electrodes propagates towards the blank and causes the blank to be deformed into a one-sided die cavity. The numerical model of the EHFmore » process was validated experimentally and was successfully applied to the design of the electrode system and to a multi-electrode EHF chamber for full scale validation of the process. The numerical model was able to predict stresses in the dies during pulsed forming and was validated by the experimental study of the die insert failure mode for corner filling operations. The electrohydraulic forming process and its major subsystems, including durable electrodes, an EHF chamber, a water/air management system, a pulse generator and integrated process controls, were validated to be capable to operate in a fully automated, computer controlled mode for forming of a portion of a full-scale sheet metal component in laboratory conditions. Additionally, the novel processes of electrohydraulic trimming and electrohydraulic calibration were demonstrated at a reduced-scale component level. Furthermore, a hybrid process combining conventional stamping with EHF was demonstrated as a laboratory process for a full-scale automotive panel formed out of AHSS material. The economic feasibility of the developed EHF processes was defined by developing a cost model of the EHF process in comparison to the conventional stamping process.« less

R&D issues in scale-up and manufacturing of amorphous silicon tandem modules

NASA Astrophysics Data System (ADS)

Arya, R. R.; Carlson, D. E.; Chen, L. F.; Ganguly, G.; He, M.; Lin, G.; Middya, R.; Wood, G.; Newton, J.; Bennett, M.; Jackson, F.; Willing, F.

1999-03-01

R & D on amorphous silicon based tandem junction devices has improved the throughtput, the material utilization, and the performance of devices on commercial tin oxide coated glass. The tandem junction technology has been scaled-up to produce 8.6 Ft2 monolithically integrated modules in manufacturing at the TF1 plant. Optimization of performance and stability of these modules is ongoing.

Study of Potential Cost Reductions Resulting from Super-Large-Scale Manufacturing of PV Modules: Final Subcontract Report, 7 August 2003--30 September 2004

DOE Office of Scientific and Technical Information (OSTI.GOV)

Keshner, M. S.; Arya, R.

2004-10-01

Hewlett Packard has created a design for a ''Solar City'' factory that will process 30 million sq. meters of glass panels per year and produce 2.1-3.6 GW of solar panels per year-100x the volume of a typical, thin-film, solar panel manufacturer in 2004. We have shown that with a reasonable selection of materials, and conservative assumptions, this ''Solar City'' can produce solar panels and hit the price target of $1.00 per peak watt (6.5x-8.5x lower than prices in 2004) as the total price for a complete and installed rooftop (or ground mounted) solar energy system. This breakthrough in the pricemore » of solar energy comes without the need for any significant new invention. It comes entirely from the manufacturing scale of a large plant and the cost savings inherent in operating at such a large manufacturing scale. We expect that further optimizations from these simple designs will lead to further improvements in cost. The manufacturing process and cost depend on the choice for the active layer that converts sunlight into electricity. The efficiency by which sunlight is converted into electricity can range from 7% to 15%. This parameter has a large effect on the overall price per watt. There are other impacts, as well, and we have attempted to capture them without creating undue distractions. Our primary purpose is to demonstrate the impact of large-scale manufacturing. This impact is largely independent of the choice of active layer. It is not our purpose to compare the pro's and con's for various types of active layers. Significant improvements in cost per watt can also come from scientific advances in active layers that lead to higher efficiency. But, again, our focus is on manufacturing gains and not on the potential advances in the basic technology.« less

Monitoring the progression of calcium and protein solubilisation as affected by calcium chelators during small-scale manufacture of casein-based food matrices.

PubMed

McIntyre, Irene; O'Sullivan, Michael; O'Riordan, Dolores

2017-12-15

Calcium and protein solubilisation during small-scale manufacture of semi-solid casein-based food matrices was investigated and found to be very different in the presence or absence of calcium chelating salts. Calcium concentrations in the dispersed phase increased and calcium-ion activity (A Ca ++ ) decreased during manufacture of the matrices containing calcium chelating salts; with ∼23% of total calcium solubilised by the end of manufacture. In the absence of calcium chelating salts, these concentrations were significantly lower at equivalent processing times and remained unchanged as did A Ca ++ , throughout manufacture. The protein content of the dispersed phase was low (≤3% of total protein), but was significantly higher for matrices containing calcium chelating salts. This study elucidates the critical role of calcium chelating salts in modulating casein hydration and dispersion and gives an indication of the levels of soluble calcium and protein required to allow matrix formation during manufacture of casein-based food structures e.g. processed and analogue cheese. Copyright © 2017 Elsevier Ltd. All rights reserved.

Adaptive Multi-scale Prognostics and Health Management for Smart Manufacturing Systems

PubMed Central

Choo, Benjamin Y.; Adams, Stephen C.; Weiss, Brian A.; Marvel, Jeremy A.; Beling, Peter A.

2017-01-01

The Adaptive Multi-scale Prognostics and Health Management (AM-PHM) is a methodology designed to enable PHM in smart manufacturing systems. In application, PHM information is not yet fully utilized in higher-level decision-making in manufacturing systems. AM-PHM leverages and integrates lower-level PHM information such as from a machine or component with hierarchical relationships across the component, machine, work cell, and assembly line levels in a manufacturing system. The AM-PHM methodology enables the creation of actionable prognostic and diagnostic intelligence up and down the manufacturing process hierarchy. Decisions are then made with the knowledge of the current and projected health state of the system at decision points along the nodes of the hierarchical structure. To overcome the issue of exponential explosion of complexity associated with describing a large manufacturing system, the AM-PHM methodology takes a hierarchical Markov Decision Process (MDP) approach into describing the system and solving for an optimized policy. A description of the AM-PHM methodology is followed by a simulated industry-inspired example to demonstrate the effectiveness of AM-PHM. PMID:28736651

Manufacturing development of DC-10 advanced rudder

NASA Technical Reports Server (NTRS)

Cominsky, A.

1979-01-01

The design, manufacture, and ground test activities during development of production methods for an advanced composite rudder for the DC-10 transport aircraft are described. The advanced composite aft rudder is satisfactory for airline service and a cost saving in a full production manufacturing mode is anticipated.

40 CFR 91.1006 - Manufacturer-owned exemption and precertification exemption.

Code of Federal Regulations, 2010 CFR

2010-07-01

... (CONTINUED) AIR PROGRAMS (CONTINUED) CONTROL OF EMISSIONS FROM MARINE SPARK-IGNITION ENGINES Exclusion and Exemption of Marine SI Engines § 91.1006 Manufacturer-owned exemption and precertification exemption. (a... “Emission Control Information;” (B) Full corporate name and trademark of manufacturer; (C) Engine...

IDENTIFYING PERFORMANCE ASSURANCE CHALLENGES FOR SMART MANUFACTURING.

PubMed

Helu, Moneer; Morris, Katherine; Jung, Kiwook; Lyons, Kevin; Leong, Swee

2015-10-01

Smart manufacturing has the potential to address many of the challenges faced by industry. However, the manufacturing community often needs assistance to leverage available technologies to improve their systems. To assure the performance of these technologies, this paper proposes a shared knowledge base that collects problem areas, solutions, and best practices for manufacturing technology. An Implementation Risk Assessment Framework (IRAF) is also described to identify the primary weaknesses of technologies in specific manufacturing contexts. Such approaches have the potential to stimulate new ideas and drive standardization activities critical to scale up and deploy smart manufacturing technologies successfully and quickly.

IDENTIFYING PERFORMANCE ASSURANCE CHALLENGES FOR SMART MANUFACTURING

PubMed Central

Helu, Moneer; Morris, Katherine; Jung, Kiwook; Lyons, Kevin; Leong, Swee

2015-01-01

Smart manufacturing has the potential to address many of the challenges faced by industry. However, the manufacturing community often needs assistance to leverage available technologies to improve their systems. To assure the performance of these technologies, this paper proposes a shared knowledge base that collects problem areas, solutions, and best practices for manufacturing technology. An Implementation Risk Assessment Framework (IRAF) is also described to identify the primary weaknesses of technologies in specific manufacturing contexts. Such approaches have the potential to stimulate new ideas and drive standardization activities critical to scale up and deploy smart manufacturing technologies successfully and quickly. PMID:26783512

A carbon dioxide stripping model for mammalian cell culture in manufacturing scale bioreactors.

PubMed

Xing, Zizhuo; Lewis, Amanda M; Borys, Michael C; Li, Zheng Jian

2017-06-01

Control of carbon dioxide within the optimum range is important in mammalian bioprocesses at the manufacturing scale in order to ensure robust cell growth, high protein yields, and consistent quality attributes. The majority of bioprocess development work is done in laboratory bioreactors, in which carbon dioxide levels are more easily controlled. Some challenges in carbon dioxide control can present themselves when cell culture processes are scaled up, because carbon dioxide accumulation is a common feature due to longer gas-residence time of mammalian cell culture in large scale bioreactors. A carbon dioxide stripping model can be used to better understand and optimize parameters that are critical to cell culture processes at the manufacturing scale. The prevailing carbon dioxide stripping models in literature depend on mass transfer coefficients and were applicable to cell culture processes with low cell density or at stationary/cell death phase. However, it was reported that gas bubbles are saturated with carbon dioxide before leaving the culture, which makes carbon dioxide stripping no longer depend on a mass transfer coefficient in the new generation cell culture processes characterized by longer exponential growth phase, higher peak viable cell densities, and higher specific production rate. Here, we present a new carbon dioxide stripping model for manufacturing scale bioreactors, which is independent of carbon dioxide mass transfer coefficient, but takes into account the gas-residence time and gas CO 2 saturation time. The model was verified by CHO cell culture processes with different peak viable cell densities (7 to 12 × 10 6  cells mL -1 ) for two products in 5,000-L and 25,000-L bioreactors. The model was also applied to a next generation cell culture process to optimize cell culture conditions and reduce carbon dioxide levels at manufacturing scale. The model provides a useful tool to understand and better control cell culture carbon dioxide profiles for process development, scale up, and characterization. Biotechnol. Bioeng. 2017;114: 1184-1194. © 2016 Wiley Periodicals, Inc. © 2016 Wiley Periodicals, Inc.

Industrial biomanufacturing: The future of chemical production.

PubMed

Clomburg, James M; Crumbley, Anna M; Gonzalez, Ramon

2017-01-06

The current model for industrial chemical manufacturing employs large-scale megafacilities that benefit from economies of unit scale. However, this strategy faces environmental, geographical, political, and economic challenges associated with energy and manufacturing demands. We review how exploiting biological processes for manufacturing (i.e., industrial biomanufacturing) addresses these concerns while also supporting and benefiting from economies of unit number. Key to this approach is the inherent small scale and capital efficiency of bioprocesses and the ability of engineered biocatalysts to produce designer products at high carbon and energy efficiency with adjustable output, at high selectivity, and under mild process conditions. The biological conversion of single-carbon compounds represents a test bed to establish this paradigm, enabling rapid, mobile, and widespread deployment, access to remote and distributed resources, and adaptation to new and changing markets. Copyright © 2017, American Association for the Advancement of Science.

Asphalt Roofing Shingles Into Energy Project Summary Report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Jameson, Rex, PE

2008-04-28

Based on a widely cited September, 1999 report by the Vermont Agency of Natural Resources, nearly 11 million tons of asphalt roofing shingle wastes are produced in the United States each year. Recent data suggests that the total is made up of about 9.4 million tons from roofing tear-offs and about 1.6 million tons from manufacturing scrap. Developing beneficial uses for these materials would conserve natural resources, promote protection of the environment and strengthen the economy. This project explored the feasibility of using chipped asphalt shingle materials in cement manufacturing kilns and circulating fluidized bed (CFB) boilers. A method ofmore » enhancing the value of chipped shingle materials for use as fuel by removing certain fractions for use as substitute raw materials for the manufacture of new shingles was also explored. Procedures were developed to prevent asbestos containing materials from being processed at the chipping facilities, and the frequency of the occurrence of asbestos in residential roofing tear-off materials was evaluated. The economic feasibility of each potential use was evaluated based on experience gained during the project and on a review of the well established use of shingle materials in hot mix asphalt. This project demonstrated that chipped asphalt shingle materials can be suitable for use as fuel in circulating fluidized boilers and cement kilns. More experience would be necessary to determine the full benefits that could be derived and to discover long term effects, but no technical barriers to full scale commercial use of chipped asphalt shingle materials in these applications were discovered. While the technical feasibility of various options was demonstrated, only the use of asphalt shingle materials in hot mix asphalt applications is currently viable economically.« less

Stability of picrotoxin during yogurt manufacture and storage.

PubMed

Jablonski, J E; Jackson, L S

2008-10-01

Picrotoxin is a neurotoxin found in the berries of Anamirta cocculus, a plant native to Southeast Asia. Picrotoxin has potential for being used as a biological weapon since the toxin is relatively easy to isolate and purify. Limited information exists on the stability and detection of picrotoxin added to foods before or after processing. The objective of this study was to determine the stability of picrotoxin during yogurt manufacture and storage. Direct, cup-set yogurt was produced by using methods that mimic the conditions used in full-scale production of yogurt. Milk (full-fat or low-fat) was pasteurized at 85 degrees C for 30 min, and then cooled to 43 degrees C. Yogurt starter culture (thermophilic culture or thermophilic + probiotic culture) and picrotoxin (200 mug/mL milk) were added. Samples of yogurt during fermentation (5 to 6 h, 43 degrees C) and during 30 d refrigerated (4 to 6 degrees C) storage were analyzed for pH, titratable acidity, and picrototoxin levels. Regardless of starter culture used or fat content of milk, there were no significant differences in the pH and titratable acidities of the picrotoxin-spiked yogurt and the control yogurt (no added picrotoxin) during fermentation and up to 4 wk of refrigerated storage. The color or texture of the yogurt was not affected by addition of picrotoxin. Levels of picrotoxinin and picrotin (components of picrotoxin) in yogurt, as measured by LC/MS (APCI(+)/SIR) did not change significantly during fermentation and storage. A separate experiment determined that addition of picrotoxin to milk before pasteurization (85 degrees C, 30 min) did not affect picrotoxin stability. These results indicate that picrotoxin is stable in yogurt during manufacture and storage.

Large-scale self-assembled zirconium phosphate smectic layers via a simple spray-coating process

NASA Astrophysics Data System (ADS)

Wong, Minhao; Ishige, Ryohei; White, Kevin L.; Li, Peng; Kim, Daehak; Krishnamoorti, Ramanan; Gunther, Robert; Higuchi, Takeshi; Jinnai, Hiroshi; Takahara, Atsushi; Nishimura, Riichi; Sue, Hung-Jue

2014-04-01

The large-scale assembly of asymmetric colloidal particles is used in creating high-performance fibres. A similar concept is extended to the manufacturing of thin films of self-assembled two-dimensional crystal-type materials with enhanced and tunable properties. Here we present a spray-coating method to manufacture thin, flexible and transparent epoxy films containing zirconium phosphate nanoplatelets self-assembled into a lamellar arrangement aligned parallel to the substrate. The self-assembled mesophase of zirconium phosphate nanoplatelets is stabilized by epoxy pre-polymer and exhibits rheology favourable towards large-scale manufacturing. The thermally cured film forms a mechanically robust coating and shows excellent gas barrier properties at both low- and high humidity levels as a result of the highly aligned and overlapping arrangement of nanoplatelets. This work shows that the large-scale ordering of high aspect ratio nanoplatelets is easier to achieve than previously thought and may have implications in the technological applications for similar materials.

Orodispersible films: Product transfer from lab-scale to continuous manufacturing.

PubMed

Thabet, Yasmin; Breitkreutz, Joerg

2018-01-15

Orodispersible films have been described as new beneficial dosage forms for special patient populations. Due to various production settings, different requirements on film formulations are required for non- continuous and continuous manufacturing. In this study, a continuous coating machine was qualified in regards of the process conditions for film compositions and their effects on the formed films. To investigate differences between both manufacturing processes, various film formulations of hydrochlorothiazide and hydroxypropylcellulose (HPC) or hydroxypropylmethycellulose (HPMC) as film formers were produced and the resulting films were characterized. The qualification of the continuously operating coating machine reveals no uniform heat distribution during drying. Coating solutions for continuous manufacturing should provide at least a dynamic viscosity of 1 Pa*s (wet film thickness of 500 μm, velocity of 15.9 cm/min). HPC films contain higher residuals of ethanol or acetone in bench-scale than in continuous production mode. Continuous production lead to lower drug content of the films. All continuously produced films disintegrate within less than 30 s. There are observed significant effects of the production process on the film characteristics. When transferring film manufacturing from lab-scale to continuous mode, film compositions, processing conditions and suitable characterization methods have to be carefully selected and adopted. Copyright © 2017 Elsevier B.V. All rights reserved.

DOE Office of Scientific and Technical Information (OSTI.GOV)

None

This factsheet describes a project that developed and demonstrated a new manufacturing-informed design framework that utilizes advanced multi-scale, physics-based process modeling to dramatically improve manufacturing productivity and quality in machining operations while reducing the cost of machined components.

Bioresorbable scaffolds for bone tissue engineering: optimal design, fabrication, mechanical testing and scale-size effects analysis.

PubMed

Coelho, Pedro G; Hollister, Scott J; Flanagan, Colleen L; Fernandes, Paulo R

2015-03-01

Bone scaffolds for tissue regeneration require an optimal trade-off between biological and mechanical criteria. Optimal designs may be obtained using topology optimization (homogenization approach) and prototypes produced using additive manufacturing techniques. However, the process from design to manufacture remains a research challenge and will be a requirement of FDA design controls to engineering scaffolds. This work investigates how the design to manufacture chain affects the reproducibility of complex optimized design characteristics in the manufactured product. The design and prototypes are analyzed taking into account the computational assumptions and the final mechanical properties determined through mechanical tests. The scaffold is an assembly of unit-cells, and thus scale size effects on the mechanical response considering finite periodicity are investigated and compared with the predictions from the homogenization method which assumes in the limit infinitely repeated unit cells. Results show that a limited number of unit-cells (3-5 repeated on a side) introduce some scale-effects but the discrepancies are below 10%. Higher discrepancies are found when comparing the experimental data to numerical simulations due to differences between the manufactured and designed scaffold feature shapes and sizes as well as micro-porosities introduced by the manufacturing process. However good regression correlations (R(2) > 0.85) were found between numerical and experimental values, with slopes close to 1 for 2 out of 3 designs. Copyright © 2015 IPEM. Published by Elsevier Ltd. All rights reserved.

The impact of manufacturing variables on in vitro release of clobetasol 17-propionate from pilot scale cream formulations.

PubMed

Fauzee, Ayeshah Fateemah Beebee; Khamanga, Sandile Maswazi; Walker, Roderick Bryan

2014-12-01

The purpose of the study was to evaluate the effect of different homogenization speeds and times, anchor speeds and cooling times on the viscosity and cumulative % clobetasol 17-propionate released per unit area at 72 h from pilot scale cream formulations. A 2(4) full factorial central composite design for four independent variables were investigated. Thirty pilot scale batches of cream formulations were manufactured using a Wintech® cream/ointment plant. The viscosity and in vitro release of CP were monitored and compared to an innovator product that is commercially available on the South African market, namely, Dermovate® cream. Contour and three-dimensional response surface plots were produced and the viscosity and cumulative % CP released per unit area at 72 h were found to be primarily dependent on the homogenization and anchor speeds. An increase in the homogenization and anchor speeds appeared to exhibit a synergistic effect on the resultant viscosity of the cream whereas an antagonistic effect was observed for the in vitro release of CP from the experimental cream formulations. The in vitro release profiles were best fitted to a Higuchi model and diffusion proved to be the dominant mechanism of drug release that was confirmed by use of the Korsmeyer-Peppas model. The research was further validated and confirmed by the high prognostic ability of response surface methodology (RSM) with a resultant mean percentage error of (±SD) 0.17 ± 0.093 suggesting that RSM may be an efficient tool for the development and optimization of topical formulations.

Performance Evaluation of Pressure Transducers for Water Impacts

NASA Technical Reports Server (NTRS)

Vassilakos, Gregory J.; Stegall, David E.; Treadway, Sean

2012-01-01

The Orion Multi-Purpose Crew Vehicle is being designed for water landings. In order to benchmark the ability of engineering tools to predict water landing loads, test programs are underway for scale model and full-scale water impacts. These test programs are predicated on the reliable measurement of impact pressure histories. Tests have been performed with a variety of pressure transducers from various manufacturers. Both piezoelectric and piezoresistive devices have been tested. Effects such as thermal shock, pinching of the transducer head, and flushness of the transducer mounting have been studied. Data acquisition issues such as sampling rate and anti-aliasing filtering also have been studied. The response of pressure transducers have been compared side-by-side on an impulse test rig and on a 20-inch diameter hemisphere dropped into a pool of water. The results have identified a range of viable configurations for pressure measurement dependent on the objectives of the test program.

Manufacturing of GLARE Parts and Structures

NASA Astrophysics Data System (ADS)

Sinke, J.

2003-07-01

GLARE is a hybrid material consisting of alternating layers of metal sheets and composite layers, requiring special attention when manufacturing of parts and structures is concerned. On one hand the applicable manufacturing processes for GLARE are limited, on the other hand, due to the constituents and composition of the laminate, it offers new opportunities for production. One of the opportunities is the manufacture of very large skin panels by lay-up techniques. Lay-up techniques are common for full composites, but uncommon for metallic structures. Nevertheless, large GLARE skin panels are made by lay-up processes. In addition, the sequences of forming and laminating processes, that can be selected, offer manufacturing options that are not applicable to metals or full composites. With respect to conventional manufacturing processes, the possibilities for Fibre Metal Laminates in general, are limited. The limits are partly due to the different failure modes, partly due to the properties of the constituents in the laminate. For machining processes: the wear of the cutting tools during machining operations of GLARE stems from the abrasive nature of the glass fibres. For the forming processes: the limited formability, expressed by a small failure strain, is related to the glass fibres. However, although these manufacturing issues may restrict the use of manufacturing processes for FMLs, application of these laminates in aircraft is not hindered.

BAAM Additive Manufacturing of Magnetically Levitated Wind Turbine

DOE Office of Scientific and Technical Information (OSTI.GOV)

Richardson, Bradley S.; Noakes, Mark W.; Roschli, Alex C.

ORNL worked with Hover Energy LLC (Hover) on the design of Big Area Additive Manufacturing (BAAM) extrusion components. The objective of this technical collaboration was to identify and evaluate fabrication of components using alternative additive manufacturing techniques. Multiple candidate parts were identified. A design modification to fabricate diverters using additive manufacturing (AM) was performed and the part was analyzed based on anticipated wind loading. Scaled versions of two parts were printed using the BAAM for wind tunnel testing.

Advanced, High Power, Next Scale, Wave Energy Conversion Device

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mekhiche, Mike; Dufera, Hiz; Montagna, Deb

2012-10-29

The project conducted under DOE contract DE‐EE0002649 is defined as the Advanced, High Power, Next Scale, Wave Energy Converter. The overall project is split into a seven‐stage, gated development program. The work conducted under the DOE contract is OPT Stage Gate III work and a portion of Stage Gate IV work of the seven stage product development process. The project effort includes Full Concept Design & Prototype Assembly Testing building on our existing PowerBuoy technology to deliver a device with much increased power delivery. Scaling‐up from 150kW to 500kW power generating capacity required changes in the PowerBuoy design that addressedmore » cost reduction and mass manufacturing by implementing a Design for Manufacturing (DFM) approach. The design changes also focused on reducing PowerBuoy Installation, Operation and Maintenance (IO&M) costs which are essential to reducing the overall cost of energy. In this design, changes to the core PowerBuoy technology were implemented to increase capability and reduce both CAPEX and OPEX costs. OPT conceptually envisaged moving from a floating structure to a seabed structure. The design change from a floating structure to seabed structure would provide the implementation of stroke‐ unlimited Power Take‐Off (PTO) which has a potential to provide significant power delivery improvement and transform the wave energy industry if proven feasible.« less

Smouldering Remediation (STAR) Technology: Field Pilot Tests and First Full Scale Application

NASA Astrophysics Data System (ADS)

Gerhard, J.; Kinsman, L.; Torero, J. L.

2015-12-01

STAR (Self-sustaining Treatment for Active Remediation) is an innovative remediation technology based on the principles of smoldering combustion where the contaminants are the fuel. The self-sustaining aspect means that a single, local ignition event can result in many days of contaminant destruction in situ. Presented research to date has focused on bench scale experiments, numerical modelling and process understanding. Presented here is the maturation of the in situ technology, including three field pilot tests and a full-scale implementation to treat coal tar-impacted soils. The first pilot determined a Radius of Influence (ROI) for a single ignition of approximately eight feet with an average propagation rate of the reaction of approximately one foot per day. TPH concentrations in soils were reduced from 10,000 milligrams per kilogram to a few hundred milligrams per kilogram. The second pilot was conducted in an area of significant void spaces created through the anthropogenic deposition of clay bricks and tiles. The void spaces led to pre-mature termination of the combustion reaction, limiting ROI and the effectiveness of the technology in this setting. The third case study involved the pilot testing, design, and full-scale implementation of STAR at a 37-acre former chemical manufacturing facility. Three phases of pilot testing were conducted within two hydrogeologic units at the site (i.e., surficial fill and deep alluvial sand units). Pilot testing within the fill demonstrated self-sustained coal tar destruction rates in excess of 800 kg/day supported through air injection at a single well. Deep sand unit testing (twenty-five feet below the water table) resulted in the treatment of a targeted six-foot layer of impacted fine sands to a radial distance of approximately twelve feet. These results (and additional parameters) were used to develop a full-scale STAR design consisting of approximately 1500 surficial fill ignition points and 500 deep sand ignition points and two treatment (air distribution and vapor collection / treatment) systems to remediate an approximately 14-acre footprint of contaminated soils within the project timelines (i.e., by mid-2016). Field activities began in 2014 and progress is currently on-schedule.

Program for establishing long-time flight service performance of composite materials in the center wing structure of C-130 aircraft. Phase 4: Ground/flight acceptance tests

NASA Technical Reports Server (NTRS)

Harvill, W. E.; Kizer, J. A.

1976-01-01

The advantageous structural uses of advanced filamentary composites are demonstrated by design, fabrication, and test of three boron-epoxy reinforced C-130 center wing boxes. The advanced development work necessary to support detailed design of a composite reinforced C-130 center wing box was conducted. Activities included the development of a basis for structural design, selection and verification of materials and processes, manufacturing and tooling development, and fabrication and test of full-scale portions of the center wing box. Detailed design drawings, and necessary analytical structural substantiation including static strength, fatigue endurance, flutter, and weight analyses are considered. Some additional component testing was conducted to verify the design for panel buckling, and to evaluate specific local design areas. Development of the cool tool restraint concept was completed, and bonding capabilities were evaluated using full-length skin panel and stringer specimens.

Advanced composite elevator for Boeing 727 aircraft, volume 2

NASA Technical Reports Server (NTRS)

Chovil, D. V.; Grant, W. D.; Jamison, E. S.; Syder, H.; Desper, O. E.; Harvey, S. T.; Mccarty, J. E.

1980-01-01

Preliminary design activity consisted of developing and analyzing alternate design concepts and selecting the optimum elevator configuration. This included trade studies in which durability, inspectability, producibility, repairability, and customer acceptance were evaluated. Preliminary development efforts consisted of evaluating and selecting material, identifying ancillary structural development test requirements, and defining full scale ground and flight test requirements necessary to obtain Federal Aviation Administration (FAA) certification. After selection of the optimum elevator configuration, detail design was begun and included basic configuration design improvements resulting from manufacturing verification hardware, the ancillary test program, weight analysis, and structural analysis. Detail and assembly tools were designed and fabricated to support a full-scope production program, rather than a limited run. The producibility development programs were used to verify tooling approaches, fabrication processes, and inspection methods for the production mode. Quality parts were readily fabricated and assembled with a minimum rejection rate, using prior inspection methods.

Issues and solutions: opportunities for European LED manufacturers

NASA Astrophysics Data System (ADS)

Pearsall, T. P.

2007-09-01

Marketing studies by EPIC show significant revenue opportunities by 2012 for UHB-LEDs in the automotive, LCD backlighting, and architectural lighting sectors. The goal of this workshop on manufacturing issues is to consider five key issues for UHB-LED manufacturing and to propose solutions that will pave the way to full exploitation of the opportunities.

Full-Scale Prestress Loss Monitoring of Damaged RC Structures Using Distributed Optical Fiber Sensing Technology

PubMed Central

Lan, Chunguang; Zhou, Zhi; Ou, Jinping

2012-01-01

For the safety of prestressed structures, prestress loss is a critical issue that will increase with structural damage, so it is necessary to investigate prestress loss of prestressed structures under different damage scenarios. Unfortunately, to date, no qualified techniques are available due to difficulty for sensors to survive in harsh construction environments of long service life and large span. In this paper, a novel smart steel strand based on the Brillouin optical time domain analysis (BOTDA) sensing technique was designed and manufactured, and then series of tests were used to characterize properties of the smart steel strands. Based on prestress loss principle analysis of damaged structures, laboratory tests of two similar beams with different damages were used to verify the concept of full-scale prestress loss monitoring of damaged reinforced concrete (RC) beams by using the smart steel strands. The prestress losses obtained from the Brillouin sensors are compared with that from conventional sensors, which provided the evolution law of prestress losses of damaged RC beams. The monitoring results from the proposed smart strand can reveal both spatial distribution and time history of prestress losses of damaged RC beams. PMID:22778590

Full-scale prestress loss monitoring of damaged RC structures using distributed optical fiber sensing technology.

PubMed

Lan, Chunguang; Zhou, Zhi; Ou, Jinping

2012-01-01

For the safety of prestressed structures, prestress loss is a critical issue that will increase with structural damage, so it is necessary to investigate prestress loss of prestressed structures under different damage scenarios. Unfortunately, to date, no qualified techniques are available due to difficulty for sensors to survive in harsh construction environments of long service life and large span. In this paper, a novel smart steel strand based on the Brillouin optical time domain analysis (BOTDA) sensing technique was designed and manufactured, and then series of tests were used to characterize properties of the smart steel strands. Based on prestress loss principle analysis of damaged structures, laboratory tests of two similar beams with different damages were used to verify the concept of full-scale prestress loss monitoring of damaged reinforced concrete (RC) beams by using the smart steel strands. The prestress losses obtained from the Brillouin sensors are compared with that from conventional sensors, which provided the evolution law of prestress losses of damaged RC beams. The monitoring results from the proposed smart strand can reveal both spatial distribution and time history of prestress losses of damaged RC beams.

R&D issues in scale-up and manufacturing of amorphous silicon tandem modules

DOE Office of Scientific and Technical Information (OSTI.GOV)

Arya, R.R.; Carlson, D.E.; Chen, L.F.

1999-03-01

R & D on amorphous silicon based tandem junction devices has improved the throughtput, the material utilization, and the performance of devices on commercial tin oxide coated glass. The tandem junction technology has been scaled-up to produce 8.6&hthinsp;Ft{sup 2} monolithically integrated modules in manufacturing at the TF1 plant. Optimization of performance and stability of these modules is ongoing. {copyright} {ital 1999 American Institute of Physics.}

Design, Manufacture and Test of Cryotank Components

NASA Technical Reports Server (NTRS)

McCarville, Douglas A.; Guzman, Juan C.; Dillon. Alexandra K.; Jackson, Justin R.; Birkland, Jordan O.

2017-01-01

On the composite cryotank technology development (CCTD) project, the Boeing Company built two cryotanks as a means of advancing technology and manufacturing readiness levels (TRL and MRL) and lowering the risk of fabricating full-scale fuel containment vessels.1 CCTD focused on upper stage extended duration applications where long term storage of propellants is required. The project involved the design, analysis, fabrication, and test of manufacturing demonstration units (MDU), a 2.4 m (precursor) and a 5.5 m composite cryotank. Key design features included one-piece wall construction to minimize overall weight (eliminating the need for a bellyband joint), 3-dimensionally (3D) reinforced y-joint material to alleviate stress concentrations at the tank to skirt interface and a purge-able ?uted core skirt to carry high axial launch loads. The tanks were made with OoA curing pre-impregnated (prepreg) carbon/epoxy (C/E) slit-tape tow (STT) that contained thin micro-crack resistant plies in the tank wall center to impede permeation. The tanks were fabricated at Boeing's Seattle-based Advanced Development Center (ADC) using RAFP and multipiece break-down tooling. The tooling was designed and built by Janicki Industries (JI) at Sedro Woolley, Washington. Tank assemblage consisted of co-bonded dome covers, one-piece ?uted core skirts and mechanical fastened cover/sump. Ultrasonic inspection was performed after every cure or bond and a structural health monitoring system (SHMS) was installed to identify potential impact damage events (in-process and/or during transportation). The tanks were low temperature tested at NASA's George C. Marshall Space Flight Center (MSFC) in Huntsville, Alabama. The testing, which consisted of a sequence of ?ll/drain pressure and thermal cycles using LH2, was successfully concluded in 2012 on the 2.4 m tank and in 2014 on the 5.5 m tank. Structural, thermal, and permeation performance data was obtained. 2 Critical design features and manufacturing advancements, which helped to validate 25% weight and 30% cost reduction projections, were matured. These advancements will help to guide future composite tank integration activities on next generation long duration aircraft and space launch vehicles. Because CCTD addressed innovative design features, heavy lift size scale-up, multipiece captured tooling, new generation automated material placement (AMP) equipment and OoA materials, this chapter should be of interest to educators, students and manufacturers of composite hardware and ?ight vehicles.

Evaluation of powder metallurgy superalloy disk materials

NASA Technical Reports Server (NTRS)

Evans, D. J.

1975-01-01

A program was conducted to develop nickel-base superalloy disk material using prealloyed powder metallurgy techniques. The program included fabrication of test specimens and subscale turbine disks from four different prealloyed powders (NASA-TRW-VIA, AF2-1DA, Mar-M-432 and MERL 80). Based on evaluation of these specimens and disks, two alloys (AF2-1DA and Mar-M-432) were selected for scale-up evaluation. Using fabricating experience gained in the subscale turbine disk effort, test specimens and full scale turbine disks were formed from the selected alloys. These specimens and disks were then subjected to a rigorous test program to evaluate their physical properties and determine their suitability for use in advanced performance turbine engines. A major objective of the program was to develop processes which would yield alloy properties that would be repeatable in producing jet engine disks from the same powder metallurgy alloys. The feasibility of manufacturing full scale gas turbine engine disks by thermomechanical processing of pre-alloyed metal powders was demonstrated. AF2-1DA was shown to possess tensile and creep-rupture properties in excess of those of Astroloy, one of the highest temperature capability disk alloys now in production. It was determined that metallographic evaluation after post-HIP elevated temperature exposure should be used to verify the effectiveness of consolidation of hot isostatically pressed billets.

The cost of a large-scale hollow fibre MBR.

PubMed

Verrecht, Bart; Maere, Thomas; Nopens, Ingmar; Brepols, Christoph; Judd, Simon

2010-10-01

A cost sensitivity analysis was carried out for a full-scale hollow fibre membrane bioreactor to quantify the effect of design choices and operational parameters on cost. Different options were subjected to a long term dynamic influent profile and evaluated using ASM1 for effluent quality, aeration requirements and sludge production. The results were used to calculate a net present value (NPV), incorporating both capital expenditure (capex), based on costs obtained from equipment manufacturers and full-scale plants, and operating expenditure (opex), accounting for energy demand, sludge production and chemical cleaning costs. Results show that the amount of contingency built in to cope with changes in feedwater flow has a large impact on NPV. Deviation from a constant daily flow increases NPV as mean plant utilisation decreases. Conversely, adding a buffer tank reduces NPV, since less membrane surface is required when average plant utilisation increases. Membrane cost and lifetime is decisive in determining NPV: an increased membrane replacement interval from 5 to 10 years reduces NPV by 19%. Operation at higher SRT increases the NPV, since the reduced costs for sludge treatment are offset by correspondingly higher aeration costs at higher MLSS levels, though the analysis is very sensitive to sludge treatment costs. A higher sustainable flux demands greater membrane aeration, but the subsequent opex increase is offset by the reduced membrane area and the corresponding lower capex. Copyright © 2010 Elsevier Ltd. All rights reserved.

High Fidelity Additive Manufacturing of Optically Transparent Glass Structures

NASA Astrophysics Data System (ADS)

Inamura, Chikara

Glass has been an integral part of human civilization with expressions across scales and disciplines: from the microscope to the telescope, from fiber optics to mobile interface, and from the petri dish to a building envelope. Such a diverse range of applications is enabled by the inherent material properties including mechanical strength, optical transparency and chemical inertness. Additive manufacturing provides opportunities for integrating the unique properties of glass to engineer novel structures that are functionary graded through precise spatiotemporal deposition of molten glass. This talk presents the Mediated Matter Group's latest development of a novel additive manufacturing platform, and related processes, for 3D Printing optically transparent glass for architectural scale applications.

Dendritic cells for active immunotherapy: optimizing design and manufacture in order to develop commercially and clinically viable products.

PubMed

Nicolette, C A; Healey, D; Tcherepanova, I; Whelton, P; Monesmith, T; Coombs, L; Finke, L H; Whiteside, T; Miesowicz, F

2007-09-27

Dendritic cell (DC) active immunotherapy is potentially efficacious in a broad array of malignant disease settings. However, challenges remain in optimizing DC-based therapy for maximum clinical efficacy within manufacturing processes that permit quality control and scale-up of consistent products. In this review we discuss the critical issues that must be addressed in order to optimize DC-based product design and manufacture, and highlight the DC based platforms currently addressing these issues. Variables in DC-based product design include the type of antigenic payload used, DC maturation steps and activation processes, and functional assays. Issues to consider in development include: (a) minimizing the invasiveness of patient biological material collection; (b) minimizing handling and manipulations of tissue at the clinical site; (c) centralized product manufacturing and standardized processing and capacity for commercial-scale production; (d) rapid product release turnaround time; (e) the ability to manufacture sufficient product from limited starting material; and (f) standardized release criteria for DC phenotype and function. Improvements in the design and manufacture of DC products have resulted in a handful of promising leads currently in clinical development.

Large-scale additive manufacturing with bioinspired cellulosic materials.

PubMed

Sanandiya, Naresh D; Vijay, Yadunund; Dimopoulou, Marina; Dritsas, Stylianos; Fernandez, Javier G

2018-06-05

Cellulose is the most abundant and broadly distributed organic compound and industrial by-product on Earth. However, despite decades of extensive research, the bottom-up use of cellulose to fabricate 3D objects is still plagued with problems that restrict its practical applications: derivatives with vast polluting effects, use in combination with plastics, lack of scalability and high production cost. Here we demonstrate the general use of cellulose to manufacture large 3D objects. Our approach diverges from the common association of cellulose with green plants and it is inspired by the wall of the fungus-like oomycetes, which is reproduced introducing small amounts of chitin between cellulose fibers. The resulting fungal-like adhesive material(s) (FLAM) are strong, lightweight and inexpensive, and can be molded or processed using woodworking techniques. We believe this first large-scale additive manufacture with ubiquitous biological polymers will be the catalyst for the transition to environmentally benign and circular manufacturing models.

Water soluble nano-scale transient material germanium oxide for zero toxic waste based environmentally benign nano-manufacturing

NASA Astrophysics Data System (ADS)

Almuslem, A. S.; Hanna, A. N.; Yapici, T.; Wehbe, N.; Diallo, E. M.; Kutbee, A. T.; Bahabry, R. R.; Hussain, M. M.

2017-02-01

In the recent past, with the advent of transient electronics for mostly implantable and secured electronic applications, the whole field effect transistor structure has been dissolved in a variety of chemicals. Here, we show simple water soluble nano-scale (sub-10 nm) germanium oxide (GeO2) as the dissolvable component to remove the functional structures of metal oxide semiconductor devices and then reuse the expensive germanium substrate again for functional device fabrication. This way, in addition to transiency, we also show an environmentally friendly manufacturing process for a complementary metal oxide semiconductor (CMOS) technology. Every year, trillions of complementary metal oxide semiconductor (CMOS) electronics are manufactured and billions are disposed, which extend the harmful impact to our environment. Therefore, this is a key study to show a pragmatic approach for water soluble high performance electronics for environmentally friendly manufacturing and bioresorbable electronic applications.

Perception of risk from automobile safety defects.

PubMed

Slovic, P; MacGregor, D; Kraus, N N

1987-10-01

Descriptions of safety engineering defects of the kind that compel automobile manufacturers to initiate a recall campaign were evaluated by individuals on a set of risk characteristic scales that included overall vehicle riskiness, manufacturer's ability to anticipate the defect, importance for vehicle operation, severity of consequences and likelihood of compliance with a recall notice. A factor analysis of the risk characteristics indicated that judgments could be summarized in terms of two composite scales, one representing the uncontrollability of the damage the safety defect might cause and the other representing the foreseeability of the defect by the manufacturer. Motor vehicle defects were found to be highly diverse in terms of the perceived qualities of their risks. Location of individual defects within the factor space was closely associated with perceived riskiness, perceived likelihood of purchasing another car from the same manufacturer, perceived likelihood of compliance with a recall notice, and actual compliance rates.

Full-arch milled titanium implant bridge: technical report.

PubMed

Peché, Wendy-Ann; Van Vuuren, Ludwig Jansen; Park, Chae

2011-09-01

The manufacturing of full-arch fixed implant-supported bridges with the use of the traditional lost wax technique remains a technical challenge. Distortion of the alloy during casting and subsequent heating cycles during porcelain build-up causes numerous problems. Fracturing of porcelain on large restorations is difficult and costly to restore. The fitting problems can be eliminated by utilising CAD/CAM technology in the manufacturing of long-span or full-arch titanium bridges. Repair of damaged porcelain can be simplified with the use of discrete, individually-removable crowns on the bridge.

Kinematics modeling and experimentation of the multi-manipulator tooth-arrangement robot for full denture manufacturing.

PubMed

Zhang, Yong-de; Jiang, Jin-gang; Liang, Ting; Hu, Wei-ping

2011-12-01

Artificial teeth are very complicated in shape, and not easy to be grasped and manipulated accurately by a single robot. The method of tooth-arrangement by multi-manipulator for complete denture manufacturing proposed in this paper. A novel complete denture manufacturing mechanism is designed based on multi-manipulator and dental arch generator. Kinematics model of the multi-manipulator tooth-arrangement robot is built by analytical method based on tooth-arrangement principle for full denture. Preliminary experiments on tooth-arrangement are performed using the multi-manipulator tooth-arrangement robot prototype system. The multi-manipulator tooth-arrangement robot prototype system can automatically design and manufacture a set of complete denture that is suitable for a patient according to the jaw arch parameters. The experimental results verified the validity of kinematics model of the multi-manipulator tooth-arrangement robot and the feasibility of the manufacture strategy of complete denture fulfilled by multi-manipulator tooth-arrangement robot.

Incentive mechanism based on cooperative advertising for cost information sharing in a supply chain with competing retailers

NASA Astrophysics Data System (ADS)

Setak, Mostafa; Kafshian Ahar, Hajar; Alaei, Saeed

2017-09-01

This paper proposes a new motivation for information sharing in a decentralized channel consisting of a single manufacturer and two competing retailers. The manufacturer provides a common product to the retailers at the same wholesale price. Both retailers add their own values to the product and distribute it to consumers. Factors such as retail prices, values added to the product, and local advertising of the retailers simultaneously have effect on market demand. Each retailer has full information about the own added value which is unknown to the manufacturer and other retailer. The manufacturer uses a cooperative advertising program for motivating the retailers to disclose their private information. A numerical study is presented to compare different scenarios of information sharing. Computational results show that there is a condition in which full information sharing is beneficial for all members of the supply chain through cooperative advertising program and, therefore, retailers have enough incentive to disclose their cost information to the manufacturer.

Recovery Act - Refinement of Cross Flow Turbine Airfoils

DOE Office of Scientific and Technical Information (OSTI.GOV)

McEntee, Jarlath

2013-08-30

Ocean Renewable Power Company, LLC (ORPC) is a global leader in hydrokinetic technology and project development. ORPC develops hydrokinetic power systems and eco-conscious projects that harness the power of oceans and rivers to create clean, predictable renewable energy. ORPC’s technology consists of a family of modular hydrokinetic power systems: the TidGen® Power System, for use at shallow to medium-depth tidal sites; the RivGen™ Power System, for use at river and estuary sites; and the OCGen® Power System, presently under development, for use at deep tidal and offshore ocean current sites. These power systems convert kinetic energy in moving water intomore » clean, renewable, grid-compatible electric power. The core technology component for all ORPC power systems is its patented turbine generator unit (TGU). The TGU uses proprietary advanced design cross flow (ADCF) turbines to drive an underwater permanent magnet generator mounted at the TGU’s center. It is a gearless, direct-drive system that has the potential for high reliability, requires no lubricants and releases no toxins that could contaminate the surrounding water. The hydrokinetic industry shows tremendous promise as a means of helping reduce the U.S.’s use of fossil fuels and dependence on foreign oil. To exploit this market opportunity, cross-flow hydrokinetic devices need to advance beyond the pre-commercial state and more systematic data about the structure and function of cross-flow hydrokinetic devices is required. This DOE STTR project, “Recovery Act - Refinement of Cross Flow Turbine Airfoils,” refined the cross-flow turbine design process to improve efficiency and performance and developed turbine manufacturing processes appropriate for volume production. The project proposed (1) to overcome the lack of data by extensively studying the properties of cross flow turbines, a particularly competitive design approach for extracting hydrokinetic energy and (2) to help ORPC mature its pre-commercial hydrokinetic technology into a commercially viable product over a three-year period by means of a design-for-manufacture process to be applied to the turbines which would result in a detail turbine design suitable for volume manufacture. In Phase I of the Project, ORPC systematically investigated performance of cross flow turbines by varying design parameters including solidity, foil profile, number of foils and foil toe angle using scale models of ORPC’s turbine design in a tow tank at the University of Maine (UMaine). Data collected provided information on interactions between design variables and helped ORPC improve turbine efficiency from 21% to greater than 35%. Analytical models were developed to better understand the physical phenomena at play in cross-flow turbines. In Phase II of the Project, ORPC expanded on data collected in Phase I to continue improving turbine efficiency, with a goal to optimally approach the Betz limit of 59.3%. Further tow tank testing and development of the analytical models and techniques was completed at UMaine and led to a deeper understanding of the flow phenomena involved. In addition, ORPC evaluated various designs, materials and manufacturing methods for full-scale turbine foils, and identified those most conducive to volume manufacture. Selected components of the turbine were structurally tested in a laboratory environment at UMaine. Performance and structural testing of the full scale turbine design was conducted as part of the field testing. The work funded by this project enabled the development of design tools for the rapid and efficient development of high performance cross-flow hydrokinetic turbine foils. The analytical tools are accurate and properly capture the underlying physical flow phenomena present in hydrokinetic cross-flow turbines. The ability to efficiently examine the design space provides substantial economic benefit to ORPC in that it allows for rapid design iteration at a low computational cost. The design-for-manufacture work enabled the delivery of a turbine design suitable for manufacture in intermediate to large quantity, lowering the unit cost of turbines and the levelized cost of electricity from ORPC hydrokinetic turbine. ORPC fielded the turbine design in a full scale application – the Cobscook Bay Tidal Energy Project which began operation off the coast of Eastport, Maine in September 2012. This is the first commercial, grid-connected tidal energy project in North America and the only ocean energy project not involving a dam which delivers power to a utility grid anywhere in the Americas. ORPC received a Federal Energy Regulatory Commission pilot project license to install and operate this project in February 2012. Construction of the TidGen® Power System began in March 2012, and the system was grid-connected on September 13, 2012. A 20-year commercial power purchase agreement to sell the power generated by the project was completed with Bangor Hydro Electric Company and is the first and only power purchase agreement for tidal energy. This is the first project in the U.S. to receive Renewable Energy Certificates for tidal energy production. The STTR project is a benefit to the public through its creation of jobs. ORPC’s recent deployment of the TidGen™ Power System is part of their larger project, the Maine Tidal Energy Project. According to ORPC’s report to the Maine Public Utilities Commission and the 20-year power purchase agreement, the Maine Tidal Energy Project will create and/or retain at least 80 direct full-time equivalent jobs in Maine during the development, construction and installation phase (2011 through 2016). In addition, the Maine Tidal Energy Project will create and/or retain at least 12 direct full-time equivalent jobs in Maine during the operating and maintenance phase (2016 through 2020). The STTR project has facilitated new and expanded services in manufacturing, fabrication and assembly, including major business growth for the composite technologies sector; creation of deepwater deployment, maintenance and retrieval services; and the expansion and formation of technical support services such as site assessment and design services, geotechnical services, underwater transmission services, and environmental monitoring services. The Maine Tidal Energy Project’s impact on workforce will enable other ocean energy projects – be they offshore wind, wave or additional tidal opportunities – to succeed in Maine. ORPC received a 2013 Tibbetts Award by the U.S. Small Business Administration.« less

Commercial absorption chiller models for evaluation of control strategies

DOE Office of Scientific and Technical Information (OSTI.GOV)

Koeppel, E.A.; Klein, S.A.; Mitchell, J.W.

1995-08-01

A steady-state computer simulation model of a direct fired double-effect water-lithium bromide absorption chiller in the parallel-flow configuration was developed from first principles. Unknown model parameters such as heat transfer coefficients were determined by matching the model`s calculated state points and coefficient of performance (COP) against nominal full-load operating data and COPs obtained from a manufacturer`s catalog. The model compares favorably with the manufacturer`s performance ratings for varying water circuit (chilled and cooling) temperatures at full load conditions and for chiller part-load performance. The model was used (1) to investigate the effect of varying the water circuit flow rates withmore » the chiller load and (2) to optimize chiller part-load performance with respect to the distribution and flow of the weak solution.« less

Development and Hot-fire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA Technical Reports Server (NTRS)

Gradl, Paul R.; Greene, Sandy Elam; Protz, Christopher S.; Ellis, David L.; Lerch, Bradley A.; Locci, Ivan E.

2017-01-01

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder-bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. NASA's efforts include a 4K lbf thrust liquid oxygen/methane (LOX/CH4) combustion chamber and subscale thrust chambers for 1.2K lbf LOX/hydrogen (H2) applications that have been designed and fabricated with SLM GRCop-84. The same technologies for these lower thrust applications are being applied to 25-35K lbf main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

A small-scale, rolled-membrane microfluidic artificial lung designed towards future large area manufacturing.

PubMed

Thompson, A J; Marks, L H; Goudie, M J; Rojas-Pena, A; Handa, H; Potkay, J A

2017-03-01

Artificial lungs have been used in the clinic for multiple decades to supplement patient pulmonary function. Recently, small-scale microfluidic artificial lungs (μAL) have been demonstrated with large surface area to blood volume ratios, biomimetic blood flow paths, and pressure drops compatible with pumpless operation. Initial small-scale microfluidic devices with blood flow rates in the μ l/min to ml/min range have exhibited excellent gas transfer efficiencies; however, current manufacturing techniques may not be suitable for scaling up to human applications. Here, we present a new manufacturing technology for a microfluidic artificial lung in which the structure is assembled via a continuous "rolling" and bonding procedure from a single, patterned layer of polydimethyl siloxane (PDMS). This method is demonstrated in a small-scale four-layer device, but is expected to easily scale to larger area devices. The presented devices have a biomimetic branching blood flow network, 10  μ m tall artificial capillaries, and a 66  μ m thick gas transfer membrane. Gas transfer efficiency in blood was evaluated over a range of blood flow rates (0.1-1.25 ml/min) for two different sweep gases (pure O 2 , atmospheric air). The achieved gas transfer data closely follow predicted theoretical values for oxygenation and CO 2 removal, while pressure drop is marginally higher than predicted. This work is the first step in developing a scalable method for creating large area microfluidic artificial lungs. Although designed for microfluidic artificial lungs, the presented technique is expected to result in the first manufacturing method capable of simply and easily creating large area microfluidic devices from PDMS.

Manufacturing of High-Concentration Monoclonal Antibody Formulations via Spray Drying-the Road to Manufacturing Scale.

PubMed

Gikanga, Benson; Turok, Robert; Hui, Ada; Bowen, Mayumi; Stauch, Oliver B; Maa, Yuh-Fun

2015-01-01

Spray-dried monoclonal antibody (mAb) powders may offer applications more versatile than the freeze-dried cake, including preparing high-concentration formulations for subcutaneous administration. Published studies on this topic, however, are generally scarce. This study evaluates a pilot-scale spray dryer against a laboratory-scale dryer to spray-dry multiple mAbs in consideration of scale-up, impact on mAb stability, and feasibility of a high-concentration preparation. Under similar conditions, both dryers produced powders of similar properties-for example, water content, particle size and morphology, and mAb stability profile-despite a 4-fold faster output by the pilot-scale unit. All formulations containing arginine salt or a combination of arginine salt and trehalose were able to be spray-dried with high powder collection efficiency (>95%), but yield was adversely affected in formulations with high trehalose content due to powder sticking to the drying chamber. Spray-drying production output was dictated by the size of the dryer operated at an optimal liquid feed rate. Spray-dried powders could be reconstituted to high-viscosity liquids, >300 cP, substantially beyond what an ultrafiltration process can achieve. The molar ratio of trehalose to mAb needed to be reduced to 50:1 in consideration of isotonicity of the formulation with mAb concentration at 250 mg/mL. Even with this low level of sugar protection, long-term stability of spray-dried formulations remained superior to their liquid counterparts based on size variant and potency data. This study offers a commercially viable spray-drying process for biological bulk storage and an option for high-concentration mAb manufacturing. This study evaluates a pilot-scale spray dryer against a laboratory-scale dryer to spray-dry multiple monoclonal antibodies (mAbs) from the perspective of scale-up, impact on mAb stability, and feasibility of a high-concentration preparation. The data demonstrated that there is no process limitation in solution viscosity when high-concentration mAb formulations are prepared from spray-dried powder reconstitution compared with concentration via the conventional ultrafiltration process. This study offers a commercially viable spray-drying process for biological bulk storage and a high-concentration mAb manufacturing option for subcutaneous administration. The outcomes of this study will benefit scientists and engineers who develop high-concentration mAb products by providing a viable manufacturing alternative. © PDA, Inc. 2015.

Crystal and Particle Engineering Strategies for Improving Powder Compression and Flow Properties to Enable Continuous Tablet Manufacturing by Direct Compression.

PubMed

Chattoraj, Sayantan; Sun, Changquan Calvin

2018-04-01

Continuous manufacturing of tablets has many advantages, including batch size flexibility, demand-adaptive scale up or scale down, consistent product quality, small operational foot print, and increased manufacturing efficiency. Simplicity makes direct compression the most suitable process for continuous tablet manufacturing. However, deficiencies in powder flow and compression of active pharmaceutical ingredients (APIs) limit the range of drug loading that can routinely be considered for direct compression. For the widespread adoption of continuous direct compression, effective API engineering strategies to address power flow and compression problems are needed. Appropriate implementation of these strategies would facilitate the design of high-quality robust drug products, as stipulated by the Quality-by-Design framework. Here, several crystal and particle engineering strategies for improving powder flow and compression properties are summarized. The focus is on the underlying materials science, which is the foundation for effective API engineering to enable successful continuous manufacturing by the direct compression process. Copyright © 2018 American Pharmacists Association®. Published by Elsevier Inc. All rights reserved.

Effects of Aging Hardware on Data Quality

DTIC Science & Technology

2011-09-01

the calibration period, or calper.) If co-located seismometers are from different manufacturers (e.g., Geotech , Guralp, or Kinemetrics) or of...evaluation for scaling issues Seismometer—manufacturer, model, and design DWR—manufacturer, model Geotech KS54000 broadband (acceleration/velocity...Science Horizons AIM24S3 Geotech GS21 short period Science Horizons AIM24S1 The first seismic system configuration shown in Table 1 ( Geotech

Generation of Fullspan Leading-Edge 3D Ice Shapes for Swept-Wing Aerodynamic Testing

NASA Technical Reports Server (NTRS)

Camello, Stephanie C.; Lee, Sam; Lum, Christopher; Bragg, Michael B.

2016-01-01

The deleterious effect of ice accretion on aircraft is often assessed through dry-air flight and wind tunnel testing with artificial ice shapes. This paper describes a method to create fullspan swept-wing artificial ice shapes from partial span ice segments acquired in the NASA Glenn Icing Reserch Tunnel for aerodynamic wind-tunnel testing. Full-scale ice accretion segments were laser scanned from the Inboard, Midspan, and Outboard wing station models of the 65% scale Common Research Model (CRM65) aircraft configuration. These were interpolated and extrapolated using a weighted averaging method to generate fullspan ice shapes from the root to the tip of the CRM65 wing. The results showed that this interpolation method was able to preserve many of the highly three dimensional features typically found on swept-wing ice accretions. The interpolated fullspan ice shapes were then scaled to fit the leading edge of a 8.9% scale version of the CRM65 wing for aerodynamic wind-tunnel testing. Reduced fidelity versions of the fullspan ice shapes were also created where most of the local three-dimensional features were removed. The fullspan artificial ice shapes and the reduced fidelity versions were manufactured using stereolithography.

Design and test of 1/5th scale horizontal axis tidal current turbine

NASA Astrophysics Data System (ADS)

Liu, Hong-wei; Zhou, Hong-bin; Lin, Yong-gang; Li, Wei; Gu, Hai-gang

2016-06-01

Tidal current energy is prominent and renewable. Great progress has been made in the exploitation technology of tidal current energy all over the world in recent years, and the large scale device has become the trend of tidal current turbine (TCT) for its economies. Instead of the similarity to the wind turbine, the tidal turbine has the characteristics of high hydrodynamic efficiency, big thrust, reliable sealing system, tight power transmission structure, etc. In this paper, a 1/5th scale horizontal axis tidal current turbine has been designed, manufactured and tested before the full scale device design. Firstly, the three-blade horizontal axis rotor was designed based on traditional blade element momentum theory and its hydrodynamic performance was predicted in numerical model. Then the power train system and stand-alone electrical control unit of tidal current turbine, whose performances were accessed through the bench test carried out in workshop, were designed and presented. Finally, offshore tests were carried out and the power performance of the rotor was obtained and compared with the published literatures, and the results showed that the power coefficient was satisfactory, which agrees with the theoretical predictions.

Robust, low-noise, polarization-maintaining mode-locked Er-fiber laser with a planar lightwave circuit (PLC) device as a multi-functional element.

PubMed

Kim, Chur; Kwon, Dohyeon; Kim, Dohyun; Choi, Sun Young; Cha, Sang Jun; Choi, Ki Sun; Yeom, Dong-Il; Rotermund, Fabian; Kim, Jungwon

2017-04-15

We demonstrate a new planar lightwave circuit (PLC)-based device, integrated with a 980/1550 wavelength division multiplexer, an evanescent-field-interaction-based saturable absorber, and an output tap coupler, which can be employed as a multi-functional element in mode-locked fiber lasers. Using this multi-functional PLC device, we demonstrate a simple, robust, low-noise, and polarization-maintaining mode-locked Er-fiber laser. The measured full-width at half-maximum bandwidth is 6 nm centered at 1555 nm, corresponding to 217 fs transform-limited pulse duration. The measured RIN and timing jitter are 0.22% [10 Hz-10 MHz] and 6.6 fs [10 kHz-1 MHz], respectively. Our results show that the non-gain section of mode-locked fiber lasers can be easily implemented as a single PLC chip that can be manufactured by a wafer-scale fabrication process. The use of PLC processes in mode-locked lasers has the potential for higher manufacturability of low-cost and robust fiber and waveguide lasers.

From Stochastic Foam to Designed Structure: Balancing Cost and Performance of Cellular Metals

PubMed Central

Lehmhus, Dirk; Vesenjak, Matej

2017-01-01

Over the past two decades, a large number of metallic foams have been developed. In recent years research on this multi-functional material class has further intensified. However, despite their unique properties only a limited number of large-scale applications have emerged. One important reason for this sluggish uptake is their high cost. Many cellular metals require expensive raw materials, complex manufacturing procedures, or a combination thereof. Some attempts have been made to decrease costs by introducing novel foams based on cheaper components and new manufacturing procedures. However, this has often yielded materials with unreliable properties that inhibit utilization of their full potential. The resulting balance between cost and performance of cellular metals is probed in this editorial, which attempts to consider cost not in absolute figures, but in relation to performance. To approach such a distinction, an alternative classification of cellular metals is suggested which centers on structural aspects and the effort of realizing them. The range thus covered extends from fully stochastic foams to cellular structures designed-to-purpose. PMID:28786935

Recent progress on external occulter technology for imaging exosolar planets

NASA Astrophysics Data System (ADS)

Kasdin, N. J.; Vanderbei, R. J.; Sirbu, D.; Samuels, J.; Shaklan, S.; Lisman, D.; Thomson, M.; Cady, E.; Martin, S.

Imaging planets orbiting nearby stars requires a system for suppressing the host starlight by at least ten orders of magnitude. One such approach uses an external occulter, a satellite flying far from the telescope and employing a large screen, or starshade, to suppress the incoming starlight. This trades the added complexity of building the precisely shaped starshade and flying it in formation against simplifications in the telescope since extremely precise wavefront control is no longer necessary. Much progress has been made recently in designing, testing and manufacturing starshade technology. In this paper we describe the design of starshades and report on recent accomplishments in manufacturing and measuring a prototype occulter petal as part of NASA's first Technology Development for Exoplanet Missions (TDEM) program. We demonstrate that the as-built petal is consistent with a full-size occulter achieving better than 10-10 contrast. We also discuss laboratory testing at the Princeton Occulter Testbed. These experiments use sub-scale, long-distance beam propagation to verify the diffraction analysis associated with occulter starlight suppression. We demonstrate roughly 10-10 suppression in the laboratory and discuss the important challenges and limitations.

Accidental Release of Chlorine from a Storage Facility and an On-Site Emergency Mock Drill: A Case Study

PubMed Central

Soman, Ambalathumpara Raman; Sundararaj, Gopalswamy

2015-01-01

In the current industrial scenario there is a serious need for formulating strategies to handle hazardous substances in the safest way. Manufacture, storage, and use of hazardous substances pose a serious risk to industry, people, and the environment. Accidental release of toxic chemicals can lead to emergencies. An emergency response plan (ERP) is inevitable to minimize the adverse effects of such releases. The on-site emergency plan is an integral component of any process safety and risk management system. This paper deals with an on-site emergency response plan for a chlorine manufacturing industry. It was developed on the basis of a previous study on chlorine release and a full scale mock drill has been conducted for testing the plan. Results indicated that properly trained personnel can effectively handle each level of incidents occurring in the process plant. As an extensive guideline to the district level government authorities for off-site emergency planning, risk zone has also been estimated with reference to a chlorine exposure threshold of 3 ppm. PMID:26171416

Advances in In-Situ Inspection of Automated Fiber Placement Systems

NASA Technical Reports Server (NTRS)

Juarez, Peter D.; Cramer, K. Elliott; Seebo, Jeffrey P.

2016-01-01

The advent of Automated Fiber Placement (AFP) systems have aided the rapid manufacturing of composite aerospace structures. One of the challenges that AFP systems present is the uniformity of the deposited prepreg tape layers, which are prone to laps, gaps, overlaps and twists. The current detection modus operandi involves halting fabrication and performing a time consuming visual inspection of each tape layer. Typical AFP systems use a quartz lamp to heat the base layer to make the surface tacky as it deposits another tape layer. The idea was proposed to use the preheated base layer as a through transmission heat source and to inspect the newly added tape layer using a thermographic camera. As a preliminary study of this concept a laboratory proof of concept device was designed and constructed to simulate the through transmission heat source. Using the proof of concept device, we inspected an AFP-built uncured composite specimen with artificial manufacturing defects. This paper will discuss the results of this preliminary study and the implications involved with deploying a full-scale AFP inspection system.

A Different Perspective: How Much Innovation Is Really Needed for Monoclonal Antibody Production Using Mammalian Cell Technology?

PubMed

Kelley, Brian; Kiss, Robert; Laird, Michael

2018-05-03

As biopharmaceutical companies have optimized cell line and production culture process development, titers of recombinant antibodies have risen steadily to 3-8 g/L for fed-batch mammalian cultures at production scales of 10 kL or larger. Most new antibody products are produced from Chinese Hamster Ovary (CHO) cell lines, and there are relatively few alternative production hosts under active evaluation. Many companies have adopted a strategy of using the same production cell line for early clinical phases as well as commercial production, which reduces the risk of product comparability issues during the development lifecycle. Product quality and consistency expectations rest on the platform knowledge of the CHO host cell line and processes used for the production of many licensed antibodies. The lack of impact of low-level product variants common to this platform on product safety and efficacy also builds on the established commercial history of recombinant antibodies, which dates back to 1997.Efforts to increase titers further will likely yield diminishing returns. Very few products would benefit significantly from a titer greater than 8 g/L; in many cases, a downstream processing bottleneck would preclude full recovery from production-scale bioreactors for high titer processes. The benefits of a process platform based on standard fed-batch production culture include predictable scale-up, process transfer, and production within a company's manufacturing network or at a contract manufacturing organization. Furthermore, the confidence in an established platform provides key support towards regulatory flexibility (e.g., design space) for license applications following a quality-by-design strategy.These factors suggest that novel technologies for antibody production may not provide a substantial return on investment. What, then, should be the focus of future process development efforts for companies that choose to launch antibody products using their current platform? This review proposes key focus areas in an effort to continually improve process consistency, assure acceptable product quality, and establish appropriate process parameter limits to enable flexible manufacturing options.

Status of molten carbonate fuel cell technology development

NASA Astrophysics Data System (ADS)

Parsons, E. L., Jr.; Williams, M. C.; George, T. J.

The MCFC technology has been identified by the DOE as a promising product for commercialization. Development of the MCFC technology supports the National Energy Strategy. Review of the status of the MCFC technology indicates that the MCFC technology developers are making rapid and significant progress. Manufacturing facility development and extensive testing is occurring. Improvements in performance (power density), lower costs, improved packaging, and scale up to full height are planned. MCFC developers need to continue to be responsive to end-users in potential markets. It will be market demands for the correct product definition which will ultimately determine the character of MCFC power plants. There is a need for continued MCFC product improvement and multiple product development tests.

Composite armored vehicle advanced technology demonstator

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ostberg, D.T.; Dunfee, R.S.; Thomas, G.E.

1996-12-31

Composite structures are a key technology needed to develop future lightweight combat vehicles that are both deployable and survivable. The Composite Armored Vehicle Advanced Technology Demonstrator Program that started in fiscal year 1994 will continue through 1998 to verily that composite structures are a viable solution for ground combat vehicles. Testing thus far includes material characterization, structural component tests and full scale quarter section tests. Material and manufacturing considerations, tests, results and changes, and the status of the program will be described. The structural component tests have been completed successfully, and quarter section testing is in progress. Upon completion ofmore » the critical design review, the vehicle demonstrator will be Fabricated and undergo government testing.« less

Liquid rocket booster study. Volume 2, book 3, appendices 2-5: PPIP, transition plan, AMOS plan, and environmental analysis

NASA Technical Reports Server (NTRS)

1988-01-01

This Preliminary Project Implementation Plan (PPIP) was used to examine the feasibility of replacing the current Solid Rocket Boosters on the Space Shuttle with Liquid Rocket Boosters (LRBs). The need has determined the implications of integrating the LRB with the Space Transportation System as the earliest practical date. The purpose was to identify and define all elements required in a full scale development program for the LRB. This will be a reference guide for management of the LRB program, addressing such requirement as design and development, configuration management, performance measurement, manufacturing, product assurance and verification, launch operations, and mission operations support.

Control Data ICEM: A vendors IPAD-like system

NASA Technical Reports Server (NTRS)

Feldman, H. D.

1984-01-01

The IPAD program's goal which was to integrate aerospace applications used in support of the engineering design process is discussed. It is still the key goal, and has evolved into a design centered around the use of data base management, networking, and global user executive technology. An integrated CAD/CAM system modeled in part after the IPAD program and containing elements of the program's goals was developed. The integrated computer aided engineering and manufacturing (ICEM) program started with the acquisition of AD-2000 and Synthavision. The AD-2000 has evolved to a production geometry creation and drafting system which is called CD/2000. Synthavision has grown to be a full scale 3-dimensional modeling system, the ICEM Modeler.

Update on Risk Reduction Activities for a Liquid Advanced Booster for NASA's Space Launch System

NASA Technical Reports Server (NTRS)

Crocker, Andrew M.; Greene, William D.

2017-01-01

The stated goals of NASA's Research Announcement for the Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) are to reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS and enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability. Dynetics, Inc. and Aerojet Rocketdyne (AR) formed a team to offer a wide-ranging set of risk reduction activities and full-scale, system-level demonstrations that support NASA's ABEDRR goals. During the ABEDRR effort, the Dynetics Team has modified flight-proven Apollo-Saturn F-1 engine components and subsystems to improve affordability and reliability (e.g., reduce parts counts, touch labor, or use lower cost manufacturing processes and materials). The team has built hardware to validate production costs and completed tests to demonstrate it can meet performance requirements. State-of-the-art manufacturing and processing techniques have been applied to the heritage F-1, resulting in a low recurring cost engine while retaining the benefits of Apollo-era experience. NASA test facilities have been used to perform low-cost risk-reduction engine testing. In early 2014, NASA and the Dynetics Team agreed to move additional large liquid oxygen/kerosene engine work under Dynetics' ABEDRR contract. Also led by AR, the objectives of this work are to demonstrate combustion stability and measure performance of a 500,000 lbf class Oxidizer-Rich Staged Combustion (ORSC) cycle main injector. A trade study was completed to investigate the feasibility, cost effectiveness, and technical maturity of a domestically-produced engine that could potentially both replace the RD-180 on Atlas V and satisfy NASA SLS payload-to-orbit requirements via an advanced booster application. Engine physical dimensions and performance parameters resulting from this study provide the system level requirements for the ORSC risk reduction test article. The test article is scheduled to complete fabrication and assembly soon and continue testing through late 2019. Dynetics has also designed, developed, and built innovative tank and structure assemblies using friction stir welding to leverage recent NASA investments in manufacturing tools, facilities, and processes, significantly reducing development and recurring costs. The full-scale cryotank assembly was used to verify the structural design and prove affordable processes. Dynetics performed hydrostatic and cryothermal proof tests on the assembly to verify the assembly meets performance requirements..

CeSiCò - a new technology for lightweight and cost effective space instruments structures and mirrors

NASA Astrophysics Data System (ADS)

Devilliers, Christophe; Krödel, Matthias

2017-11-01

Alcatel Alenia Space and ECM have jointly developed a new ceramic material to produce lightweight, stiff, stable and cost effective structures and mirrors for space instrument the CesicÒ. Its intrinsic properties, added to ample manufacturing capabilities allow to manufacture stiff and lightweight cost effective mirrors and structure for space instruments. Different scale 1 flight representative CesicÒ optical structures have been manufactured and successfully tested under very strong dynamic environment and cryogenic condition down to 30K CesicÒ is also envisaged for large and lightweight space telescopes mirrors, a large CesicÒ 1 meter class mirror with an area mass of less than 25 Kg/m2 has been sized again launch loads and WFE performance and manufactured. CesicÒ applicability for large focal plane have been demonstrated through different scale 1 breadboards. Based on these successful results, AlcatelAleniaSpace and ECM are now in position to propose for space this technology with new innovative concepts thanks to the CesicÒ manufacturing capabilities. CesicÒ has therefore been selected for the structure and mirrors parts of a flight instrument payload and the manufacturing of the flight hardware is already underway. An high temperature high gain lightweight antenna breadboard is also under manufacturing for Bepi colombo mission. CesicÒ is therefore a good candidate for future challenging space instruments and is currently proposed for Japan and US space projects.

Lean in healthcare: the unfilled promise?

PubMed

Radnor, Zoe J; Holweg, Matthias; Waring, Justin

2012-02-01

In an effort to improve operational efficiency, healthcare services around the world have adopted process improvement methodologies from the manufacturing sector, such as Lean Production. In this paper we report on four multi-level case studies of the implementation of Lean in the English NHS. Our results show that this generally involves the application of specific Lean 'tools', such as 'kaizen blitz' and 'rapid improvement events', which tend to produce small-scale and localised productivity gains. Although this suggests that Lean might not currently deliver the efficiency improvements desired in policy, the evolution of Lean in the manufacturing sector also reveals this initial focus on the 'tool level'. In moving to a more system-wide approach, however, we identify significant contextual differences between healthcare and manufacturing that result in two critical breaches of the assumptions behind Lean. First, the customer and commissioner in the private sector are the one and the same, which is essential in determining 'customer value' that drives process improvement activities. Second, healthcare is predominantly designed to be capacity-led, and hence there is limited ability to influence demand or make full use of freed-up resources. What is different about this research is that these breaches can be regarded as not being primarily 'professional' in origin but actually more 'organisational' and 'managerial' and, if not addressed could severely constrain Lean's impact on healthcare productivity at the systems level. Copyright © 2011 Elsevier Ltd. All rights reserved.

A Multi-Scale, Multi-Physics Optimization Framework for Additively Manufactured Structural Components

NASA Astrophysics Data System (ADS)

El-Wardany, Tahany; Lynch, Mathew; Gu, Wenjiong; Hsu, Arthur; Klecka, Michael; Nardi, Aaron; Viens, Daniel

This paper proposes an optimization framework enabling the integration of multi-scale / multi-physics simulation codes to perform structural optimization design for additively manufactured components. Cold spray was selected as the additive manufacturing (AM) process and its constraints were identified and included in the optimization scheme. The developed framework first utilizes topology optimization to maximize stiffness for conceptual design. The subsequent step applies shape optimization to refine the design for stress-life fatigue. The component weight was reduced by 20% while stresses were reduced by 75% and the rigidity was improved by 37%. The framework and analysis codes were implemented using Altair software as well as an in-house loading code. The optimized design was subsequently produced by the cold spray process.

Selection and Manufacturing of Membrane Materials for Solar Sails

NASA Technical Reports Server (NTRS)

Bryant, Robert G.; Seaman, Shane T.; Wilkie, W. Keats; Miyaucchi, Masahiko; Working, Dennis C.

2013-01-01

Commercial metallized polyimide or polyester films and hand-assembly techniques are acceptable for small solar sail technology demonstrations, although scaling this approach to large sail areas is impractical. Opportunities now exist to use new polymeric materials specifically designed for solar sailing applications, and take advantage of integrated sail manufacturing to enable large-scale solar sail construction. This approach has, in part, been demonstrated on the JAXA IKAROS solar sail demonstrator, and NASA Langley Research Center is now developing capabilities to produce ultrathin membranes for solar sails by integrating resin synthesis with film forming and sail manufacturing processes. This paper will discuss the selection and development of polymer material systems for space, and these new processes for producing ultrathin high-performance solar sail membrane films.

Economically Sustainable Scaling of Photovoltaics to Meet Climate Targets

DOE Office of Scientific and Technical Information (OSTI.GOV)

Needleman, David Berney; Poindexter, Jeremy R.; Kurchin, Rachel C.

To meet climate goals, photovoltaics (PV) deployment will have to grow rapidly over the next fifteen years. We identify two barriers to this growth: scale-up of manufacturing capacity and the cost of PV module production. We explore several technoeconomic approaches to overcoming these barriers and identify deep reductions in the capital intensity (capex) of PV module manufacturing and large increases in module efficiency as the most promising routes to rapid deployment. Given the lag inherent in rolling out new technology, we explore an approach where growth is fueled by debt or subsidies in the short-term and technological advances in themore » medium term. Finally, we analyze the current capex structure of crystalline silicon PV module manufacturing to identify potential savings.« less

Small Scale High Speed Turbomachinery

NASA Technical Reports Server (NTRS)

London, Adam P. (Inventor); Droppers, Lloyd J. (Inventor); Lehman, Matthew K. (Inventor); Mehra, Amitav (Inventor)

2015-01-01

A small scale, high speed turbomachine is described, as well as a process for manufacturing the turbomachine. The turbomachine is manufactured by diffusion bonding stacked sheets of metal foil, each of which has been pre-formed to correspond to a cross section of the turbomachine structure. The turbomachines include rotating elements as well as static structures. Using this process, turbomachines may be manufactured with rotating elements that have outer diameters of less than four inches in size, and/or blading heights of less than 0.1 inches. The rotating elements of the turbomachines are capable of rotating at speeds in excess of 150 feet per second. In addition, cooling features may be added internally to blading to facilitate cooling in high temperature operations.

At-line process analytical technology (PAT) for more efficient scale up of biopharmaceutical microfiltration unit operations.

PubMed

Watson, Douglas S; Kerchner, Kristi R; Gant, Sean S; Pedersen, Joseph W; Hamburger, James B; Ortigosa, Allison D; Potgieter, Thomas I

2016-01-01

Tangential flow microfiltration (MF) is a cost-effective and robust bioprocess separation technique, but successful full scale implementation is hindered by the empirical, trial-and-error nature of scale-up. We present an integrated approach leveraging at-line process analytical technology (PAT) and mass balance based modeling to de-risk MF scale-up. Chromatography-based PAT was employed to improve the consistency of an MF step that had been a bottleneck in the process used to manufacture a therapeutic protein. A 10-min reverse phase ultra high performance liquid chromatography (RP-UPLC) assay was developed to provide at-line monitoring of protein concentration. The method was successfully validated and method performance was comparable to previously validated methods. The PAT tool revealed areas of divergence from a mass balance-based model, highlighting specific opportunities for process improvement. Adjustment of appropriate process controls led to improved operability and significantly increased yield, providing a successful example of PAT deployment in the downstream purification of a therapeutic protein. The general approach presented here should be broadly applicable to reduce risk during scale-up of filtration processes and should be suitable for feed-forward and feed-back process control. © 2015 American Institute of Chemical Engineers.

Surface Treatments to Minimize Concrete Deterioration. Report 2. Laboratory Evaluation of Surface Treatment Materials

DTIC Science & Technology

1990-09-01

Hydrocarbon 4 Moderate to severe scaling W-CS-58 Methyl 0+ No scaling--sealer’s color methacrylate changed from clear to cloudy white W-CS-59 Polyurethap 0+ No...years ago a manufacturer of polynmers introduced a high molecular-weight methacrylate (HMWM) monomer for sealing cracks by topical application. The...followed. Material Safety Data Sheets ( MSDS ) should be obtained from the manufacturers of such materials. In cases where the effects of a chemical

Investment opportunity : the FPL EGAR lumber manufacturing system

Treesearch

George B. Harpole; Ed Williston; Hiram H. Hallock

1979-01-01

A model of present-day computer-controlled sawmilling technology is modified for the manufacture of any desired width of EGAR dimension lumber from small logs. EGAR lumber is manufactured via headrig production of 2-inch-thick flitches which are in turn dried, edged full width, edge-glued, and gang-novelty-ripped to wide widths (EGAR). The EGAR system is compared to...

The Full Scale Seal Experiment - A Seal Industrial Prototype for Cigeo - 13106

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lebon, P.; Bosgiraud, J.M.; Foin, R.

2013-07-01

The Full Scale Seal (FSS) Experiment is one of various experiments implemented by Andra, within the frame of the Cigeo (the French Deep Geological Repository) Project development, to demonstrate the technical construction feasibility and performance of seals to be constructed, at time of Repository components (shafts, ramps, drifts, disposal vaults) progressive closure. FSS is built inside a drift model fabricated on surface for the purpose. Prior to the scale 1:1 seal construction test, various design tasks are scheduled. They include the engineering work on the drift model to make it fit with the experimental needs, on the various work sequencesmore » anticipated for the swelling clay core emplacement and the concrete containment plugs construction, on the specialized handling tools (and installation equipment) manufactured and delivered for the purpose, and of course on the various swelling clay materials and low pH (below 11) concrete formulations developed for the application. The engineering of the 'seal-as-built' commissioning means (tools and methodology) must also be dealt with. The FSS construction experiment is a technological demonstrator, thus it is not focused on the phenomenological survey (and by consequence, on the performance and behaviour forecast). As such, no hydration (forced or natural) is planned. However, the FSS implementation (in particular via the construction and commissioning activities carried out) is a key milestone in view of comforting phenomenological extrapolation in time and scale. The FSS experiment also allows for qualifying the commissioning methods of a real sealing system in the Repository, as built, at time of industrial operations. (authors)« less

Toward the Factory of the Future.

ERIC Educational Resources Information Center

Hazony, Yehonathan

1983-01-01

Computer-integrated manufacturing (CIM) involves use of data processing technology as the vehicle for full integration of the total manufacturing process. A prototype research and educational facility for CIM developed with industrial sponsorship at Princeton University is described. (JN)

Making the Case for a Model-Based Definition of Engineering Materials (Postprint)

DTIC Science & Technology

2017-09-12

MBE relies on digi- tal representations, or a model-based definition (MBD), to define a product throughout design , manufacturing and sus- tainment...discovery through development, scale-up, product design and qualification, manufacture and sustainment have changed little over the past decades. This...testing data provided a certifiable material definition, so as to minimize risk and simplify procurement of materials during the design , manufacture , and

The Development of High Temperature Thermoplastic Composite Materials for Additive Manufactured Autoclave Tooling

DOE Office of Scientific and Technical Information (OSTI.GOV)

Kunc, Vlastimil; Duty, Chad E.; Lindahl, John M.

2017-08-01

In this work, ORNL and Techmer investigated and screened different high temperature thermoplastic reinforced materials to fabricate composite molds for autoclave processes using Additive Manufacturing (AM) techniques. This project directly led to the development and commercial release of two printable, high temperature composite materials available through Techmer PM. These new materials are targeted for high temperature tooling made via large scale additive manufacturing.

Laser 3D micro-manufacturing

NASA Astrophysics Data System (ADS)

Piqué, Alberto; Auyeung, Raymond C. Y.; Kim, Heungsoo; Charipar, Nicholas A.; Mathews, Scott A.

2016-06-01

Laser-based materials processing techniques are gaining widespread use in micro-manufacturing applications. The use of laser microfabrication techniques enables the processing of micro- and nanostructures from a wide range of materials and geometries without the need for masking and etching steps commonly associated with photolithography. This review aims to describe the broad applications space covered by laser-based micro- and nanoprocessing techniques and the benefits offered by the use of lasers in micro-manufacturing processes. Given their non-lithographic nature, these processes are also referred to as laser direct-write and constitute some of the earliest demonstrations of 3D printing or additive manufacturing at the microscale. As this review will show, the use of lasers enables precise control of the various types of processing steps—from subtractive to additive—over a wide range of scales with an extensive materials palette. Overall, laser-based direct-write techniques offer multiple modes of operation including the removal (via ablative processes) and addition (via photopolymerization or printing) of most classes of materials using the same equipment in many cases. The versatility provided by these multi-function, multi-material and multi-scale laser micro-manufacturing processes cannot be matched by photolithography nor with other direct-write microfabrication techniques and offer unique opportunities for current and future 3D micro-manufacturing applications.

Application of ICME Methods for the Development of Rapid Manufacturing Technologies

NASA Astrophysics Data System (ADS)

Maiwald-Immer, T.; Göhler, T.; Fischersworring-Bunk, A.; Körner, C.; Osmanlic, F.; Bauereiß, A.

Rapid manufacturing technologies are lately gaining interest as alternative manufacturing method. Due to the large parameter sets applicable in these manufacturing methods and their impact on achievable material properties and quality, support of the manufacturing process development by the use of simulation is highly attractive. This is especially true for aerospace applications with their high quality demands and controlled scatter in the resulting material properties. The applicable simulation techniques to these manufacturing methods are manifold. The paper will focus on the melt pool simulation for a SLM (selective laser melting) process which was originally developed for EBM (electron beam melting). It will be discussed in the overall context of a multi-scale simulation within a virtual process chain.

Oxygen transfer and uptake, nutrient removal, and energy footprint of parallel full-scale IFAS and activated sludge processes.

PubMed

Rosso, Diego; Lothman, Sarah E; Jeung, Matthew K; Pitt, Paul; Gellner, W James; Stone, Alan L; Howard, Don

2011-11-15

Integrated fixed-film activated sludge (IFAS) processes are becoming more popular for both secondary and sidestream treatment in wastewater facilities. These processes are a combination of biofilm reactors and activated sludge processes, achieved by introducing and retaining biofilm carrier media in activated sludge reactors. A full-scale train of three IFAS reactors equipped with AnoxKaldnes media and coarse-bubble aeration was tested using off-gas analysis. This was operated independently in parallel to an existing full-scale activated sludge process. Both processes achieved the same percent removal of COD and ammonia, despite the double oxygen demand on the IFAS reactors. In order to prevent kinetic limitations associated with DO diffusional gradients through the IFAS biofilm, this systems was operated at an elevated dissolved oxygen concentration, in line with the manufacturer's recommendation. Also, to avoid media coalescence on the reactor surface and promote biofilm contact with the substrate, high mixing requirements are specified. Therefore, the air flux in the IFAS reactors was much higher than that of the parallel activated sludge reactors. However, the standardized oxygen transfer efficiency in process water was almost same for both processes. In theory, when the oxygen transfer efficiency is the same, the air used per unit load removed should be the same. However, due to the high DO and mixing requirements, the IFAS reactors were characterized by elevated air flux and air use per unit load treated. This directly reflected in the relative energy footprint for aeration, which in this case was much higher for the IFAS system than activated sludge. Copyright © 2011 Elsevier Ltd. All rights reserved.

Shape memory alloy actuation for a variable area fan nozzle

NASA Astrophysics Data System (ADS)

Rey, Nancy; Tillman, Gregory; Miller, Robin M.; Wynosky, Thomas; Larkin, Michael J.; Flamm, Jeffrey D.; Bangert, Linda S.

2001-06-01

The ability to control fan nozzle exit area is an enabling technology for next generation high-bypass-ratio turbofan engines. Performance benefits for such designs are estimated at up to 9% in thrust specific fuel consumption (TSFC) relative to current fixed-geometry engines. Conventionally actuated variable area fan nozzle (VAN) concepts tend to be heavy and complicated, with significant aircraft integration, reliability and packaging issues. The goal of this effort was to eliminate these undesirable features and formulate a design that meets or exceeds leakage, durability, reliability, maintenance and manufacturing cost goals. A Shape Memory Alloy (SMA) bundled cable actuator acting to move an array of flaps around the fan nozzle annulus is a concept that meets these requirements. The SMA bundled cable actuator developed by the United Technologies Corporation (Patents Pending) provides significant work output (greater than 2200 in-lb per flap, through the range of motion) in a compact package and minimizes system complexity. Results of a detailed design study indicate substantial engine performance, weight, and range benefits. The SMA- based actuation system is roughly two times lighter than a conventional mechanical system, with significant aircraft direct operating cost savings (2-3%) and range improvements (5-6%) relative to a fixed-geometry nozzle geared turbofan. A full-scale sector model of this VAN system was built and then tested at the Jet Exit Test Facility at NASA Langley to demonstrate the system's ability to achieve 20% area variation of the nozzle under full scale aerodynamic loads. The actuator exceeded requirements, achieving repeated actuation against full-scale loads representative of typical cruise as well as greater than worst-case (ultimate) aerodynamic conditions. Based on these encouraging results, work is continuing with the goal of a flight test on a C-17 transport aircraft.

A Theoretical Investigation of Composite Overwrapped Pressure Vessel (COPV) Mechanics Applied to NASA Full Scale Tests

NASA Technical Reports Server (NTRS)

Thesken, John C.; Murthy, Pappu L. N.; Phoenix, S. L.; Greene, N.; Palko, Joseph L.; Eldridge, Jeffrey; Sutter, James; Saulsberry, R.; Beeson, H.

2009-01-01

A theoretical investigation of the factors controlling the stress rupture life of the National Aeronautics and Space Administration's (NASA) composite overwrapped pressure vessels (COPVs) continues. Kevlar (DuPont) fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However due to the presence of a load sharing liner, the manufacturing induced residual stresses and the complex mechanical response, the state of actual fiber stress in flight hardware and test articles is not clearly known. This paper is a companion to a previously reported experimental investigation and develops a theoretical framework necessary to design full-scale pathfinder experiments and accurately interpret the experimentally observed deformation and failure mechanisms leading up to static burst in COPVs. The fundamental mechanical response of COPVs is described using linear elasticity and thin shell theory and discussed in comparison to existing experimental observations. These comparisons reveal discrepancies between physical data and the current analytical results and suggest that the vessel s residual stress state and the spatial stress distribution as a function of pressure may be completely different from predictions based upon existing linear elastic analyses. The 3D elasticity of transversely isotropic spherical shells demonstrates that an overly compliant transverse stiffness relative to membrane stiffness can account for some of this by shifting a thin shell problem well into the realm of thick shell response. The use of calibration procedures are demonstrated as calibrated thin shell model results and finite element results are shown to be in good agreement with the experimental results. The successes reported here have lead to continuing work with full scale testing of larger NASA COPV hardware.

Advanced Material Strategies for Next-Generation Additive Manufacturing

PubMed Central

Chang, Jinke; He, Jiankang; Zhou, Wenxing; Lei, Qi; Li, Xiao; Li, Dichen

2018-01-01

Additive manufacturing (AM) has drawn tremendous attention in various fields. In recent years, great efforts have been made to develop novel additive manufacturing processes such as micro-/nano-scale 3D printing, bioprinting, and 4D printing for the fabrication of complex 3D structures with high resolution, living components, and multimaterials. The development of advanced functional materials is important for the implementation of these novel additive manufacturing processes. Here, a state-of-the-art review on advanced material strategies for novel additive manufacturing processes is provided, mainly including conductive materials, biomaterials, and smart materials. The advantages, limitations, and future perspectives of these materials for additive manufacturing are discussed. It is believed that the innovations of material strategies in parallel with the evolution of additive manufacturing processes will provide numerous possibilities for the fabrication of complex smart constructs with multiple functions, which will significantly widen the application fields of next-generation additive manufacturing. PMID:29361754

Advanced Material Strategies for Next-Generation Additive Manufacturing.

PubMed

Chang, Jinke; He, Jiankang; Mao, Mao; Zhou, Wenxing; Lei, Qi; Li, Xiao; Li, Dichen; Chua, Chee-Kai; Zhao, Xin

2018-01-22

Additive manufacturing (AM) has drawn tremendous attention in various fields. In recent years, great efforts have been made to develop novel additive manufacturing processes such as micro-/nano-scale 3D printing, bioprinting, and 4D printing for the fabrication of complex 3D structures with high resolution, living components, and multimaterials. The development of advanced functional materials is important for the implementation of these novel additive manufacturing processes. Here, a state-of-the-art review on advanced material strategies for novel additive manufacturing processes is provided, mainly including conductive materials, biomaterials, and smart materials. The advantages, limitations, and future perspectives of these materials for additive manufacturing are discussed. It is believed that the innovations of material strategies in parallel with the evolution of additive manufacturing processes will provide numerous possibilities for the fabrication of complex smart constructs with multiple functions, which will significantly widen the application fields of next-generation additive manufacturing.

Metabolic engineering: the ultimate paradigm for continuous pharmaceutical manufacturing.

PubMed

Yadav, Vikramaditya G; Stephanopoulos, Gregory

2014-07-01

Research and development (R&D) expenditures by pharmaceutical companies doubled over the past decade, yet candidate attrition rates and development times rose markedly during this period. Understandably, companies have begun downsizing their pipelines and diverting investments away from R&D in favor of manufacturing. It is estimated that transitioning to continuous manufacturing could enable companies to compete for a share in emerging markets. Accordingly, the model for continuous manufacturing that has emerged commences with the conversion of late-stage intermediates into the active pharmaceutical ingredient (API) in a series of continuous flow reactors, followed by continuous solid processing to form finished tablets. The use of flow reactions for API synthesis will certainly generate purer products at higher yields in shorter times compared to equivalent batch reactions. However, transitioning from batch to flow configuration simply alleviates transport limitations within the reaction milieu. As the catalogue of reactions used in flow syntheses is a subset of batch-based chemistries, molecules such as natural products will continue to evade drug prospectors. Also, it is uncertain whether flow synthesis can deliver improvements in the atom and energy economies of API production at the scales that would achieve the levels of revenue growth targeted by companies. Instead, it is argued that implementing metabolic engineering for the production of oxidized scaffolds as gateway molecules for flow-based addition of electrophiles is a more effective and scalable strategy for accessing natural product chemical space. This new paradigm for manufacturing, with metabolic engineering as its engine, would also permit rapid optimization of production variables and allow facile scale-up from gram to ton scale to meet material requirements for clinical trials, thus recasting manufacturing as a tool for discovery. © 2014 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Manufacturing models permitting roll out/scale out of clinically led autologous cell therapies: regulatory and scientific challenges for comparability.

PubMed

Hourd, Paul; Ginty, Patrick; Chandra, Amit; Williams, David J

2014-08-01

Manufacturing of more-than-minimally manipulated autologous cell therapies presents a number of unique challenges driven by complex supply logistics and the need to scale out production to multiple manufacturing sites or near the patient within hospital settings. The existing regulatory structure in Europe and the United States imposes a requirement to establish and maintain comparability between sites. Under a single market authorization, this is likely to become an unsurmountable burden beyond two or three sites. Unless alternative manufacturing approaches can be found to bridge the regulatory challenge of comparability, realizing a sustainable and investable business model for affordable autologous cell therapy supply is likely to be extremely demanding. Without a proactive approach by the regulators to close this "translational gap," these products may not progress down the development pipeline, threatening patient accessibility to an increasing number of clinician-led autologous cellular therapies that are already demonstrating patient benefits. We propose three prospective manufacturing models for the scale out/roll out of more-than-minimally manipulated clinically led autologous cell therapy products and test their prospects for addressing the challenge of product comparability with a selected expert reference panel of US and UK thought leaders. This paper presents the perspectives and insights of the panel and identifies where operational, technological and scientific improvements should be prioritized. The main purpose of this report is to solicit feedback and seek input from key stakeholders active in the field of autologous cell therapy in establishing a consensus-based manufacturing approach that may permit the roll out of clinically led autologous cell therapies. Copyright © 2014 International Society for Cellular Therapy. Published by Elsevier Inc. All rights reserved.

Application of quality by design principles to the development and technology transfer of a major process improvement for the manufacture of a recombinant protein.

PubMed

Looby, Mairead; Ibarra, Neysi; Pierce, James J; Buckley, Kevin; O'Donovan, Eimear; Heenan, Mary; Moran, Enda; Farid, Suzanne S; Baganz, Frank

2011-01-01

This study describes the application of quality by design (QbD) principles to the development and implementation of a major manufacturing process improvement for a commercially distributed therapeutic protein produced in Chinese hamster ovary cell culture. The intent of this article is to focus on QbD concepts, and provide guidance and understanding on how the various components combine together to deliver a robust process in keeping with the principles of QbD. A fed-batch production culture and a virus inactivation step are described as representative examples of upstream and downstream unit operations that were characterized. A systematic approach incorporating QbD principles was applied to both unit operations, involving risk assessment of potential process failure points, small-scale model qualification, design and execution of experiments, definition of operating parameter ranges and process validation acceptance criteria followed by manufacturing-scale implementation and process validation. Statistical experimental designs were applied to the execution of process characterization studies evaluating the impact of operating parameters on product quality attributes and process performance parameters. Data from process characterization experiments were used to define the proven acceptable range and classification of operating parameters for each unit operation. Analysis of variance and Monte Carlo simulation methods were used to assess the appropriateness of process design spaces. Successful implementation and validation of the process in the manufacturing facility and the subsequent manufacture of hundreds of batches of this therapeutic protein verifies the approaches taken as a suitable model for the development, scale-up and operation of any biopharmaceutical manufacturing process. Copyright © 2011 American Institute of Chemical Engineers (AIChE).

Sockets Manufactured by CAD/CAM Method Have Positive Effects on the Quality of Life of Patients With Transtibial Amputation.

PubMed

Karakoç, Mehmet; Batmaz, İbrahim; Sariyildiz, Mustafa Akif; Yazmalar, Levent; Aydin, Abdülkadir; Em, Serda

2017-08-01

Patients with amputation need prosthesis to comfortably move around. One of the most important parts of a good prosthesis is the socket. Currently, the most commonly used method is the traditional socket manufacturing method, which involves manual work; however, computer-aided design/computer-aided manufacturing (CAD/CAM) is also being used in the recent years. The present study aimed to investigate the effects of sockets manufactured by traditional and CAD/CAM method on clinical characteristics and quality of life of patients with transtibial amputation. The study included 72 patients with transtibial amputation using prosthesis, 36 of whom had CAD/CAM prosthetic sockets (group 1) and 36 had traditional prosthetic sockets (group 2). Amputation reason, prosthesis lifetime, walking time and distance with prosthesis, pain-free walking time with prosthesis, production time of the prosthesis, and adaptation time to the prosthesis were questioned. Quality of life was assessed using the 36-item Short Form Health Survey questionnaire and the Trinity Amputation and Prosthesis Experience Scales. Walking time and distance and pain-free walking time with prosthesis were significantly better in group 1 than those in group 2. Furthermore, the prosthesis was applied in a significantly shorter time, and socket adaptation time was significantly shorter in group 1. Except emotional role limitation, all 36-item Short Form Healthy Survey questionnaire parameters were significantly better in group 1 than in group 2. Trinity Amputation and Prosthesis Experience Scales activity limitation scores of group 1 were lower, and Trinity Amputation and Prosthesis Experience Scales satisfaction with the prosthesis scores were higher than those in group 2. Our study demonstrated that the sockets manufactured by CAD/CAM methods yield better outcomes in quality of life of patients with transtibial amputation than the sockets manufactured by the traditional method.

George E. Pake Prize: A Few Challenges in the Evolution of Semiconductor Device/Manufacturing Technology

NASA Astrophysics Data System (ADS)

Doering, Robert

In the early 1980s, the semiconductor industry faced the related challenges of ``scaling through the one-micron barrier'' and converting single-level-metal NMOS integrated circuits to multi-level-metal CMOS. Multiple advances in lithography technology and device materials/process integration led the way toward the deep-sub-micron transistors and interconnects that characterize today's electronic chips. In the 1990s, CMOS scaling advanced at an accelerated pace enabled by rapid advances in many aspects of optical lithography. However, the industry also needed to continue the progress in manufacturing on ever-larger silicon wafers to maintain economy-of-scale trends. Simultaneously, the increasing complexity and absolute-precision requirements of manufacturing compounded the necessity for new processes, tools, and control methodologies. This talk presents a personal perspective on some of the approaches that addressed the aforementioned challenges. In particular, early work on integrating silicides, lightly-doped-drain FETs, shallow recessed isolation, and double-level metal will be discussed. In addition, some pioneering efforts in deep-UV lithography and single-wafer processing will be covered. The latter will be mainly based on results from the MMST Program - a 100 M +, 5-year R&D effort, funded by DARPA, the U.S. Air Force, and Texas Instruments, that developed a wide range of new technologies for advanced semiconductor manufacturing. The major highlight of the program was the demonstration of sub-3-day cycle time for manufacturing 350-nm CMOS integrated circuits in 1993. This was principally enabled by the development of: (1) 100% single-wafer processing, including rapid-thermal processing (RTP), and (2) computer-integrated-manufacturing (CIM), including real-time, in-situ process control.

Nanomanufacturing : nano-structured materials made layer-by-layer.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Cox, James V.; Cheng, Shengfeng; Grest, Gary Stephen

Large-scale, high-throughput production of nano-structured materials (i.e. nanomanufacturing) is a strategic area in manufacturing, with markets projected to exceed $1T by 2015. Nanomanufacturing is still in its infancy; process/product developments are costly and only touch on potential opportunities enabled by growing nanoscience discoveries. The greatest promise for high-volume manufacturing lies in age-old coating and imprinting operations. For materials with tailored nm-scale structure, imprinting/embossing must be achieved at high speeds (roll-to-roll) and/or over large areas (batch operation) with feature sizes less than 100 nm. Dispersion coatings with nanoparticles can also tailor structure through self- or directed-assembly. Layering films structured with thesemore » processes have tremendous potential for efficient manufacturing of microelectronics, photovoltaics and other topical nano-structured devices. This project is designed to perform the requisite R and D to bring Sandia's technology base in computational mechanics to bear on this scale-up problem. Project focus is enforced by addressing a promising imprinting process currently being commercialized.« less

A Magnetic Bead-Integrated Chip for the Large Scale Manufacture of Normalized esiRNAs

PubMed Central

Wang, Zhao; Huang, Huang; Zhang, Hanshuo; Sun, Changhong; Hao, Yang; Yang, Junyu; Fan, Yu; Xi, Jianzhong Jeff

2012-01-01

The chemically-synthesized siRNA duplex has become a powerful and widely used tool for RNAi loss-of-function studies, but suffers from a high off-target effect problem. Recently, endoribonulease-prepared siRNA (esiRNA) has been shown to be an attractive alternative due to its lower off-target effect and cost effectiveness. However, the current manufacturing method for esiRNA is complicated, mainly in regards to purification and normalization on a large-scale level. In this study, we present a magnetic bead-integrated chip that can immobilize amplification or transcription products on beads and accomplish transcription, digestion, normalization and purification in a robust and convenient manner. This chip is equipped to manufacture ready-to-use esiRNAs on a large-scale level. Silencing specificity and efficiency of these esiRNAs were validated at the transcriptional, translational and functional levels. Manufacture of several normalized esiRNAs in a single well, including those silencing PARP1 and BRCA1, was successfully achieved, and the esiRNAs were subsequently utilized to effectively investigate their synergistic effect on cell viability. A small esiRNA library targeting 68 tyrosine kinase genes was constructed for a loss-of-function study, and four genes were identified in regulating the migration capability of Hela cells. We believe that this approach provides a more robust and cost-effective choice for manufacturing esiRNAs than current approaches, and therefore these heterogeneous RNA strands may have utility in most intensive and extensive applications. PMID:22761791

The Impact of Granule Density on Tabletting and Pharmaceutical Product Performance.

PubMed

van den Ban, Sander; Goodwin, Daniel J

2017-05-01

The impact of granule densification in high-shear wet granulation on tabletting and product performance was investigated, at pharmaceutical production scale. Product performance criteria need to be balanced with the need to deliver manufacturability criteria to assure robust industrial scale tablet manufacturing processes. A Quality by Design approach was used to determine in-process control specifications for tabletting, propose a design space for disintegration and dissolution, and to understand the permitted operating limits and required controls for an industrial tabletting process. Granules of varying density (filling density) were made by varying water amount added, spray rate, and wet massing time in a design of experiment (DoE) approach. Granules were compressed into tablets to a range of thicknesses to obtain tablets of varying breaking force. Disintegration and dissolution performance was evaluated for the tablets made. The impact of granule filling density on tabletting was rationalised with compressibility, tabletability and compactibility. Tabletting and product performance criteria provided competing requirements for porosity. An increase in granule filling density impacted tabletability and compactability and limited the ability to achieve tablets of adequate mechanical strength. An increase in tablet solid fraction (decreased porosity) impacted disintegration and dissolution. An attribute-based design space for disintegration and dissolution was specified to achieve both product performance and manufacturability. The method of granulation and resulting granule filling density is a key design consideration to achieve both product performance and manufacturability required for modern industrial scale pharmaceutical product manufacture and distribution.

Building components for an outpost on the Lunar soil by means of a novel 3D printing technology

NASA Astrophysics Data System (ADS)

Cesaretti, Giovanni; Dini, Enrico; De Kestelier, Xavier; Colla, Valentina; Pambaguian, Laurent

2014-01-01

3D-printing technologies are receiving an always increasing attention in architecture, due to their potential use for direct construction of buildings and other complex structures, also of considerable dimensions, with virtually any shape. Some of these technologies rely on an agglomeration process of inert materials, e.g. sand, through a special binding liquid and this capability is of interest for the space community for its potential application to space exploration. In fact, it opens the possibility for exploiting in-situ resources for the construction of buildings in harsh spatial environments. The paper presents the results of a study aimed at assessing the concept of 3D printing technology for building habitats on the Moon using lunar soil, also called regolith. A particular patented 3D-printing technology - D-shape - has been applied, which is, among the existing rapid prototyping systems, the closest to achieving full scale construction of buildings and the physical and chemical characteristics of lunar regolith and terrestrial regolith simulants have been assessed with respect to the working principles of such technology. A novel lunar regolith simulant has also been developed, which almost exactly reproduces the characteristics of the JSC-1A simulant produced in the US. Moreover, tests in air and in vacuum have been performed to demonstrate the occurrence of the reticulation reaction with the regolith simulant. The vacuum tests also showed that evaporation or freezing of the binding liquid can be prevented through a proper injection method. The general requirements of a Moon outpost have been specified, and a preliminary design of the habitat has been developed. Based on such design, a section of the outpost wall has been selected and manufactured at full scale using the D-shape printer and regolith simulant. Test pieces have also been manufactured and their mechanical properties have been assessed.

Spraying Techniques for Large Scale Manufacturing of PEM-FC Electrodes

NASA Astrophysics Data System (ADS)

Hoffman, Casey J.

Fuel cells are highly efficient energy conversion devices that represent one part of the solution to the world's current energy crisis in the midst of global climate change. When supplied with the necessary reactant gasses, fuel cells produce only electricity, heat, and water. The fuel used, namely hydrogen, is available from many sources including natural gas and the electrolysis of water. If the electricity for electrolysis is generated by renewable energy (e.g., solar and wind power), fuel cells represent a completely 'green' method of producing electricity. The thought of being able to produce electricity to power homes, vehicles, and other portable or stationary equipment with essentially zero environmentally harmful emissions has been driving academic and industrial fuel cell research and development with the goal of successfully commercializing this technology. Unfortunately, fuel cells cannot achieve any appreciable market penetration at their current costs. The author's hypothesis is that: the development of automated, non-contact deposition methods for electrode manufacturing will improve performance and process flexibility, thereby helping to accelerate the commercialization of PEMFC technology. The overarching motivation for this research was to lower the cost of manufacturing fuel cell electrodes and bring the technology one step closer to commercial viability. The author has proven this hypothesis through a detailed study of two non-contact spraying methods. These scalable deposition systems were incorporated into an automated electrode manufacturing system that was designed and built by the author for this research. The electrode manufacturing techniques developed by the author have been shown to produce electrodes that outperform a common lab-scale contact method that was studied as a baseline, as well as several commercially available electrodes. In addition, these scalable, large scale electrode manufacturing processes developed by the author are also flexible and can be used to fabricate almost any fuel cell electrodes on the market today. This dissertation provides a description of the entire electrode manufacturing process as well as an analysis of the accuracy, performance and repeatability of the methods.

Advances in compact manufacturing for shape and performance controllability of large-scale components-a review

NASA Astrophysics Data System (ADS)

Qin, Fangcheng; Li, Yongtang; Qi, Huiping; Ju, Li

2017-01-01

Research on compact manufacturing technology for shape and performance controllability of metallic components can realize the simplification and high-reliability of manufacturing process on the premise of satisfying the requirement of macro/micro-structure. It is not only the key paths in improving performance, saving material and energy, and green manufacturing of components used in major equipments, but also the challenging subjects in frontiers of advanced plastic forming. To provide a novel horizon for the manufacturing in the critical components is significant. Focused on the high-performance large-scale components such as bearing rings, flanges, railway wheels, thick-walled pipes, etc, the conventional processes and their developing situations are summarized. The existing problems including multi-pass heating, wasting material and energy, high cost and high-emission are discussed, and the present study unable to meet the manufacturing in high-quality components is also pointed out. Thus, the new techniques related to casting-rolling compound precise forming of rings, compact manufacturing for duplex-metal composite rings, compact manufacturing for railway wheels, and casting-extruding continuous forming of thick-walled pipes are introduced in detail, respectively. The corresponding research contents, such as casting ring blank, hot ring rolling, near solid-state pressure forming, hot extruding, are elaborated. Some findings in through-thickness microstructure evolution and mechanical properties are also presented. The components produced by the new techniques are mainly characterized by fine and homogeneous grains. Moreover, the possible directions for further development of those techniques are suggested. Finally, the key scientific problems are first proposed. All of these results and conclusions have reference value and guiding significance for the integrated control of shape and performance in advanced compact manufacturing.

Implementing high-temperature short-time media treatment in commercial-scale cell culture manufacturing processes.

PubMed

Pohlscheidt, Michael; Charaniya, Salim; Kulenovic, Fikret; Corrales, Mahalia; Shiratori, Masaru; Bourret, Justin; Meier, Steven; Fallon, Eric; Kiss, Robert

2014-04-01

The production of therapeutic proteins by mammalian cell culture is complex and sets high requirements for process, facility, and equipment design, as well as rigorous regulatory and quality standards. One particular point of concern and significant risk to supply chain is the susceptibility to contamination such as bacteria, fungi, mycoplasma, and viruses. Several technologies have been developed to create barriers for these agents to enter the process, e.g. filtration, UV inactivation, and temperature inactivation. However, if not implemented during development of the manufacturing process, these types of process changes can have significant impact on process performance if not managed appropriately. This article describes the implementation of the high-temperature short-time (HTST) treatment of cell culture media as an additional safety barrier against adventitious agents during the transfer of a large-scale commercial cell culture manufacturing process. The necessary steps and experiments, as well as subsequent results during qualification runs and routine manufacturing, are shown.

Full-scale fatigue tests of CX-100 wind turbine blades. Part I: testing

NASA Astrophysics Data System (ADS)

Farinholt, Kevin M.; Taylor, Stuart G.; Park, Gyuhae; Ammerman, Curtt M.

2012-04-01

This paper overviews the test setup and experimental methods for structural health monitoring (SHM) of two 9-meter CX-100 wind turbine blades that underwent fatigue loading at the National Renewable Energy Laboratory's (NREL) National Wind Technology Center (NWTC). The first blade was a pristine blade, which was manufactured to standard specifications for the CX-100 design. The second blade was manufactured for the University of Massachusetts, Lowell with intentional simulated defects within the fabric layup. Each blade was instrumented with piezoelectric transducers, accelerometers, acoustic emission sensors, and foil strain gauges. The blades underwent harmonic excitation at their first natural frequency using the Universal Resonant Excitation (UREX) system at NREL. Blades were initially excited at 25% of their design load, and then with steadily increasing loads until each blade reached failure. Data from the sensors were collected between and during fatigue loading sessions. The data were measured over multi-scale frequency ranges using a variety of acquisition equipment, including off-the-shelf systems and specially designed hardware developed at Los Alamos National Laboratory (LANL). The hardware systems were evaluated for their aptness in data collection for effective application of SHM methods to the blades. The results of this assessment will inform the selection of acquisition hardware and sensor types to be deployed on a CX-100 flight test to be conducted in collaboration with Sandia National Laboratory at the U.S. Department of Agriculture's (USDA) Conservation and Production Research Laboratory (CPRL) in Bushland, Texas.

A Miniaturized Extruder to Prototype Amorphous Solid Dispersions: Selection of Plasticizers for Hot Melt Extrusion.

PubMed

Lauer, Matthias E; Maurer, Reto; Paepe, Anne T De; Stillhart, Cordula; Jacob, Laurence; James, Rajesh; Kojima, Yuki; Rietmann, Rene; Kissling, Tom; van den Ende, Joost A; Schwarz, Sabine; Grassmann, Olaf; Page, Susanne

2018-05-19

Hot-melt extrusion is an option to fabricate amorphous solid dispersions and to enhance oral bioavailability of poorly soluble compounds. The selection of suitable polymer carriers and processing aids determines the dissolution, homogeneity and stability performance of this solid dosage form. A miniaturized extrusion device (MinEx) was developed and Hypromellose acetate succinate type L (HPMCAS-L) based extrudates containing the model drugs neurokinin-1 (NK1) and cholesterylester transfer protein (CETP) were manufactured, plasticizers were added and their impact on dissolution and solid-state properties were assessed. Similar mixtures were manufactured with a lab-scale extruder, for face to face comparison. The properties of MinEx extrudates widely translated to those manufactured with a lab-scale extruder. Plasticizers, Polyethyleneglycol 4000 (PEG4000) and Poloxamer 188, were homogenously distributed but decreased the storage stability of the extrudates. Stearic acid was found condensed in ultrathin nanoplatelets which did not impact the storage stability of the system. Depending on their distribution and physicochemical properties, plasticizers can modulate storage stability and dissolution performance of extrudates. MinEx is a valuable prototyping-screening method and enables rational selection of plasticizers in a time and material sparing manner. In eight out of eight cases the properties of the extrudates translated to products manufactured in lab-scale extrusion trials.

Economically sustainable scaling of photovoltaics to meet climate targets

DOE Office of Scientific and Technical Information (OSTI.GOV)

Needleman, David Berney; Poindexter, Jeremy R.; Kurchin, Rachel C.

To meet climate targets, power generation capacity from photovoltaics (PV) in 2030 will have to be much greater than is predicted from either steady state growth using today's manufacturing capacity or industry roadmaps. Analysis of whether current technology can scale, in an economically sustainable way, to sufficient levels to meet these targets has not yet been undertaken, nor have tools to perform this analysis been presented. Here, we use bottom-up cost modeling to predict cumulative capacity as a function of technological and economic variables. We find that today's technology falls short in two ways: profits are too small relative tomore » upfront factory costs to grow manufacturing capacity rapidly enough to meet climate targets, and costs are too high to generate enough demand to meet climate targets. We show that decreasing the capital intensity (capex) of PV manufacturing to increase manufacturing capacity and effectively reducing cost (e.g., through higher efficiency) to increase demand are the most effective and least risky ways to address these barriers to scale. We also assess the effects of variations in demand due to hard-to-predict factors, like public policy, on the necessary reductions in cost.Lastly, we review examples of redundant technology pathways for crystalline silicon PV to achieve the necessary innovations in capex, performance, and price.« less

Economically sustainable scaling of photovoltaics to meet climate targets

DOE PAGES

Needleman, David Berney; Poindexter, Jeremy R.; Kurchin, Rachel C.; ...

2016-04-21

To meet climate targets, power generation capacity from photovoltaics (PV) in 2030 will have to be much greater than is predicted from either steady state growth using today's manufacturing capacity or industry roadmaps. Analysis of whether current technology can scale, in an economically sustainable way, to sufficient levels to meet these targets has not yet been undertaken, nor have tools to perform this analysis been presented. Here, we use bottom-up cost modeling to predict cumulative capacity as a function of technological and economic variables. We find that today's technology falls short in two ways: profits are too small relative tomore » upfront factory costs to grow manufacturing capacity rapidly enough to meet climate targets, and costs are too high to generate enough demand to meet climate targets. We show that decreasing the capital intensity (capex) of PV manufacturing to increase manufacturing capacity and effectively reducing cost (e.g., through higher efficiency) to increase demand are the most effective and least risky ways to address these barriers to scale. We also assess the effects of variations in demand due to hard-to-predict factors, like public policy, on the necessary reductions in cost.Lastly, we review examples of redundant technology pathways for crystalline silicon PV to achieve the necessary innovations in capex, performance, and price.« less

Update on Risk Reduction Activities for a Liquid Advanced Booster for NASA's Space Launch System

NASA Technical Reports Server (NTRS)

Crocker, Andrew M.; Doering, Kimberly B; Meadows, Robert G.; Lariviere, Brian W.; Graham, Jerry B.

2015-01-01

The stated goals of NASA's Research Announcement for the Space Launch System (SLS) Advanced Booster Engineering Demonstration and/or Risk Reduction (ABEDRR) are to reduce risks leading to an affordable Advanced Booster that meets the evolved capabilities of SLS; and enable competition by mitigating targeted Advanced Booster risks to enhance SLS affordability. Dynetics, Inc. and Aerojet Rocketdyne (AR) formed a team to offer a wide-ranging set of risk reduction activities and full-scale, system-level demonstrations that support NASA's ABEDRR goals. For NASA's SLS ABEDRR procurement, Dynetics and AR formed a team to offer a series of full-scale risk mitigation hardware demonstrations for an affordable booster approach that meets the evolved capabilities of the SLS. To establish a basis for the risk reduction activities, the Dynetics Team developed a booster design that takes advantage of the flight-proven Apollo-Saturn F-1. Using NASA's vehicle assumptions for the SLS Block 2, a two-engine, F-1-based booster design delivers 150 mT (331 klbm) payload to LEO, 20 mT (44 klbm) above NASA's requirements. This enables a low-cost, robust approach to structural design. During the ABEDRR effort, the Dynetics Team has modified proven Apollo-Saturn components and subsystems to improve affordability and reliability (e.g., reduce parts counts, touch labor, or use lower cost manufacturing processes and materials). The team has built hardware to validate production costs and completed tests to demonstrate it can meet performance requirements. State-of-the-art manufacturing and processing techniques have been applied to the heritage F-1, resulting in a low recurring cost engine while retaining the benefits of Apollo-era experience. NASA test facilities have been used to perform low-cost risk-reduction engine testing. In early 2014, NASA and the Dynetics Team agreed to move additional large liquid oxygen/kerosene engine work under Dynetics' ABEDRR contract. Also led by AR, the objectives of this work are to demonstrate combustion stability and measure performance of a 500,000 lbf class Oxidizer-Rich Staged Combustion (ORSC) cycle main injector. A trade study was completed to investigate the feasibility, cost effectiveness, and technical maturity of a domestically produced Atlas V engine that could also potentially satisfy NASA SLS payload-to-orbit requirements via an advanced booster application. Engine physical dimensions and performance parameters resulting from this study provide the system level requirements for the ORSC risk reduction test article. The test article is scheduled to complete critical design review this fall and begin testing in 2017. Dynetics has also designed, developed, and built innovative tank and structure assemblies using friction stir welding to leverage recent NASA investments in manufacturing tools, facilities, and processes, significantly reducing development and recurring costs. The full-scale cryotank assembly was used to verify the structural design and prove affordable processes. Dynetics performed hydrostatic and cryothermal proof tests on the assembly to verify the assembly meets performance requirements. This paper will discuss the ABEDRR engine task and structures task achievements to date and the remaining effort through the end of the contract.

Materials Manufactured from 3D Printed Synthetic Biology Arrays

NASA Technical Reports Server (NTRS)

Gentry, Diana; Micks, Ashley

2013-01-01

Many complex, biologically-derived materials have extremely useful properties (think wood or silk), but are unsuitable for space-related applications due to production, manufacturing, or processing limitations. Large-scale ecosystem-based production, such as raising and harvesting trees for wood, is impractical in a self-contained habitat such as a space station or potential Mars colony. Manufacturing requirements, such as the specialized equipment needed to harvest and process cotton, add too much upmass for current launch technology. Cells in nature are already highly specialized for making complex biological materials on a micro scale. We envision combining these strengths with the recently emergent technologies of synthetic biology and 3D printing to create 3D-structured arrays of cells that are bioengineered to secrete different materials in a specified three-dimensional pattern.

Maintaining Moore's law: enabling cost-friendly dimensional scaling

NASA Astrophysics Data System (ADS)

Mallik, Arindam; Ryckaert, Julien; Mercha, Abdelkarim; Verkest, Diederik; Ronse, Kurt; Thean, Aaron

2015-03-01

Moore's Law (Moore's Observation) has been driving the progress in semiconductor technology for the past 50 years. The semiconductor industry is at a juncture where significant increase in manufacturing cost is foreseen to sustain the past trend of dimensional scaling. At N10 and N7 technology nodes, the industry is struggling to find a cost-friendly solution. At a device level, technologists have come up with novel devices (finFET, Gate-All-Around), material innovations (SiGe, Ge) to boost performance and reduce power consumption. On the other hand, from the patterning side, the relative slow ramp-up of alternative lithography technologies like EUVL and DSA pushes the industry to adopt a severely multi-patterning-based solution. Both of these technological transformations have a big impact on die yield and eventually die cost. This paper is aimed to analyze the impact on manufacturing cost to keep the Moore's law alive. We have proposed and analyzed various patterning schemes that can enable cost-friendly scaling. We evaluated the impact of EUVL introduction on tackling the high cost of manufacturing. The primary objective of this paper is to maintain Moore's scaling from a patterning perspective and analyzing EUV lithography introduction at a die level.

Scalable fabrication of perovskite solar cells

DOE PAGES

Li, Zhen; Klein, Talysa R.; Kim, Dong Hoe; ...

2018-03-27

Perovskite materials use earth-abundant elements, have low formation energies for deposition and are compatible with roll-to-roll and other high-volume manufacturing techniques. These features make perovskite solar cells (PSCs) suitable for terawatt-scale energy production with low production costs and low capital expenditure. Demonstrations of performance comparable to that of other thin-film photovoltaics (PVs) and improvements in laboratory-scale cell stability have recently made scale up of this PV technology an intense area of research focus. Here, we review recent progress and challenges in scaling up PSCs and related efforts to enable the terawatt-scale manufacturing and deployment of this PV technology. We discussmore » common device and module architectures, scalable deposition methods and progress in the scalable deposition of perovskite and charge-transport layers. We also provide an overview of device and module stability, module-level characterization techniques and techno-economic analyses of perovskite PV modules.« less

DOE Office of Scientific and Technical Information (OSTI.GOV)

Li, Zhen; Klein, Talysa R.; Kim, Dong Hoe

Perovskite materials use earth-abundant elements, have low formation energies for deposition and are compatible with roll-to-roll and other high-volume manufacturing techniques. These features make perovskite solar cells (PSCs) suitable for terawatt-scale energy production with low production costs and low capital expenditure. Demonstrations of performance comparable to that of other thin-film photovoltaics (PVs) and improvements in laboratory-scale cell stability have recently made scale up of this PV technology an intense area of research focus. Here, we review recent progress and challenges in scaling up PSCs and related efforts to enable the terawatt-scale manufacturing and deployment of this PV technology. We discussmore » common device and module architectures, scalable deposition methods and progress in the scalable deposition of perovskite and charge-transport layers. We also provide an overview of device and module stability, module-level characterization techniques and techno-economic analyses of perovskite PV modules.« less

Design, manufacturing and characterization of aero-elastically scaled wind turbine blades for testing active and passive load alleviation techniques within a ABL wind tunnel

NASA Astrophysics Data System (ADS)

Campagnolo, Filippo; Bottasso, Carlo L.; Bettini, Paolo

2014-06-01

In the research described in this paper, a scaled wind turbine model featuring individual pitch control (IPC) capabilities, and equipped with aero-elastically scaled blades featuring passive load reduction capabilities (bend-twist coupling, BTC), was constructed to investigate, by means of wind tunnel testing, the load alleviation potential of BTC and its synergy with active load reduction techniques. The paper mainly focus on the design of the aero-elastic blades and their dynamic and static structural characterization. The experimental results highlight that manufactured blades show desired bend-twist coupling behavior and are a first milestone toward their testing in the wind tunnel.

Small Scale Turbopump Manufacturing Technology and Material Processes

NASA Technical Reports Server (NTRS)

Alvarez, Erika; Morgan, Kristin; Wells, Doug; Zimmerman, Frank

2011-01-01

As part of an internal research and development project, NASA Marshall Space Flight Center (MSFC) has been developing a high specific impulse 9,000-lbf LOX/LH2 pump-fed engine testbed with the capability to throttle 10:1. A Fuel Turbopump (FTP) with the ability to operate across a speed range of 30,000-rpm to 100,000-rpm was developed and analyzed. This small size and flight-like Fuel Turbopump has completed the design and analysis phase and is currently in the manufacturing phase. This paper highlights the manufacturing and processes efforts to fabricate an approximately 20-lb turbopump with small flow passages, intricately bladed components and approximately 3-in diameter impellers. As a result of the small scale and tight tolerances of the hardware on this turbopump, several unique manufacturing and material challenges were encountered. Some of the technologies highlighted in this paper include the use of powder metallurgy technology to manufacture small impellers, electron beam welding of a turbine blisk shroud, and casting challenges. The use of risk reduction efforts such as non-destructive testing (NDT) and evaluation (NDE), fractography, material testing, and component spin testing are also discussed in this paper.

Radiation Tests of Highly Scaled, High-Density, Commercial, Nonvolatile NAND Flash Memories - Update 2010

NASA Technical Reports Server (NTRS)

Irom, Farokh; Nguyen, Duc N.

2010-01-01

High-density, commercial, nonvolatile flash memories with NAND architecture are now available from several manufacturers. This report examines SEE effects and TID response in single-level cell (SLC) and multi-level cell (MLC) NAND flash memories manufactured by Micron Technology.

Source emission and model evaluation of formaldehyde from composite and solid wood furniture in a full-scale chamber

NASA Astrophysics Data System (ADS)

Liu, Xiaoyu; Mason, Mark A.; Guo, Zhishi; Krebs, Kenneth A.; Roache, Nancy F.

2015-12-01

This paper describes the measurement and model evaluation of formaldehyde source emissions from composite and solid wood furniture in a full-scale chamber at different ventilation rates for up to 4000 h using ASTM D 6670-01 (2007). Tests were performed on four types of furniture constructed of different materials and from different manufacturers. The data were used to evaluate two empirical emission models, i.e., a first-order and power-law decay model. The experimental results showed that some furniture tested in this study, made only of solid wood and with less surface area, had low formaldehyde source emissions. The effect of ventilation rate on formaldehyde emissions was also examined. Model simulation results indicated that the power-law decay model showed better agreement than the first-order decay model for the data collected from the tests, especially for long-term emissions. This research was limited to a laboratory study with only four types of furniture products tested. It was not intended to comprehensively test or compare the large number of furniture products available in the market place. Therefore, care should be taken when applying the test results to real-world scenarios. Also, it was beyond the scope of this study to link the emissions to human exposure and potential health risks.

Short communication: The effects of frozen storage on the survival of probiotic microorganisms found in traditionally and commercially manufactured kefir.

PubMed

O'Brien, K V; Aryana, K J; Prinyawiwatkul, W; Ordonez, K M Carabante; Boeneke, C A

2016-09-01

Kefir is a fermented milk traditionally made from a unique starter culture, which consists of numerous bacteria and yeast species bound together in an exopolysaccharide matrix produced by certain lactic acid bacteria. Many health benefits are associated with traditionally produced kefir; however, bulging and leaking packaging, caused by secondary yeast fermentation during storage, has limited large-scale manufacture. Commercial kefir products have been designed to reduce these effects by using a pure starter culture consisting of a mixture of bacteria and yeast species that give a flavor similar to traditional kefir, but some health benefits may be lost in commercial production due to reduced microbial diversity and lack of beneficial exopolysaccharides. In this study, traditional and commercial kefir was frozen to study the effects of frozen storage on the viability of probiotic bacteria over time. Traditional kefir was prepared by inoculating 1L of pasteurized whole goat milk with approximately 30g of kefir grains. Commercial kefir was prepared by inoculating 1L of full-fat, pasteurized goat milk with a commercial kefir starter. The milk was allowed to ferment at room temperature (24-28°C) until pH 4.6 was reached. Samples were frozen (-8 to -14°C) immediately following the completion of fermentation and were thawed and plated for lactobacilli, lactococci, and yeasts on d 0, 7, 14, and 30 of frozen storage. Lactobacilli, lactococci, and yeasts were significantly reduced in number during frozen storage; however, the traditionally produced kefir was shown to have significantly higher counts of bacteria and yeast at each sampling. We concluded that frozen storage and the development of frozen kefir products could eliminate most packaging concerns associated with the large-scale manufacture of traditionally produced kefir, resulting in increased production and marketability of this healthful product. Copyright © 2016 American Dairy Science Association. Published by Elsevier Inc. All rights reserved.

Capacity planning for batch and perfusion bioprocesses across multiple biopharmaceutical facilities.

PubMed

Siganporia, Cyrus C; Ghosh, Soumitra; Daszkowski, Thomas; Papageorgiou, Lazaros G; Farid, Suzanne S

2014-01-01

Production planning for biopharmaceutical portfolios becomes more complex when products switch between fed-batch and continuous perfusion culture processes. This article describes the development of a discrete-time mixed integer linear programming (MILP) model to optimize capacity plans for multiple biopharmaceutical products, with either batch or perfusion bioprocesses, across multiple facilities to meet quarterly demands. The model comprised specific features to account for products with fed-batch or perfusion culture processes such as sequence-dependent changeover times, continuous culture constraints, and decoupled upstream and downstream operations that permit independent scheduling of each. Strategic inventory levels were accounted for by applying cost penalties when they were not met. A rolling time horizon methodology was utilized in conjunction with the MILP model and was shown to obtain solutions with greater optimality in less computational time than the full-scale model. The model was applied to an industrial case study to illustrate how the framework aids decisions regarding outsourcing capacity to third party manufacturers or building new facilities. The impact of variations on key parameters such as demand or titres on the optimal production plans and costs was captured. The analysis identified the critical ratio of in-house to contract manufacturing organization (CMO) manufacturing costs that led the optimization results to favor building a future facility over using a CMO. The tool predicted that if titres were higher than expected then the optimal solution would allocate more production to in-house facilities, where manufacturing costs were lower. Utilization graphs indicated when capacity expansion should be considered. © 2014 The Authors Biotechnology Progress published by Wiley Periodicals, Inc. on behalf of American Institute of Chemical Engineers.

Capacity Planning for Batch and Perfusion Bioprocesses Across Multiple Biopharmaceutical Facilities

PubMed Central

Siganporia, Cyrus C; Ghosh, Soumitra; Daszkowski, Thomas; Papageorgiou, Lazaros G; Farid, Suzanne S

2014-01-01

Production planning for biopharmaceutical portfolios becomes more complex when products switch between fed-batch and continuous perfusion culture processes. This article describes the development of a discrete-time mixed integer linear programming (MILP) model to optimize capacity plans for multiple biopharmaceutical products, with either batch or perfusion bioprocesses, across multiple facilities to meet quarterly demands. The model comprised specific features to account for products with fed-batch or perfusion culture processes such as sequence-dependent changeover times, continuous culture constraints, and decoupled upstream and downstream operations that permit independent scheduling of each. Strategic inventory levels were accounted for by applying cost penalties when they were not met. A rolling time horizon methodology was utilized in conjunction with the MILP model and was shown to obtain solutions with greater optimality in less computational time than the full-scale model. The model was applied to an industrial case study to illustrate how the framework aids decisions regarding outsourcing capacity to third party manufacturers or building new facilities. The impact of variations on key parameters such as demand or titres on the optimal production plans and costs was captured. The analysis identified the critical ratio of in-house to contract manufacturing organization (CMO) manufacturing costs that led the optimization results to favor building a future facility over using a CMO. The tool predicted that if titres were higher than expected then the optimal solution would allocate more production to in-house facilities, where manufacturing costs were lower. Utilization graphs indicated when capacity expansion should be considered. © 2013 The Authors Biotechnology Progress published by Wiley Periodicals, Inc. on behalf of American Institute of Chemical Engineers Biotechnol. Prog., 30:594–606, 2014 PMID:24376262

Development and Hotfire Testing of Additively Manufactured Copper Combustion Chambers for Liquid Rocket Engine Applications

NASA Technical Reports Server (NTRS)

Gradl, Paul R.; Greene, Sandy; Protz, Chris

2017-01-01

NASA and industry partners are working towards fabrication process development to reduce costs and schedules associated with manufacturing liquid rocket engine components with the goal of reducing overall mission costs. One such technique being evaluated is powder-bed fusion or selective laser melting (SLM), commonly referred to as additive manufacturing (AM). The NASA Low Cost Upper Stage Propulsion (LCUSP) program was designed to develop processes and material characterization for GRCop-84 (a NASA Glenn Research Center-developed copper, chrome, niobium alloy) commensurate with powder bed AM, evaluate bimetallic deposition, and complete testing of a full scale combustion chamber. As part of this development, the process has been transferred to industry partners to enable a long-term supply chain of monolithic copper combustion chambers. To advance the processes further and allow for optimization with multiple materials, NASA is also investigating the feasibility of bimetallic AM chambers. In addition to the LCUSP program, NASA’s Marshall Space Flight Center (MSFC) has completed a series of development programs and hot-fire tests to demonstrate SLM GRCop-84 and other AM techniques. MSFC’s efforts include a 4,000 pounds-force thrust liquid oxygen/methane (LOX/CH4) combustion chamber. Small thrust chambers for 1,200 pounds-force LOX/hydrogen (H2) applications have also been designed and fabricated with SLM GRCop-84. Similar chambers have also completed development with an Inconel 625 jacket bonded to the GRCop-84 material, evaluating direct metal deposition (DMD) laser- and arc-based techniques. The same technologies for these lower thrust applications are being applied to 25,000-35,000 pounds-force main combustion chamber (MCC) designs. This paper describes the design, development, manufacturing and testing of these numerous combustion chambers, and the associated lessons learned throughout their design and development processes.

Total quality through computer integrated manufacturing in the pharmaceutical industry.

PubMed

Ufret, C M

1995-01-01

The role of Computer Integrated Manufacturing (CIM) in the pursue of total quality in pharmaceutical manufacturing is assessed. CIM key objectives, design criteria, and performance measurements, in addition to its scope and implementation in a hierarchical structure, are explored in detail. Key elements for the success of each phase in a CIM project and a brief status of current CIM implementations in the pharmaceutical industry are presented. The role of World Class Manufacturing performance standards and other key issues to achieve full CIM benefits are also addressed.

A practical and scalable manufacturing process for an anti-fungal agent, Nikkomycin Z.

PubMed

Stenland, Christopher J; Lis, Lev G; Schendel, Frederick J; Hahn, Nicholas J; Smart, Mary A; Miller, Amy L; von Keitz, Marc G; Gurvich, Vadim J

2013-02-15

A scalable and reliable manufacturing process for Nikkomycin Z HCl on a 170 g scale has been developed and optimized. The process is characterized by a 2.3 g/L fermentation yield, 79% purification yield, and >98% relative purity of the final product. This method is suitable for further scale up and cGMP production. The Streptomyces tendae ΔNikQ strain developed during the course of this study is superior to any previously reported strain in terms of higher yield and purity of Nikkomycin Z.

Silicone elastomers capable of large isotropic dimensional change

DOEpatents

Lewicki, James; Worsley, Marcus A.

2017-07-18

Described herein is a highly effective route towards the controlled and isotropic reduction in size-scale, of complex 3D structures using silicone network polymer chemistry. In particular, a class of silicone structures were developed that once patterned and cured can `shrink` micron scale additive manufactured and lithographically patterned structures by as much as 1 order of magnitude while preserving the dimensions and integrity of these parts. This class of silicone materials is compatible with existing additive manufacture and soft lithographic fabrication processes and will allow access to a hitherto unobtainable dimensionality of fabrication.

Microchannel Reactor System for Catalytic Hydrogenation

DOE Office of Scientific and Technical Information (OSTI.GOV)

Adeniyi Lawal; Woo Lee; Ron Besser

2010-12-22

We successfully demonstrated a novel process intensification concept enabled by the development of microchannel reactors, for energy efficient catalytic hydrogenation reactions at moderate temperature, and pressure, and low solvent levels. We designed, fabricated, evaluated, and optimized a laboratory-scale microchannel reactor system for hydrogenation of onitroanisole and a proprietary BMS molecule. In the second phase of the program, as a prelude to full-scale commercialization, we designed and developed a fully-automated skid-mounted multichannel microreactor pilot plant system for multiphase reactions. The system is capable of processing 1 – 10 kg/h of liquid substrate, and an industrially relevant immiscible liquid-liquid was successfully demonstratedmore » on the system. Our microreactor-based pilot plant is one-of-akind. We anticipate that this process intensification concept, if successfully demonstrated, will provide a paradigm-changing basis for replacing existing energy inefficient, cost ineffective, environmentally detrimental slurry semi-batch reactor-based manufacturing practiced in the pharmaceutical and fine chemicals industries.« less

Modular Engine Noise Component Prediction System (MCP) Program Users' Guide

NASA Technical Reports Server (NTRS)

Golub, Robert A. (Technical Monitor); Herkes, William H.; Reed, David H.

2004-01-01

This is a user's manual for Modular Engine Noise Component Prediction System (MCP). This computer code allows the user to predict turbofan engine noise estimates. The program is based on an empirical procedure that has evolved over many years at The Boeing Company. The data used to develop the procedure include both full-scale engine data and small-scale model data, and include testing done by Boeing, by the engine manufacturers, and by NASA. In order to generate a noise estimate, the user specifies the appropriate engine properties (including both geometry and performance parameters), the microphone locations, the atmospheric conditions, and certain data processing options. The version of the program described here allows the user to predict three components: inlet-radiated fan noise, aft-radiated fan noise, and jet noise. MCP predicts one-third octave band noise levels over the frequency range of 50 to 10,000 Hertz. It also calculates overall sound pressure levels and certain subjective noise metrics (e.g., perceived noise levels).

7 CFR 3430.702 - Definitions.

Code of Federal Regulations, 2013 CFR

2013-01-01

... original manufacturing process (42 U.S.C. 6903 (19)). Recycling means the series of activities, including... process flow diagrams and mass and energy balances for the purposes of scaling up to a demonstration scale...

7 CFR 3430.702 - Definitions.

Code of Federal Regulations, 2014 CFR

2014-01-01

... original manufacturing process (42 U.S.C. 6903 (19)). Recycling means the series of activities, including... process flow diagrams and mass and energy balances for the purposes of scaling up to a demonstration scale...

7 CFR 3430.702 - Definitions.

Code of Federal Regulations, 2012 CFR

2012-01-01

... original manufacturing process (42 U.S.C. 6903 (19)). Recycling means the series of activities, including... process flow diagrams and mass and energy balances for the purposes of scaling up to a demonstration scale...

Optimization of a micro-scale, high throughput process development tool and the demonstration of comparable process performance and product quality with biopharmaceutical manufacturing processes.

PubMed

Evans, Steven T; Stewart, Kevin D; Afdahl, Chris; Patel, Rohan; Newell, Kelcy J

2017-07-14

In this paper, we discuss the optimization and implementation of a high throughput process development (HTPD) tool that utilizes commercially available micro-liter sized column technology for the purification of multiple clinically significant monoclonal antibodies. Chromatographic profiles generated using this optimized tool are shown to overlay with comparable profiles from the conventional bench-scale and clinical manufacturing scale. Further, all product quality attributes measured are comparable across scales for the mAb purifications. In addition to supporting chromatography process development efforts (e.g., optimization screening), comparable product quality results at all scales makes this tool is an appropriate scale model to enable purification and product quality comparisons of HTPD bioreactors conditions. The ability to perform up to 8 chromatography purifications in parallel with reduced material requirements per run creates opportunities for gathering more process knowledge in less time. Copyright © 2017 The Authors. Published by Elsevier B.V. All rights reserved.

Engineering the Future: Cell 6

NASA Technical Reports Server (NTRS)

Stahl, P. H.

2010-01-01

This slide presentation reviews the development of the James Webb Space Telescope (JWST), explaining the development using a systems engineering methodology. Included are slides showing the organizational chart, the JWST Science Goals, the size of the primary mirror, and full scale mockups of the JSWT. Also included is a review of the JWST Optical Telescope Requirements, a review of the preliminary design and analysis, the technology development required to create the JWST, with particular interest in the specific mirror technology that was required, and views of the mirror manufacturing process. Several slides review the process of verification and validation by testing and analysis, including a diagram of the Cryogenic Test Facility at Marshall, and views of the primary mirror while being tested in the cryogenic facility.

Coater/developer based techniques to improve high-resolution EUV patterning defectivity

NASA Astrophysics Data System (ADS)

Hontake, Koichi; Huli, Lior; Lemley, Corey; Hetzer, Dave; Liu, Eric; Ko, Akiteru; Kawakami, Shinichiro; Shimoaoki, Takeshi; Hashimoto, Yusaku; Tanaka, Koichiro; Petrillo, Karen; Meli, Luciana; De Silva, Anuja; Xu, Yongan; Felix, Nelson; Johnson, Richard; Murray, Cody; Hubbard, Alex

2017-10-01

Extreme ultraviolet lithography (EUVL) technology is one of the leading candidates under consideration for enabling the next generation of devices, for 7nm node and beyond. As the focus shifts to driving down the 'effective' k1 factor and enabling the full scaling entitlement of EUV patterning, new techniques and methods must be developed to reduce the overall defectivity, mitigate pattern collapse, and eliminate film-related defects. In addition, CD uniformity and LWR/LER must be improved in terms of patterning performance. Tokyo Electron Limited (TEL™) and IBM Corporation are continuously developing manufacturing quality processes for EUV. In this paper, we review the ongoing progress in coater/developer based processes (coating, developing, baking) that are required to enable EUV patterning.

Radiation Tests of Highly scaled, High-Density, Commercial, Nonvolatile NAND Flash Memories--Update 2011

NASA Technical Reports Server (NTRS)

Irom, Farokh; Nguyen, Duc N.

2011-01-01

High-density, commercial, nonvolatile flash memories with NAND architecture are now available from several manufacturers. This report examines SEE effects and TID response in single-level cell (SLC) 32Gb and multi-level cell (MLC) 64Gb NAND flash memories manufactured by Micron Technology.

Improved Large Aperture Collector Manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

O'Rourke, Deven; Farr, Adrian

2015-12-01

The parabolic trough is the most established CSP technology and carries a long history of design experimentation dating back to the 1970’s. This has led to relatively standardized collector architectures, a maturing global supply chain, and a fairly uniform cost reduction strategy. Abengoa has deployed more than 1,500MWe of CSP troughs across several countries and has built and tested full-scale prototypes of many R&D concepts. The latest trough R&D efforts involved efforts to internalize non-CSP industry experience including a preliminary DFMA principles review done with Boothroyd Dewhurst, a construction literature review by the Arizona State University School of Construction Management,more » and two more focused manufacturing engineering subcontracts done by Ricardo Inc. and the nonprofit Edison Welding Institute. The first two studies highlighted strong opportunities in lowering part count, standardizing components and fasteners, developing modular designs to support prefabrication and automation, and devising simple, error-proof manual assembly methods. These principles have delivered major new cost savings in otherwise “mature” products in analogous industries like automotive, truck trailer manufacture, metal building fabrication, and shipbuilding. For this reason, they were core in the design development of the SpaceTube® collector, and arguably key to its early successes. The latter two studies were applied specifically to the first-generation SpaceTube® design and were important in setting the direction of the present SolarMat project. These studies developed a methodology to analyze the costs of manufacture and assembly, and identify new tooling concepts for more efficient manufacture. Among the main opportunities identified in these studies were the automated mirror arm manufacturing concept and the need for a less infrastructure-intensive assembly line, both of which now form central pillars of the SolarMat project strategy. These new designs will be supported by new technology in the area of quality control inspection, in which state of the art photogrammetry and laser CMM inspection methods will be used to qualify parts and assemblies, and in which the recently-developed Absorber Reflection Method will enable in-line quality control inspection of modules produced by the new high-rate production line.« less

Industrializing Autologous Adoptive Immunotherapies: Manufacturing Advances and Challenges

PubMed Central

Iyer, Rohin K.; Bowles, Paul A.; Kim, Howard; Dulgar-Tulloch, Aaron

2018-01-01

Cell therapy has proven to be a burgeoning field of investigation, evidenced by hundreds of clinical trials being conducted worldwide across a variety of cell types and indications. Many cell therapies have been shown to be efficacious in humans, such as modified T-cells and natural killer (NK) cells. Adoptive immunotherapy has shown the most promise in recent years, with particular emphasis on autologous cell sources. Chimeric Antigen Receptor (CAR)-based T-cell therapy targeting CD19-expressing B-cell leukemias has shown remarkable efficacy and reproducibility in numerous clinical trials. Recent marketing approval of Novartis' Kymriah™ (tisagenlecleucel) and Gilead/Kite's Yescarta™ (axicabtagene ciloleucel) by the FDA further underscores both the promise and legwork to be done if manufacturing processes are to become widely accessible. Further work is needed to standardize, automate, close, and scale production to bring down costs and democratize these and other cell therapies. Given the multiple processing steps involved, commercial-scale manufacturing of these therapies necessitates tighter control over process parameters. This focused review highlights some of the most recent advances used in the manufacturing of therapeutic immune cells, with a focus on T-cells. We summarize key unit operations and pain points around current manufacturing solutions. We also review emerging technologies, approaches and reagents used in cell isolation, activation, transduction, expansion, in-process analytics, harvest, cryopreservation and thaw, and conclude with a forward-look at future directions in the manufacture of adoptive immunotherapies.

Industrializing Autologous Adoptive Immunotherapies: Manufacturing Advances and Challenges.

PubMed

Iyer, Rohin K; Bowles, Paul A; Kim, Howard; Dulgar-Tulloch, Aaron

2018-01-01

Cell therapy has proven to be a burgeoning field of investigation, evidenced by hundreds of clinical trials being conducted worldwide across a variety of cell types and indications. Many cell therapies have been shown to be efficacious in humans, such as modified T-cells and natural killer (NK) cells. Adoptive immunotherapy has shown the most promise in recent years, with particular emphasis on autologous cell sources. Chimeric Antigen Receptor (CAR)-based T-cell therapy targeting CD19-expressing B-cell leukemias has shown remarkable efficacy and reproducibility in numerous clinical trials. Recent marketing approval of Novartis' Kymriah™ (tisagenlecleucel) and Gilead/Kite's Yescarta™ (axicabtagene ciloleucel) by the FDA further underscores both the promise and legwork to be done if manufacturing processes are to become widely accessible. Further work is needed to standardize, automate, close, and scale production to bring down costs and democratize these and other cell therapies. Given the multiple processing steps involved, commercial-scale manufacturing of these therapies necessitates tighter control over process parameters. This focused review highlights some of the most recent advances used in the manufacturing of therapeutic immune cells, with a focus on T-cells. We summarize key unit operations and pain points around current manufacturing solutions. We also review emerging technologies, approaches and reagents used in cell isolation, activation, transduction, expansion, in-process analytics, harvest, cryopreservation and thaw, and conclude with a forward-look at future directions in the manufacture of adoptive immunotherapies.

Review of the Need for a Large-scale Test Facility for Research on the Effects of Extreme Winds on Structures

DOE Office of Scientific and Technical Information (OSTI.GOV)

R. G. Little

1999-03-01

The Idaho National Engineering and Environmental Laboratory (INEEL), through the US Department of Energy (DOE), has proposed that a large-scale wind test facility (LSWTF) be constructed to study, in full-scale, the behavior of low-rise structures under simulated extreme wind conditions. To determine the need for, and potential benefits of, such a facility, the Idaho Operations Office of the DOE requested that the National Research Council (NRC) perform an independent assessment of the role and potential value of an LSWTF in the overall context of wind engineering research. The NRC established the Committee to Review the Need for a Large-scale Testmore » Facility for Research on the Effects of Extreme Winds on Structures, under the auspices of the Board on Infrastructure and the Constructed Environment, to perform this assessment. This report conveys the results of the committee's deliberations as well as its findings and recommendations. Data developed at large-scale would enhanced the understanding of how structures, particularly light-frame structures, are affected by extreme winds (e.g., hurricanes, tornadoes, sever thunderstorms, and other events). With a large-scale wind test facility, full-sized structures, such as site-built or manufactured housing and small commercial or industrial buildings, could be tested under a range of wind conditions in a controlled, repeatable environment. At this time, the US has no facility specifically constructed for this purpose. During the course of this study, the committee was confronted by three difficult questions: (1) does the lack of a facility equate to a need for the facility? (2) is need alone sufficient justification for the construction of a facility? and (3) would the benefits derived from information produced in an LSWTF justify the costs of producing that information? The committee's evaluation of the need and justification for an LSWTF was shaped by these realities.« less

40 CFR 86.010-38 - Maintenance instructions.

Code of Federal Regulations, 2011 CFR

2011-07-01

..., excluding any research and development costs incurred in designing and implementing, upgrading or altering... months lead time to meet this requirement. Each manufacturer Web site shall: (i) Provide access in full... same time as manufacturer-franchised dealership World Wide Web sites; (iii) Provide users with a...

40 CFR 86.010-38 - Maintenance instructions.

Code of Federal Regulations, 2010 CFR

2010-07-01

..., excluding any research and development costs incurred in designing and implementing, upgrading or altering... months lead time to meet this requirement. Each manufacturer Web site shall: (i) Provide access in full... same time as manufacturer-franchised dealership World Wide Web sites; (iii) Provide users with a...

40 CFR 86.010-38 - Maintenance instructions.

Code of Federal Regulations, 2013 CFR

2013-07-01

..., excluding any research and development costs incurred in designing and implementing, upgrading or altering... months lead time to meet this requirement. Each manufacturer Web site shall: (i) Provide access in full... same time as manufacturer-franchised dealership World Wide Web sites; (iii) Provide users with a...

40 CFR 86.010-38 - Maintenance instructions.

Code of Federal Regulations, 2012 CFR

2012-07-01

..., excluding any research and development costs incurred in designing and implementing, upgrading or altering... months lead time to meet this requirement. Each manufacturer Web site shall: (i) Provide access in full... same time as manufacturer-franchised dealership World Wide Web sites; (iii) Provide users with a...

March 2017 Grenada Manufacturing, LLC Data Validation Reports and Analytical Laboratory Reports for the Main Plant Building Vapor Intrusion Sampling

EPA Pesticide Factsheets

Data Validation Reports and Full Analytical Lab Reports for Indoor Air, Ambient Air and Sub-slab samples taken during the facility vapor intrusion investigation in March 2017 at the Grenada Manufacturing plant

Aerosol based direct-write micro-additive fabrication method for sub-mm 3D metal-dielectric structures

NASA Astrophysics Data System (ADS)

Rahman, Taibur; Renaud, Luke; Heo, Deuk; Renn, Michael; Panat, Rahul

2015-10-01

The fabrication of 3D metal-dielectric structures at sub-mm length scale is highly important in order to realize low-loss passives and GHz wavelength antennas with applications in wearable and Internet-of-Things (IoT) devices. The inherent 2D nature of lithographic processes severely limits the available manufacturing routes to fabricate 3D structures. Further, the lithographic processes are subtractive and require the use of environmentally harmful chemicals. In this letter, we demonstrate an additive manufacturing method to fabricate 3D metal-dielectric structures at sub-mm length scale. A UV curable dielectric is dispensed from an Aerosol Jet system at 10-100 µm length scale and instantaneously cured to build complex 3D shapes at a length scale  <1 mm. A metal nanoparticle ink is then dispensed over the 3D dielectric using a combination of jetting action and tilted dispense head, also using the Aerosol Jet technique and at a length scale 10-100 µm, followed by the nanoparticle sintering. Simulation studies are carried out to demonstrate the feasibility of using such structures as mm-wave antennas. The manufacturing method described in this letter opens up the possibility of fabricating an entirely new class of custom-shaped 3D structures at a sub-mm length scale with potential applications in 3D antennas and passives.

Custom hip prostheses by integrating CAD and casting technology

NASA Astrophysics Data System (ADS)

Silva, Pedro F.; Leal, Nuno; Neto, Rui J.; Lino, F. Jorge; Reis, Ana

2012-09-01

Total Hip Arthroplasty (THA) is a surgical intervention that is being achieving high rates of success, leaving room to research on long run durability, patient comfort and costs reduction. Even so, up to the present, little research has been done to improve the method of manufacturing customized prosthesis. The common customized prostheses are made by full machining. This document presents a different approach methodology which combines the study of medical images, through CAD (Computer Aided Design) software, SLadditive manufacturing, ceramic shell manufacture, precision foundry with Titanium alloys and Computer Aided Manufacturing (CAM). The goal is to achieve the best comfort for the patient, stress distribution and the maximum lifetime of the prosthesis produced by this integrated methodology. The way to achieve this desiderate is to make custom hip prosthesis which are adapted to each patient needs and natural physiognomy. Not only the process is reliable, but also represents a cost reduction comparing to the conventional full machined custom hip prosthesis.

Fabrication and testing of the first 8.4-m off-axis segment for the Giant Magellan Telescope

NASA Astrophysics Data System (ADS)

Martin, H. M.; Allen, R. G.; Burge, J. H.; Kim, D. W.; Kingsley, J. S.; Tuell, M. T.; West, S. C.; Zhao, C.; Zobrist, T.

2010-07-01

The primary mirror of the Giant Magellan Telescope consists of seven 8.4 m segments which are borosilicate honeycomb sandwich mirrors. Fabrication and testing of the off-axis segments is challenging and has led to a number of innovations in manufacturing technology. The polishing system includes an actively stressed lap that follows the shape of the aspheric surface, used for large-scale figuring and smoothing, and a passive "rigid conformal lap" for small-scale figuring and smoothing. Four independent measurement systems support all stages of fabrication and provide redundant measurements of all critical parameters including mirror figure, radius of curvature, off-axis distance and clocking. The first measurement uses a laser tracker to scan the surface, with external references to compensate for rigid body displacements and refractive index variations. The main optical test is a full-aperture interferometric measurement, but it requires an asymmetric null corrector with three elements, including a 3.75 m mirror and a computer-generated hologram, to compensate for the surface's 14 mm departure from the best-fit sphere. Two additional optical tests measure large-scale and small-scale structure, with some overlap. Together these measurements provide high confidence that the segments meet all requirements.

Directing Matter: Toward Atomic-Scale 3D Nanofabrication.

PubMed

Jesse, Stephen; Borisevich, Albina Y; Fowlkes, Jason D; Lupini, Andrew R; Rack, Philip D; Unocic, Raymond R; Sumpter, Bobby G; Kalinin, Sergei V; Belianinov, Alex; Ovchinnikova, Olga S

2016-06-28

Enabling memristive, neuromorphic, and quantum-based computing as well as efficient mainstream energy storage and conversion technologies requires the next generation of materials customized at the atomic scale. This requires full control of atomic arrangement and bonding in three dimensions. The last two decades witnessed substantial industrial, academic, and government research efforts directed toward this goal through various lithographies and scanning-probe-based methods. These technologies emphasize 2D surface structures, with some limited 3D capability. Recently, a range of focused electron- and ion-based methods have demonstrated compelling alternative pathways to achieving atomically precise manufacturing of 3D structures in solids, liquids, and at interfaces. Electron and ion microscopies offer a platform that can simultaneously observe dynamic and static structures at the nano- and atomic scales and also induce structural rearrangements and chemical transformation. The addition of predictive modeling or rapid image analytics and feedback enables guiding these in a controlled manner. Here, we review the recent results that used focused electron and ion beams to create free-standing nanoscale 3D structures, radiolysis, and the fabrication potential with liquid precursors, epitaxial crystallization of amorphous oxides with atomic layer precision, as well as visualization and control of individual dopant motion within a 3D crystal lattice. These works lay the foundation for approaches to directing nanoscale level architectures and offer a potential roadmap to full 3D atomic control in materials. In this paper, we lay out the gaps that currently constrain the processing range of these platforms, reflect on indirect requirements, such as the integration of large-scale data analysis with theory, and discuss future prospects of these technologies.

Directing Matter: Toward Atomic-Scale 3D Nanofabrication

DOE PAGES

Jesse, Stephen; Borisevich, Albina Y.; Fowlkes, Jason D.; ...

2016-05-16

Here we report that enabling memristive, neuromorphic, and quantum based computing as well as efficient mainstream energy storage and conversion technologies requires next generation of materials customized at the atomic scale. This requires full control of atomic arrangement and bonding in three dimensions. The last two decades witnessed substantial industrial, academic, and government research efforts directed towards this goal through various lithographies and scanning probe based methods. These technologies emphasize 2D surface structures, with some limited 3D capability. Recently, a range of focused electron and ion based methods have demonstrated compelling alternative pathways to achieving atomically precise manufacturing of 3Dmore » structures in solids, liquids, and at interfaces. Electron and ion microscopies offer a platform that can simultaneously observe dynamic and static structures at the nano and atomic scales, and also induce structural rearrangements and chemical transformation. The addition of predictive modeling or rapid image analytics and feedback enables guiding these in a controlled manner. Here, we review the recent results that used focused electron and ion beams to create free-standing nanoscale 3D structures, radiolysis and the fabrication potential with liquid precursors, epitaxial crystallization of amorphous oxides with atomic layer precision, as well as visualization and control of individual dopant motion within a 3D crystal lattice. These works lay the foundation for new approaches to directing nanoscale level architectures and offer a potential roadmap to full 3D atomic control in materials. Lastly, in this perspective we lay out the gaps that currently constrain the processing range of these platforms, reflect on indirect requirements, such as the integration of large scale data analysis with theory, and discuss future prospects of these technologies.« less

MATERIALS DEGRADATION ANALYSIS AND DEVELOPMENT TO ENABLE ULTRA LOW COST, WEB-PROCESSED WHITE P-OLED FOR SSL

DOE Office of Scientific and Technical Information (OSTI.GOV)

DR. DEVIN MACKENZIE

2011-12-13

Progress over Phase II of DE-FG02-07ER86293 'Materials Degradation Analysis and Development to Enable Ultra Low Cost, Web-Processed White P-OLED for SSL' was initially rapid in terms of device performance improvements. We exceeded our device luminance lifetime goals for printed flexible white OLEDs as laid out in our project proposal. Our Phase II performance target was to demonstrate >1500 hours luminance lifetime at 100 Cd/m2 from a printed flexible device. We now have R&D devices well in excess of 8000 hrs lifetime at 100 Cd/m2, tested in air. We also were able to produce devices which met the voltage target ofmore » >1500 hours below 15V operation. After completing the initial performance milestones, we went on to focus on color-related degradation issues which were cited as important to commercialization of the technology by our manufacturing partners. We also put additional focus on cathode work as the active material development that occurred over the STTR time period required an adaptation of the cathode from the original cathode formulations which were developed based on previous generation active layer materials. We were able to improve compatibility of the cathode with some of the newer generation active layer materials and improve device yield and voltage behavior. An additional objective of the initial Phase II was to further develop the underlying manufacturing technology and real-life product specifications. This is a key requirement that must be met to ensure eventual commercialization of this DOE-funded technology. The link between commercial investment for full commercialization and R&D efforts in OLED solid State Lighting is often a large one. Add-Vision's lower cost, printed OLED manufacturing approach is an attraction, but close engagement with manufacturing partners and addressing customer specifications is a very important link. Manufacturing technology encompasses development of moisture reduction encapsulation technology, improved cost performance, and reductions in operating voltage through thinner and higher uniformity active device layers. We have now installed a pilot encapsulation system at AVI for controlled, high throughput lamination encapsulation of flexible OLEDs in a novel process. Along with this, we have developed, with our materials supply partners, adhesives, barrier films and other encapsulation materials and we are showing total air product lifetimes in the 2-4 years range from a process consistent with our throughput goals of {approx}1M device per month ({approx}30,000 sq. ft. of processed OLEDs). Within the last year of the project, we have been working to introduce the manufacturing improvements made in our LEP deposition and annealing process to our commercial partners. Based on the success of this, a pilot scale-up program was begun. During this process, Add-Vision was acquired by a strategic partner, in no small part, because of the promise of future success of the technology as evidenced by our commercial partners pilot scale-up plans. Overall, the performance, manufacturing and product work in this project has been successful. Additional analysis and device work at LBL has also shown a unique adhesion change with device bias stressing which may result from active layer polymer cross-linking during bias stressing of device. It was shown that even small bias stresses, as a fraction of a full device lifetime stress period, result in measurable chemical change in the device. Further work needs to be conducted to fully understand the chemical nature of this interaction. Elucidation of this effect would enable doped OLED formulation to be engineered to suppress this effect and further extend lifetimes and reduce voltage climb.« less

The HSOB GAIA: a cryogenic high stability cesic optical bench for missions requiring sub-nanometric optical stability

NASA Astrophysics Data System (ADS)

Courteau, Pascal; Poupinet, Anne; Kroedel, Mathias; Sarri, Giuseppe

2017-11-01

Global astrometry, very demanding in term of stability, requires extremely stable material for optical bench. CeSiC developed by ECM and Alcatel Alenia Space for mirrors and high stability structures, offers the best compromise in term of structural strength, stability and very high lightweight capability, with characteristics leading to be insensitive to thermo-elastic at cryogenic T°. The HSOB GAIA study realised by Alcatel Alenia Space under ESA contract aimed to design, develop and test a full scale representative High Stability Optical Bench in CeSiC. The bench has been equipped with SAGEIS-CSO laser metrology system MOUSE1, Michelson interferometer composed of integrated optics with a nm resolution. The HSOB bench has been submitted to an homogeneous T° step under vacuum to characterise the homothetic behaviour of its two arms. The quite negligible inter-arms differential measured with a nm range reproducibility, demonstrates that a complete 3D structure in CeSiC has the same CTE homogeneity as characterisation samples, fully in line with the GAIA need (1pm at 120K). This participates to the demonstration that CeSiC properties at cryogenic T° is fully appropriate to the manufacturing of complex highly stable optical structures. This successful study confirms ECM and Alcatel Alenia Space ability to define and manufacture monolithic lightweight highly stable optical structures, based on inner cells triangular design made only possible by the unique CeSiC manufacturing process.

Design Process of Flight Vehicle Structures for a Common Bulkhead and an MPCV Spacecraft Adapter

NASA Technical Reports Server (NTRS)

Aggarwal, Pravin; Hull, Patrick V.

2015-01-01

Design and manufacturing space flight vehicle structures is a skillset that has grown considerably at NASA during that last several years. Beginning with the Ares program and followed by the Space Launch System (SLS); in-house designs were produced for both the Upper Stage and the SLS Multipurpose crew vehicle (MPCV) spacecraft adapter. Specifically, critical design review (CDR) level analysis and flight production drawing were produced for the above mentioned hardware. In particular, the experience of this in-house design work led to increased manufacturing infrastructure for both Marshal Space Flight Center (MSFC) and Michoud Assembly Facility (MAF), improved skillsets in both analysis and design, and hands on experience in building and testing (MSA) full scale hardware. The hardware design and development processes from initiation to CDR and finally flight; resulted in many challenges and experiences that produced valuable lessons. This paper builds on these experiences of NASA in recent years on designing and fabricating flight hardware and examines the design/development processes used, as well as the challenges and lessons learned, i.e. from the initial design, loads estimation and mass constraints to structural optimization/affordability to release of production drawing to hardware manufacturing. While there are many documented design processes which a design engineer can follow, these unique experiences can offer insight into designing hardware in current program environments and present solutions to many of the challenges experienced by the engineering team.

Towards a commercial process for the manufacture of genetically modified T cells for therapy

PubMed Central

Kaiser, A D; Assenmacher, M; Schröder, B; Meyer, M; Orentas, R; Bethke, U; Dropulic, B

2015-01-01

The recent successes of adoptive T-cell immunotherapy for the treatment of hematologic malignancies have highlighted the need for manufacturing processes that are robust and scalable for product commercialization. Here we review some of the more outstanding issues surrounding commercial scale manufacturing of personalized-adoptive T-cell medicinal products. These include closed system operations, improving process robustness and simplifying work flows, reducing labor intensity by implementing process automation, scalability and cost, as well as appropriate testing and tracking of products, all while maintaining strict adherence to Current Good Manufacturing Practices and regulatory guidelines. A decentralized manufacturing model is proposed, where in the future patients' cells could be processed at the point-of-care in the hospital. PMID:25613483

50 CFR 680.23 - Equipment and operational requirements.

Code of Federal Regulations, 2011 CFR

2011-10-01

... (882 lb) of crab or an alternative material supplied by the scale manufacturer on the scale under test... bottom of the hopper unless an alternative testing method is approved by NMFS. The MPE for the daily at... delivery. The scale operator may write this information on the scale printout in ink at the time of landing...

Achieving a Successful Scale-Down Model and Optimized Economics through Parvovirus Filter Validation using Purified TrueSpikeTM Viruses.

PubMed

De Vilmorin, Philippe; Slocum, Ashley; Jaber, Tareq; Schaefer, Oliver; Ruppach, Horst; Genest, Paul

2015-01-01

This article describes a four virus panel validation of EMD Millipore's (Bedford, MA) small virus-retentive filter, Viresolve® Pro, using TrueSpike(TM) viruses for a Biogen Idec process intermediate. The study was performed at Charles River Labs in King of Prussia, PA. Greater than 900 L/m(2) filter throughput was achieved with the approximately 8 g/L monoclonal antibody feed. No viruses were detected in any filtrate samples. All virus log reduction values were between ≥3.66 and ≥5.60. The use of TrueSpike(TM) at Charles River Labs allowed Biogen Idec to achieve a more representative scaled-down model and potentially reduce the cost of its virus filtration step and the overall cost of goods. The body of data presented here is an example of the benefits of following the guidance from the PDA Technical Report 47, The Preparation of Virus Spikes Used for Viral Clearance Studies. The safety of biopharmaceuticals is assured through the use of multiple steps in the purification process that are capable of virus clearance, including filtration with virus-retentive filters. The amount of virus present at the downstream stages in the process is expected to be and is typically low. The viral clearance capability of the filtration step is assessed in a validation study. The study utilizes a small version of the larger manufacturing size filter, and a large, known amount of virus is added to the feed prior to filtration. Viral assay before and after filtration allows the virus log reduction value to be quantified. The representativeness of the small-scale model is supported by comparing large-scale filter performance to small-scale filter performance. The large-scale and small-scale filtration runs are performed using the same operating conditions. If the filter performance at both scales is comparable, it supports the applicability of the virus log reduction value obtained with the small-scale filter to the large-scale manufacturing process. However, the virus preparation used to spike the feed material often contains impurities that contribute adversely to virus filter performance in the small-scale model. The added impurities from the virus spike, which are not present at manufacturing scale, compromise the scale-down model and put into question the direct applicability of the virus clearance results. Another consequence of decreased filter performance due to virus spike impurities is the unnecessary over-sizing of the manufacturing system to match the low filter capacity observed in the scale-down model. This article describes how improvements in mammalian virus spike purity ensure the validity of the log reduction value obtained with the scale-down model and support economically optimized filter usage. © PDA, Inc. 2015.

High Performance, Low Cost Hydrogen Generation from Renewable Energy

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ayers, Katherine; Dalton, Luke; Roemer, Andy

Renewable hydrogen from proton exchange membrane (PEM) electrolysis is gaining strong interest in Europe, especially in Germany where wind penetration is already at critical levels for grid stability. For this application as well as biogas conversion and vehicle fueling, megawatt (MW) scale electrolysis is required. Proton has established a technology roadmap to achieve the necessary cost reductions and manufacturing scale up to maintain U.S. competitiveness in these markets. This project represents a highly successful example of the potential for cost reduction in PEM electrolysis, and provides the initial stack design and manufacturing development for Proton’s MW scale product launch. Themore » majority of the program focused on the bipolar assembly, from electrochemical modeling to subscale stack development through prototyping and manufacturing qualification for a large active area cell platform. Feasibility for an advanced membrane electrode assembly (MEA) with 50% reduction in catalyst loading was also demonstrated. Based on the progress in this program and other parallel efforts, H2A analysis shows the status of PEM electrolysis technology dropping below $3.50/kg production costs, exceeding the 2015 target.« less

In vitro evaluation of microbial contamination of orthodontic brackets as received from the manufacturer using microbiological and molecular tests.

PubMed

Dos Santos Gerzson, Darlene R; Simon, Daniel; Dos Anjos, Aline Lima; Freitas, Maria Perpétua Mota

2015-11-01

To test the null hypothesis that orthodontic brackets as supplied by manufacturers do not have microbial contamination. The sample comprised 140 brackets of four different commercially available brands, used directly from the manufacturer's packaging, divided into 14 groups (n  =  10 brackets each). Of the 140 pieces, 60 were full cases and 80 were replacement brackets. Materials were tested to detect bacterial growth, analyze types of bacteria present (biochemical test), and identify bacteria (molecular test with polymerase chain reaction [PCR]). In two of 12 groups the brackets showed microbial contamination: group 1, Morelli full case brackets, and group 12, Abzil-3M Unitek replacement brackets. Staphylococcus aureus and Staphylococcus epidermidis were the bacteria identified in groups 1 and 12, respectively (suggested by the biochemical test and confirmed by PCR). Brackets of two brands (Morelli and Abzil-3M Unitek) were found to be contaminated by bacteria in the original packages supplied by the manufacturers, which suggests a risk for patient contamination. These data suggest that the manufacturers of these materials should improve the quality control of the packaging used, including sterilization, for the security of patient health.

Manufacturing methods of a composite cell case for a Ni-Cd battery

NASA Technical Reports Server (NTRS)

Bauer, J. L.

1979-01-01

Basic manufacturing method refinements for using graphite epoxy material for a nickel cadmium battery cell case were performed to demonstrate production feasibility. The various facets of production scale-up, i.e., process and tooling development, together with material and process control, were integrated into a comprehensive manufacturing process that assures production reproducibility and product uniformity. Test results substantiate that a battery cell case produced from graphite epoxy pre-impregnated material, utilizing the internal pressure bag fabrication method, is feasible.

Composite transport wing technology development: Design development tests and advanced structural concepts

NASA Technical Reports Server (NTRS)

Griffin, Charles F.; Harvill, William E.

1988-01-01

Numerous design concepts, materials, and manufacturing methods were investigated for the covers and spars of a transport box wing. Cover panels and spar segments were fabricated and tested to verify the structural integrity of design concepts and fabrication techniques. Compression tests on stiffened panels demonstrated the ability of graphite/epoxy wing upper cover designs to achieve a 35 percent weight savings compared to the aluminum baseline. The impact damage tolerance of the designs and materials used for these panels limits the allowable compression strain and therefore the maximum achievable weight savings. Bending and shear tests on various spar designs verified an average weight savings of 37 percent compared to the aluminum baseline. Impact damage to spar webs did not significantly degrade structural performance. Predictions of spar web shear instability correlated well with measured performance. The structural integrity of spars manufactured by filament winding equalled or exceeded those fabricated by hand lay-up. The information obtained will be applied to the design, fabrication, and test of a full-scale section of a wing box. When completed, the tests on the technology integration box beam will demonstrate the structural integrity of an advanced composite wing design which is 25 percent lighter than the metal baseline.

Manufacturing technology of integrated textile-based sensor networks for in situ monitoring applications of composite wind turbine blades

NASA Astrophysics Data System (ADS)

Haentzsche, Eric; Mueller, Ralf; Huebner, Matthias; Ruder, Tristan; Unger, Reimar; Nocke, Andreas; Cherif, Chokri

2016-10-01

Based on in situ strain sensors consisting of piezo-resistive carbon filament yarns (CFYs), which have been successfully integrated into textile reinforcement structures during their textile-technological manufacturing process, a continuous load of fibre-reinforced plastic (FRP) components has been realised. These sensors are also suitable for structural health monitoring (SHM) applications. The two-dimensional sensor layout is made feasible by the usage of a modular warp yarn path manipulation unit. Using a functional model of a small wind turbine blade in thermoset composite design, the sensor function for basic SHM applications (e.g. static load monitoring) are demonstrated. Any mechanical loads along the pressure or suction side of the wind turbine blade can be measured and calculated via a correlative change in resistance of the CFYs within the textile reinforcement plies. Performing quasi-static load tests on both tensile specimen and full-scale wind turbine blade, elementary results have been obtained concerning electro-mechanical behaviour and spatial resolution of global and even local static stresses according to the CFY sensor integration length. This paper demonstrates the great potential of textile-based and textile-technological integrated sensors in reinforcement structures for future SHM applications of FRPs.

Can Standards Increase Consumer Welfare? Evidence from a Change in Clothes Washer

DOE Office of Scientific and Technical Information (OSTI.GOV)

Chen, Xiaomei; Roberts, Michael J.; Yang, Hung-Chia

We study prices and sales of individual clothes washer models before, during and after a 2007 standard that banned manufacture (but not sale) of low-e ciency units and increased the threshold for Energy Star certi cation. While quantities sold of washer models banned from manufacture decreased sharply, prices for banned models increased only modestly. At the same time, sales of higher-e ciency units rose markedly while prices for high-e ciency units declined. On average, washer e ciency increased but prices changed little. A simple welfare analysis indicates that consumer welfare loss from banned washers was far outweighed by gains frommore » lower-priced high-e ciency units. While a full cost-bene t analysis is not feasible with the available data, we estimate a lower-bound gain in consumer surplus equal to 6-16 percent of total sales. This result may accord with earlier theoretical research that shows quality standards can increase welfare in monopolistically competitive industries that possess increasing returns to scale (Ronnen, 1991). Thus, if energy e ciency is a close proxy for quality, energy e ciency standards may increase competition, market e ciency and welfare.« less

The new large-scale sweet sorghum industry in the USA

USDA-ARS?s Scientific Manuscript database

Sweet sorghum (Sorghum bicolor) has been widely recognized as a promising sugar feedstock crop for the large-scale manufacture of food-grade and non food-grade bioproducts in the USA. Heckemeyer Mill, located in Sikeston, Missouri, has built and equipped the largest, commercial-scale sweet sorghum ...

The Plight of Manufacturing: What Can Be Done?

ERIC Educational Resources Information Center

Cyert, Richard M.

1985-01-01

Proposes that full automation is the best current option for the United States' manufacturing industries. Advocates increased use of electronics, robotics, and computers in the establishment of unmanned factories. Implications of this movement are examined in terms of labor, management, and the structure of the economy. (ML)

40 CFR 86.1825-01 - Durability demonstration procedures for refueling emissions.

Code of Federal Regulations, 2012 CFR

2012-07-01

... life. The manufacturer shall use good engineering judgment in determining this process. (a) Service... full useful life. The manufacturer shall use good engineering judgement in developing this method. (2... accumulation programs, all emission control components and systems (including both hardware and software) must...

40 CFR 86.1825-01 - Durability demonstration procedures for refueling emissions.

Code of Federal Regulations, 2011 CFR

2011-07-01

... life. The manufacturer shall use good engineering judgment in determining this process. (a) Service... full useful life. The manufacturer shall use good engineering judgement in developing this method. (2... accumulation programs, all emission control components and systems (including both hardware and software) must...

40 CFR 86.1825-01 - Durability demonstration procedures for refueling emissions.

Code of Federal Regulations, 2013 CFR

2013-07-01

... life. The manufacturer shall use good engineering judgment in determining this process. (a) Service... full useful life. The manufacturer shall use good engineering judgement in developing this method. (2... accumulation programs, all emission control components and systems (including both hardware and software) must...

PILOT-SCALE INCINERATION TESTING OF FLUFF AND SOIL FROM THE M.W. MANUFACTURING SUPERFUND SITE

EPA Science Inventory

A series of six tests was performed on wastes (fluff and contaminated soil) from the M.W. Manufacturing Superfund Site to determine the efficacy of incineration as the proposed remediation technology. he fluff, which is the insulation from scrap wire, and the soil wastes are cont...

Energy requirement for the production of silicon solar arrays

NASA Technical Reports Server (NTRS)

Lindmayer, J.; Wihl, M.; Scheinine, A.; Morrison, A.

1977-01-01

An assessment of potential changes and alternative technologies which could impact the photovoltaic manufacturing process is presented. Topics discussed include: a multiple wire saw, ribbon growth techniques, silicon casting, and a computer model for a large-scale solar power plant. Emphasis is placed on reducing the energy demands of the manufacturing process.

Using Simulation to Explore Lean Manufacturing Implementation Strategies

ERIC Educational Resources Information Center

Shannon, Patrick W.; Krumwiede, Kip R.; Street, Jeffrey N.

2010-01-01

Lean manufacturing, an outgrowth of the Toyota Production System, has spread far beyond the automobile industry and is seen by many leaders as a key management philosophy in the battle to compete on an international scale. Successful implementation of lean requires that managers and employees be educated in the proper application of lean tools and…

Scale factor management in the studies of affine models of shockproof garment elements

NASA Astrophysics Data System (ADS)

Denisov, Oleg; Pleshko, Mikhail; Ponomareva, Irina; Merenyashev, Vitaliy

2018-03-01

New samples of protective garment for performing construction work at height require numerous tests in conditions close to real conditions of extreme vital activity. The article presents some results of shockproof garment element studies and a description of a patented prototype. The tests were carried out on a model which geometric dimensions were convenient for manufacturing it in a limited batch. In addition, the used laboratory equipment (for example, a unique power pendulum), blanks made of a titanium-nickel alloy with a shape memory effect also imposed their limitations. The problem of the adequacy of the obtained experimental results transfer to mass-produced products was solved using tools of the classical similarity theory. Scale factor management influence in the affine modeling of the shockproof element, studied on the basis of the equiatomic titanium-nickel alloy with the shape memory effect, allowed us to assume, with a sufficient degree of reliability, the technical possibility of extrapolating the results of experimental studies to full-scale objects for the formation of the initial data of the mathematical model of shockproof garment dynamics elastoplastic deformation (while observing the similarity of the features of external loading).

Manufacturing Methods for Liposome Adjuvants.

PubMed

Perrie, Yvonne; Kastner, Elisabeth; Khadke, Swapnil; Roces, Carla B; Stone, Peter

2017-01-01

A wide range of studies have shown that liposomes can act as suitable adjuvants for a range of vaccine antigens. Properties such as their amphiphilic character and biphasic nature allow them to incorporate antigens within the lipid bilayer, on the surface, or encapsulated within the inner core. However, appropriate methods for the manufacture of liposomes are limited and this has resulted in issues with cost, supply, and wider scale application of these systems. Within this chapter we explore manufacturing processes that can be used for the production of liposomal adjuvants, and we outline new manufacturing methods can that offer fast, scalable, and cost-effective production of liposomal adjuvants.

Optimization of the Manufacturing Process of Conical Shell Structures Using Prepreg Laminatees

NASA Astrophysics Data System (ADS)

Khakimova, Regina; Zimmermann, Rolf; Burau, Florian; Siebert, Marc; Arbelo, Mariano; Castro, Saullo; Degenhardt, Richard

2014-06-01

The design and manufacture of an unstiffened composite conical structure which is a scaled-down version of the Ariane 5 Midlife Evolution Equipment Bay Structure is presented. For such benchmarking structures the fiber orientation error is critical and then the manufacturing process becomes a big challenge. The paper therefore is focused on the implementation of a tailoring study and on the manufacturing process. The conical structure will be tested to validate a new design approach.This study contributes to the European Union (EU) project DESICOS, whose aim is to develop less conservative design guidelines for imperfection sensitive thin-walled structures.

3D printing of tablets using inkjet with UV photoinitiation.

PubMed

Clark, Elizabeth A; Alexander, Morgan R; Irvine, Derek J; Roberts, Clive J; Wallace, Martin J; Sharpe, Sonja; Yoo, Jae; Hague, Richard J M; Tuck, Chris J; Wildman, Ricky D

2017-08-30

Additive manufacturing (AM) offers significant potential benefits in the field of drug delivery and pharmaceutical/medical device manufacture. Of AM processes, 3D inkjet printing enables precise deposition of a formulation, whilst offering the potential for significant scale up or scale out as a manufacturing platform. This work hypothesizes that suitable solvent based ink formulations can be developed that allow the production of solid dosage forms that meet the standards required for pharmaceutical tablets, whilst offering a platform for flexible and personalized manufacture. We demonstrate this using piezo-activated inkjetting to 3D print ropinirole hydrochloride. The tablets produced consist of a cross-linked poly(ethylene glycol diacrylate) (PEGDA) hydrogel matrix containing the drug, photoinitiated in a low oxygen environment using an aqueous solution of Irgacure 2959. At a Ropinirole HCl loading of 0.41mg, drug release from the tablet is shown to be Fickian. Raman and IR spectroscopy indicate a high degree of cross-linking and formation of an amorphous solid dispersion. This is the first publication of a UV inkjet 3D printed tablet. Consequently, this work opens the possibility for the translation of scalable, high precision and bespoke ink-jet based additive manufacturing to the pharmaceutical sector. Copyright © 2017. Published by Elsevier B.V.

Analysis and Test Correlation of Proof of Concept Box for Blended Wing Body-Low Speed Vehicle

NASA Technical Reports Server (NTRS)

Spellman, Regina L.

2003-01-01

The Low Speed Vehicle (LSV) is a 14.2% scale remotely piloted vehicle of the revolutionary Blended Wing Body concept. The design of the LSV includes an all composite airframe. Due to internal manufacturing capability restrictions, room temperature layups were necessary. An extensive materials testing and manufacturing process development effort was underwent to establish a process that would achieve the high modulus/low weight properties required to meet the design requirements. The analysis process involved a loads development effort that incorporated aero loads to determine internal forces that could be applied to a traditional FEM of the vehicle and to conduct detailed component analyses. A new tool, Hypersizer, was added to the design process to address various composite failure modes and to optimize the skin panel thickness of the upper and lower skins for the vehicle. The analysis required an iterative approach as material properties were continually changing. As a part of the material characterization effort, test articles, including a proof of concept wing box and a full-scale wing, were fabricated. The proof of concept box was fabricated based on very preliminary material studies and tested in bending, torsion, and shear. The box was then tested to failure under shear. The proof of concept box was also analyzed using Nastran and Hypersizer. The results of both analyses were scaled to determine the predicted failure load. The test results were compared to both the Nastran and Hypersizer analytical predictions. The actual failure occurred at 899 lbs. The failure was predicted at 1167 lbs based on the Nastran analysis. The Hypersizer analysis predicted a lower failure load of 960 lbs. The Nastran analysis alone was not sufficient to predict the failure load because it does not identify local composite failure modes. This analysis has traditionally been done using closed form solutions. Although Hypersizer is typically used as an optimizer for the design process, the failure prediction was used to help gain acceptance and confidence in this new tool. The correlated models and process were to be used to analyze the full BWB-LSV airframe design. The analysis and correlation with test results of the proof of concept box is presented here, including the comparison of the Nastran and Hypersizer results.

Detecting Nano-Scale Vibrations in Rotating Devices by Using Advanced Computational Methods

PubMed Central

del Toro, Raúl M.; Haber, Rodolfo E.; Schmittdiel, Michael C.

2010-01-01

This paper presents a computational method for detecting vibrations related to eccentricity in ultra precision rotation devices used for nano-scale manufacturing. The vibration is indirectly measured via a frequency domain analysis of the signal from a piezoelectric sensor attached to the stationary component of the rotating device. The algorithm searches for particular harmonic sequences associated with the eccentricity of the device rotation axis. The detected sequence is quantified and serves as input to a regression model that estimates the eccentricity. A case study presents the application of the computational algorithm during precision manufacturing processes. PMID:22399918

Optimising the design and operation of semi-continuous affinity chromatography for clinical and commercial manufacture.

PubMed

Pollock, James; Bolton, Glen; Coffman, Jon; Ho, Sa V; Bracewell, Daniel G; Farid, Suzanne S

2013-04-05

This paper presents an integrated experimental and modelling approach to evaluate the potential of semi-continuous chromatography for the capture of monoclonal antibodies (mAb) in clinical and commercial manufacture. Small-scale single-column experimental breakthrough studies were used to derive design equations for the semi-continuous affinity chromatography system. Verification runs with the semi-continuous 3-column and 4-column periodic counter current (PCC) chromatography system indicated the robustness of the design approach. The product quality profiles and step yields (after wash step optimisation) achieved were comparable to the standard batch process. The experimentally-derived design equations were incorporated into a decisional tool comprising dynamic simulation, process economics and sizing optimisation. The decisional tool was used to evaluate the economic and operational feasibility of whole mAb bioprocesses employing PCC affinity capture chromatography versus standard batch chromatography across a product's lifecycle from clinical to commercial manufacture. The tool predicted that PCC capture chromatography would offer more significant savings in direct costs for early-stage clinical manufacture (proof-of-concept) (∼30%) than for late-stage clinical (∼10-15%) or commercial (∼5%) manufacture. The evaluation also highlighted the potential facility fit issues that could arise with a capture resin (MabSelect) that experiences losses in binding capacity when operated in continuous mode over lengthy commercial campaigns. Consequently, the analysis explored the scenario of adopting the PCC system for clinical manufacture and switching to the standard batch process following product launch. The tool determined the PCC system design required to operate at commercial scale without facility fit issues and with similar costs to the standard batch process whilst pursuing a process change application. A retrofitting analysis established that the direct cost savings obtained by 8 proof-of-concept batches would be sufficient to pay back the investment cost of the pilot-scale semi-continuous chromatography system. Copyright © 2013 Elsevier B.V. All rights reserved.

3D printing via ambient reactive extrusion

DOE PAGES

Rios, Orlando; Carter, William G.; Post, Brian K.; ...

2018-03-14

Here, Additive Manufacturing (AM) has the potential to offer many benefits over traditional manufacturing methods in the fabrication of complex parts with advantages such as low weight, complex geometry, and embedded functionality. In practice, today’s AM technologies are limited by their slow speed and highly directional properties. To address both issues, we have developed a reactive mixture deposition approach that can enable 3D printing of polymer materials at over 100X the volumetric deposition rate, enabled by a greater than 10X reduction in print head mass compared to existing large-scale thermoplastic deposition methods, with material chemistries that can be tuned formore » specific properties. Additionally, the reaction kinetics and transient rheological properties are specifically designed for the target deposition rates, enabling the synchronized development of increasing shear modulus and extensive cross linking across the printed layers. This ambient cure eliminates the internal stresses and bulk distortions that typically hamper AM of large parts, and yields a printed part with inter-layer covalent bonds that significantly improve the strength of the part along the build direction. The fast cure kinetics combined with the fine-tuned viscoelastic properties of the mixture enable rapid vertical builds that are not possible using other approaches. Through rheological characterization of mixtures that were capable of printing in this process as well as materials that have sufficient structural integrity for layer-on-layer printing, a “printability” rheological phase diagram has been developed, and is presented here. We envision this approach implemented as a deployable manufacturing system, where manufacturing is done on-site using the efficiently-shipped polymer, locally-sourced fillers, and a small, deployable print system. Unlike existing additive manufacturing approaches which require larger and slower print systems and complex thermal management strategies as scale increases, liquid reactive polymers decouple performance and print speed from the scale of the part, enabling a new class of cost-effective, fuel-efficient additive manufacturing.« less

3D printing via ambient reactive extrusion

DOE Office of Scientific and Technical Information (OSTI.GOV)

Rios, Orlando; Carter, William G.; Post, Brian K.

Here, Additive Manufacturing (AM) has the potential to offer many benefits over traditional manufacturing methods in the fabrication of complex parts with advantages such as low weight, complex geometry, and embedded functionality. In practice, today’s AM technologies are limited by their slow speed and highly directional properties. To address both issues, we have developed a reactive mixture deposition approach that can enable 3D printing of polymer materials at over 100X the volumetric deposition rate, enabled by a greater than 10X reduction in print head mass compared to existing large-scale thermoplastic deposition methods, with material chemistries that can be tuned formore » specific properties. Additionally, the reaction kinetics and transient rheological properties are specifically designed for the target deposition rates, enabling the synchronized development of increasing shear modulus and extensive cross linking across the printed layers. This ambient cure eliminates the internal stresses and bulk distortions that typically hamper AM of large parts, and yields a printed part with inter-layer covalent bonds that significantly improve the strength of the part along the build direction. The fast cure kinetics combined with the fine-tuned viscoelastic properties of the mixture enable rapid vertical builds that are not possible using other approaches. Through rheological characterization of mixtures that were capable of printing in this process as well as materials that have sufficient structural integrity for layer-on-layer printing, a “printability” rheological phase diagram has been developed, and is presented here. We envision this approach implemented as a deployable manufacturing system, where manufacturing is done on-site using the efficiently-shipped polymer, locally-sourced fillers, and a small, deployable print system. Unlike existing additive manufacturing approaches which require larger and slower print systems and complex thermal management strategies as scale increases, liquid reactive polymers decouple performance and print speed from the scale of the part, enabling a new class of cost-effective, fuel-efficient additive manufacturing.« less

An analysis of variability in the manufacturing of dexosomes: implications for development of an autologous therapy.

PubMed

Patel, Sanjay; Mehta-Damani, Anita; Shu, Helen; Le Pecq, Jean-Bernard

2005-10-20

Dexosomes are nanometer-size vesicles released by dendritic-cells, possessing much of the cellular machinery required to stimulate an immune response (i.e. MHC Class I and II). The ability of patient-derived dexosomes loaded with tumor antigens to elicit anti-tumor activity is currently being evaluated in clinical trials. Unlike conventional biologics, where variability between lots of product arises mostly from the manufacturing process, an autologous product has inherent variability in the starting material due to heterogeneity in the human population. In an effort to assess the variability arising from the dexosome manufacturing process versus the human starting material, 144 dexosome preparations from normal donors (111) and cancer patients (33) from two Phase I clinical trials were analyzed. A large variability in the quantity of dexosomes (measured as the number of MHC Class II molecules) produced between individual lots was observed ( > 50-fold). An analysis of intra-lot variability shows that the manufacturing process introduces relatively little of this variability. To identify the source(s) of variability arising from the human starting material, distributions of the key parameters involved in dexosome production were established, and a model created. Computer simulations using this model were performed, and compared to the actual data observed. The main conclusion from these simulations is that the number of cells collected per individual and the productivity of these cells of are the principal sources of variability in the production of Class II. The approach described here can be extended to other autologous therapies in general to evaluate control of manufacturing processes. Moreover, this analysis of process variability is directly applicable to production at a commercial scale, since the large scale manufacture of autologous products entails an exact process replication rather than scale-up in volume, as is the case with traditional drugs or biologics. Copyright 2005 Wiley Periodicals, Inc.

Breath-Figure Self-Assembly, a Versatile Method of Manufacturing Membranes and Porous Structures: Physical, Chemical and Technological Aspects

PubMed Central

2017-01-01

The review is devoted to the physical, chemical, and technological aspects of the breath-figure self-assembly process. The main stages of the process and impact of the polymer architecture and physical parameters of breath-figure self-assembly on the eventual pattern are covered. The review is focused on the hierarchy of spatial and temporal scales inherent to breath-figure self-assembly. Multi-scale patterns arising from the process are addressed. The characteristic spatial lateral scales of patterns vary from nanometers to dozens of micrometers. The temporal scale of the process spans from microseconds to seconds. The qualitative analysis performed in the paper demonstrates that the process is mainly governed by interfacial phenomena, whereas the impact of inertia and gravity are negligible. Characterization and applications of polymer films manufactured with breath-figure self-assembly are discussed. PMID:28813026

40 CFR 86.1824-08 - Durability demonstration procedures for evaporative emissions.

Code of Federal Regulations, 2014 CFR

2014-07-01

... for evaporative emissions. Eligible small-volume manufacturers or small-volume test groups may...-based measurements except the bleed emission test. The standard for bleed emissions applies for the full... manufacturer must conduct at least one evaporative emission test at each of the five different mileage points...

40 CFR 86.1824-08 - Durability demonstration procedures for evaporative emissions.

Code of Federal Regulations, 2012 CFR

2012-07-01

... the applicability provisions of § 86.1801. Eligible small volume manufacturers or small volume test... manufacturer must conduct at least one evaporative emission test at each of the five different mileage points... the highest mileage point run during mileage accumulation (e.g. the full useful life mileage...

75 FR 81943 - Appliance Labeling Rule

Federal Register 2010, 2011, 2012, 2013, 2014

2010-12-29

....\\5\\ This substantial increase--from as many as 1,500 packaging styles per full- line bulb manufacturer in 1994 to as many as 3,500 packaging styles today--greatly increases the burden on manufacturers.... Specifically, the much larger number of packaging styles involved than in 1994, the difficulties posed by...

40 CFR 1033.810 - In-use testing program.

Code of Federal Regulations, 2011 CFR

2011-07-01

... each calendar year. At a minimum, include the following: (1) Your full corporate name and address. (2) For each locomotive tested, all the following: (i) Corporate name of the manufacturer and last... corporate name of the manufacturer or last remanufacturer(s) of the engine if different than that of the...

40 CFR 1033.810 - In-use testing program.

Code of Federal Regulations, 2012 CFR

2012-07-01

... each calendar year. At a minimum, include the following: (1) Your full corporate name and address. (2) For each locomotive tested, all the following: (i) Corporate name of the manufacturer and last... corporate name of the manufacturer or last remanufacturer(s) of the engine if different than that of the...

40 CFR 1033.810 - In-use testing program.

Code of Federal Regulations, 2014 CFR

2014-07-01

... each calendar year. At a minimum, include the following: (1) Your full corporate name and address. (2) For each locomotive tested, all the following: (i) Corporate name of the manufacturer and last... corporate name of the manufacturer or last remanufacturer(s) of the engine if different than that of the...

40 CFR 1033.810 - In-use testing program.

Code of Federal Regulations, 2013 CFR

2013-07-01

... each calendar year. At a minimum, include the following: (1) Your full corporate name and address. (2) For each locomotive tested, all the following: (i) Corporate name of the manufacturer and last... corporate name of the manufacturer or last remanufacturer(s) of the engine if different than that of the...

Scientific and Technological Foundations for Scaling Production of Nanostructured Metals

NASA Astrophysics Data System (ADS)

Lowe, Terry C.; Davis, Casey F.; Rovira, Peter M.; Hayne, Mathew L.; Campbell, Gordon S.; Grzenia, Joel E.; Stock, Paige J.; Meagher, Rilee C.; Rack, Henry J.

2017-05-01

Severe Plastic Deformation (SPD) has been explored in a wide range of metals and alloys. However, there are only a few industrial scale implementations of SPD for commercial alloys. To demonstrate and evolve technology for producing ultrafine grain metals by SPD, a Nanostructured Metals Manufacturing Testbed (NMMT) has been established in Golden, Colorado. Machines for research scale and pilot scale Equal Channel Angular Pressing-Conform (ECAP-C) technology have been configured in the NMMT to systematically evaluate and evolve SPD processing and advance the foundational science and technology for manufacturing. We highlight the scientific and technological areas that are critical for scale up of continuous SPD of aluminum, copper, magnesium, titanium, and iron-based alloys. Key areas that we will address in this presentation include the need for comprehensive analysis of starting microstructures, data on operating deformation mechanisms, high pressure thermodynamics and phase transformation kinetics, tribological behaviors, temperature dependence of lubricant properties, adaptation of tolerances and shear intensity to match viscoplastic behaviors, real-time process monitoring, and mechanics of billet/tooling interactions.

Metabolic profiling reveals that time related physiological changes in mammalian cell perfusion cultures are bioreactor scale independent.

PubMed

Vernardis, Spyros I; Goudar, Chetan T; Klapa, Maria I

2013-09-01

Metabolic profiling was used to characterize the time course of cell physiology both in laboratory- and manufacturing-scale mammalian cell perfusion cultures. Two independent experiments were performed involving three vials from the same BHK cell bank, used to inoculate three laboratory-scale bioreactors, from which four manufacturing-scale cultures were initiated. It was shown that metabolomic analysis can indeed enhance the prime variable dataset for the monitoring of perfusion cultures by providing a higher resolution view of the metabolic state. Metabolic profiles could capture physiological state shifts over the course of the perfusion cultures and indicated a metabolic "signature" of the phase transitions, which was not observable from prime variable data. Specifically, the vast majority of metabolites had lower concentrations in the middle compared to the other two phases. Notably, metabolomics provided orthogonal (to prime variables) evidence that all cultures followed this same metabolic state shift with cell age, independently of bioreactor scale. © 2013 Elsevier Inc. All rights reserved.

Measures of International Manufacturing and Trade of Clean Energy Technologies

DOE Office of Scientific and Technical Information (OSTI.GOV)

Engel-Cox, Jill; Sandor, Debbie; Keyser, David

The technologies that produce clean energy, such as solar photovoltaic panels and lithium ion batteries for electric vehicles, are globally manufactured and traded. As demand and deployment of these technologies grows exponentially, the innovation to reach significant economies of scale and drive down energy production costs becomes less in the technology and more in the manufacturing of the technology. Manufacturing innovations and other manufacturing decisions can reduce costs of labor, materials, equipment, operating costs, and transportation, across all the links in the supply chain. To better understand the manufacturing aspect of the clean energy economy, we have developed key metricsmore » for systematically measuring and benchmarking international manufacturing of clean energy technologies. The metrics are: trade, market size, manufacturing value-added, and manufacturing capacity and production. These metrics were applied to twelve global economies and four representative technologies: wind turbine components, crystalline silicon solar photovoltaic modules, vehicle lithium ion battery cells, and light emitting diode packages for efficient lighting and other consumer products. The results indicated that clean energy technologies are being developed via complex, dynamic, and global supply chains, with individual economies benefiting from different technologies and links in the supply chain, through both domestic manufacturing and global trade.« less

A Knowledge Database on Thermal Control in Manufacturing Processes

NASA Astrophysics Data System (ADS)

Hirasawa, Shigeki; Satoh, Isao

A prototype version of a knowledge database on thermal control in manufacturing processes, specifically, molding, semiconductor manufacturing, and micro-scale manufacturing has been developed. The knowledge database has search functions for technical data, evaluated benchmark data, academic papers, and patents. The database also displays trends and future roadmaps for research topics. It has quick-calculation functions for basic design. This paper summarizes present research topics and future research on thermal control in manufacturing engineering to collate the information to the knowledge database. In the molding process, the initial mold and melt temperatures are very important parameters. In addition, thermal control is related to many semiconductor processes, and the main parameter is temperature variation in wafers. Accurate in-situ temperature measurment of wafers is important. And many technologies are being developed to manufacture micro-structures. Accordingly, the knowledge database will help further advance these technologies.

Feasibility of Carbon Fiber/PEEK Composites for Cryogenic Fuel Tank Applications

NASA Astrophysics Data System (ADS)

Doyle, K.; Doyle, A.; O Bradaigh, C. M.; Jaredson, D.

2012-07-01

This paper investigates the feasibility of CF/PEEK composites for manufacture of cryogenic fuel tanks for Next Generation Space Launchers. The material considered is CF/PEEK tape from Suprem SA and the proposed manufacturing process for the fuel tank is Automated Tape Placement. Material characterization was carried out on test laminates manufactured in an autoclave and also by Automated Tape Placement with in-situ consolidation. The results of the two processes were compared to establish if there is any knock down in properties for the automated tape placement process. A permeability test rig was setup with a helium leak detector and the effect of thermal cycling on the permeability properties of CF/PEEK was measured. A 1/10th scale demonstrator was designed and manufactured consisting of a cylinder manufactured by automated tape placement and an upper dome manufactured by autoclave processing. The assembly was achieved by Amorphous Interlayer Bonding with PEI.

Controlling high-throughput manufacturing at the nano-scale

NASA Astrophysics Data System (ADS)

Cooper, Khershed P.

2013-09-01

Interest in nano-scale manufacturing research and development is growing. The reason is to accelerate the translation of discoveries and inventions of nanoscience and nanotechnology into products that would benefit industry, economy and society. Ongoing research in nanomanufacturing is focused primarily on developing novel nanofabrication techniques for a variety of applications—materials, energy, electronics, photonics, biomedical, etc. Our goal is to foster the development of high-throughput methods of fabricating nano-enabled products. Large-area parallel processing and highspeed continuous processing are high-throughput means for mass production. An example of large-area processing is step-and-repeat nanoimprinting, by which nanostructures are reproduced again and again over a large area, such as a 12 in wafer. Roll-to-roll processing is an example of continuous processing, by which it is possible to print and imprint multi-level nanostructures and nanodevices on a moving flexible substrate. The big pay-off is high-volume production and low unit cost. However, the anticipated cost benefits can only be realized if the increased production rate is accompanied by high yields of high quality products. To ensure product quality, we need to design and construct manufacturing systems such that the processes can be closely monitored and controlled. One approach is to bring cyber-physical systems (CPS) concepts to nanomanufacturing. CPS involves the control of a physical system such as manufacturing through modeling, computation, communication and control. Such a closely coupled system will involve in-situ metrology and closed-loop control of the physical processes guided by physics-based models and driven by appropriate instrumentation, sensing and actuation. This paper will discuss these ideas in the context of controlling high-throughput manufacturing at the nano-scale.

Universal pooled plasma (Uniplas(®)) does not induce complement-mediated hemolysis of human red blood cells in vitro.

PubMed

Heger, Andrea; Brandstätter, Hubert; Prager, Bettina; Brainovic, Janja; Cortes, Rhoda; Römisch, Jürgen

2015-02-01

Pooling of plasma of different blood groups before large scale manufacturing of Uniplas(®) results in the formation of low levels of soluble immune complexes (CIC). The aim of this study was to investigate the level and removal of CIC during Uniplas(®) manufacturing. In addition, an in vitro hemolysis assay should be developed and investigate if Uniplas(®) does induce complement-mediated hemolysis of human red blood cells (RBC). In-process samples from Uniplas(®) (universal plasma) and Octaplas(LG)(®) (blood group specific plasma) routine manufacturing batches were tested on CIC using commercially available ELISA test kits. In addition, CIC was produced by admixing heat-aggregated immunoglobulins or monoclonal anti-A/anti-B antibodies to plasma and removal of CIC was followed in studies of the Uniplas(®) manufacturing process under down-scale conditions. The extent of RBC lysis was investigated in plasma samples using the in-house hemolysis assay. Levels of CIC in Uniplas(®) are within the normal ranges for plasma and comparable to that found in Octaplas(LG)(®). Down-scale experiments showed that both IgG/IgM-CIC levels are significantly removed on average by 40-50% during Uniplas(®) manufacturing. Uniplas(®) does not induce hemolysis of RBCs in vitro. Hemolysis occurs only after spiking with high titers of anti-A/anti-B antibodies and depends on the antibody specificity (i.e. titer) in the plasma sample. The results of this study confirm the safety of Uniplas(®) regarding transfusion to patients of all ABO blood groups. Copyright © 2013 Elsevier Ltd. All rights reserved.

Full-scale fatigue tests of CX-100 wind turbine blades. Part II: analysis

NASA Astrophysics Data System (ADS)

Taylor, Stuart G.; Jeong, Hyomi; Jang, Jae Kyeong; Park, Gyuhae; Farinholt, Kevin M.; Todd, Michael D.; Ammerman, Curtt M.

2012-04-01

This paper presents the initial analysis results of several structural health monitoring (SHM) methods applied to two 9- meter CX-100 wind turbine blades subjected to fatigue loading at the National Renewable Energy Laboratory's (NREL) National Wind Technology Center (NWTC). The first blade was a pristine blade, manufactured to standard CX-100 design specifications. The second blade was manufactured for the University of Massachusetts, Lowell (UMass), with intentional simulated defects within the fabric layup. Each blade was instrumented with a variety of sensors on its surface. The blades were subject to harmonic excitation at their first natural frequency with steadily increasing loading until ultimately reaching failure. Data from the sensors were collected between and during fatigue loading sessions. The data were measured at multi-scale frequency ranges using a variety of data acquisition equipment, including off-the-shelf systems and prototype data acquisition hardware. The data were analyzed to identify fatigue damage initiation and to assess damage progression. Modal response, diffuse wave-field transfer functions in time and frequency domains, and wave propagation methods were applied to assess the condition of the turbine blade. The analysis methods implemented were evaluated in conjunction with hardware-specific performance for their efficacy in enabling the assessment of damage progression in the blade. The results of this assessment will inform the selection of specific data to be collected and analysis methods to be implemented for a CX-100 flight test to be conducted in collaboration with Sandia National Laboratory at the U.S. Department of Agriculture's (USDA) Conservation and Production Research Laboratory (CPRL) in Bushland, Texas.

3 dimensional cell cultures: a comparison between manually and automatically produced alginate beads.

PubMed

Lehmann, R; Gallert, C; Roddelkopf, T; Junginger, S; Wree, A; Thurow, K

2016-08-01

Cancer diseases are a common problem of the population caused by age and increased harmful environmental influences. Herein, new therapeutic strategies and compound screenings are necessary. The regular 2D cultivation has to be replaced by three dimensional cell culturing (3D) for better simulation of in vivo conditions. The 3D cultivation with alginate matrix is an appropriate method for encapsulate cells to form cancer constructs. The automated manufacturing of alginate beads might be an ultimate method for large-scaled manufacturing constructs similar to cancer tissue. The aim of this study was the integration of full automated systems for the production, cultivation and screening of 3D cell cultures. We compared the automated methods with the regular manual processes. Furthermore, we investigated the influence of antibiotics on these 3D cell culture systems. The alginate beads were formed by automated and manual procedures. The automated steps were processes by the Biomek(®) Cell Workstation (celisca, Rostock, Germany). The proliferation and toxicity were manually and automatically evaluated at day 14 and 35 of cultivation. The results visualized an accumulation and expansion of cell aggregates over the period of incubation. However, the proliferation and toxicity were faintly and partly significantly decreased on day 35 compared to day 14. The comparison of the manual and automated methods displayed similar results. We conclude that the manual production process could be replaced by the automation. Using automation, 3D cell cultures can be produced in industrial scale and improve the drug development and screening to treat serious illnesses like cancer.

Lithography-induced limits to scaling of design quality

NASA Astrophysics Data System (ADS)

Kahng, Andrew B.

2014-03-01

Quality and value of an IC product are functions of power, performance, area, cost and reliability. The forthcoming 2013 ITRS roadmap observes that while manufacturers continue to enable potential Moore's Law scaling of layout densities, the "realizable" scaling in competitive products has for some years been significantly less. In this paper, we consider aspects of the question, "To what extent should this scaling gap be blamed on lithography?" Non-ideal scaling of layout densities has been attributed to (i) layout restrictions associated with multi-patterning technologies (SADP, LELE, LELELE), as well as (ii) various ground rule and layout style choices that stem from misalignment, reliability, variability, device architecture, and electrical performance vs. power constraints. Certain impacts seem obvious, e.g., loss of 2D flexibility and new line-end placement constraints with SADP, or algorithmically intractable layout stitching and mask coloring formulations with LELELE. However, these impacts may well be outweighed by weaknesses in design methodology and tooling. Arguably, the industry has entered a new era in which many new factors - (i) standard-cell library architecture, and layout guardbanding for automated place-and-route: (ii) performance model guardbanding and signoff analyses: (iii) physical design and manufacturing handoff algorithms spanning detailed placement and routing, stitching and RET; and (iv) reliability guardbanding - all contribute, hand in hand with lithography, to a newly-identified "design capability gap". How specific aspects of process and design enablements limit the scaling of design quality is a fundamental question whose answer must guide future RandD investment at the design-manufacturing interface. terface.

Chemometrics applications in biotechnology processes: predicting column integrity and impurity clearance during reuse of chromatography resin.

PubMed

Rathore, Anurag S; Mittal, Shachi; Lute, Scott; Brorson, Kurt

2012-01-01

Separation media, in particular chromatography media, is typically one of the major contributors to the cost of goods for production of a biotechnology therapeutic. To be cost-effective, it is industry practice that media be reused over several cycles before being discarded. The traditional approach for estimating the number of cycles a particular media can be reused for involves performing laboratory scale experiments that monitor column performance and carryover. This dataset is then used to predict the number of cycles the media can be used at manufacturing scale (concurrent validation). Although, well accepted and widely practiced, there are challenges associated with extrapolating the laboratory scale data to manufacturing scale due to differences that may exist across scales. Factors that may be different include: level of impurities in the feed material, lot to lot variability in feedstock impurities, design of the column housing unit with respect to cleanability, and homogeneity of the column packing. In view of these challenges, there is a need for approaches that may be able to predict column underperformance at the manufacturing scale over the product lifecycle. In case such an underperformance is predicted, the operators can unpack and repack the chromatography column beforehand and thus avoid batch loss. Chemometrics offers one such solution. In this article, we present an application of chemometrics toward the analysis of a set of chromatography profiles with the intention of predicting the various events of column underperformance including the backpressure buildup and inefficient deoxyribonucleic acid clearance. Copyright © 2012 American Institute of Chemical Engineers (AIChE).

Rapid manufacturing of metallic Molds for parts in Automobile

NASA Astrophysics Data System (ADS)

Zhang, Renji; Xu, Da; Liu, Yuan; Yan, Xudong; Yan, Yongnian

1998-03-01

The recent research of RPM (Rapid Prototyping Manufacturing) in our lab has been focused on the rapid creation of alloyed cast iron (ACI) molds. There are a lot of machinery parts in an automobile, so a lot of mettallic molds are needed in automobile industry. A new mold manufacturing technology has been proposed. A new large scale RP machine has been set up in our lab now. Then rapid prototypes could be manufactured by means of laminated object manufacturing (LOM) technology. The molds for parts in automobile have been produced by ceramic shell precision casting. An example is a drawing mold for cover parts in automobile. Sufficient precision and surface roughness have been obtained. Itis proved that this is a vew kind of technology. Work supported by the Mational Science Foundation of China.

Selective Laser Melting of Hot Gas Turbine Components: Materials, Design and Manufacturing Aspects

NASA Astrophysics Data System (ADS)

Goutianos, Stergios

2017-07-01

Selective Laser Melting (SLM) allows the design and manufacturing of novel parts and structures with improved performance e.g. by incorporating complex and more efficient cooling schemes in hot gas turbine parts. In contrast to conventional manufacturing of removing material, with SLM parts are built additively to nearly net shape. This allows the fabrication of arbitrary complex geometries that cannot be made by conventional manufacturing techniques. However, despite the powerful capabilities of SLM, a number of issues (e.g. part orientation, support structures, internal stresses), have to be considered in order to manufacture cost-effective and high quality parts at an industrial scale. These issues are discussed in the present work from an engineering point of view with the aim to provide simple quidelines to produce high quality SLM parts.

Small transport aircraft technology

NASA Technical Reports Server (NTRS)

Williams, L. J.

1983-01-01

Information on commuter airline trends and aircraft developments is provided to upgrade the preliminary findings of a NASA-formed small transport aircraft technology (STAT) team, established to determine whether the agency's research and development programs could help commuter aircraft manufacturers solve technical problems related to passenger acceptance and use of 19- to 50-passenger aircraft. The results and conclusions of the full set of completed STAT studies are presented. These studies were performed by five airplane manufacturers, five engine manufacturers, and two propeller manufacturers. Those portions of NASA's overall aeronautics research and development programs which are applicable to commuter aircraft design are summarized. Areas of technology that might beneficially be expanded or initiated to aid the US commuter aircraft manufacturers in the evolution of improved aircraft for the market are suggested.

Manufacture of Third-Generation Lentivirus for Preclinical Use, with Process Development Considerations for Translation to Good Manufacturing Practice.

PubMed

Gándara, Carolina; Affleck, Valerie; Stoll, Elizabeth Ann

2018-02-01

Lentiviral vectors are used in laboratories around the world for in vivo and ex vivo delivery of gene therapies, and increasingly clinical investigation as well as preclinical applications. The third-generation lentiviral vector system has many advantages, including high packaging capacity, stable gene expression in both dividing and post-mitotic cells, and low immunogenicity in the recipient organism. Yet, the manufacture of these vectors is challenging, especially at high titers required for direct use in vivo, and further challenges are presented by the process of translating preclinical gene therapies toward manufacture of products for clinical investigation. The goals of this paper are to report the protocol for manufacturing high-titer third-generation lentivirus for preclinical testing and to provide detailed information on considerations for translating preclinical viral vector manufacture toward scaled-up platforms and processes in order to make gene therapies under Good Manufacturing Practice that are suitable for clinical trials.

Manufacture of Third-Generation Lentivirus for Preclinical Use, with Process Development Considerations for Translation to Good Manufacturing Practice

PubMed Central

Gándara, Carolina; Affleck, Valerie; Stoll, Elizabeth Ann

2018-01-01

Lentiviral vectors are used in laboratories around the world for in vivo and ex vivo delivery of gene therapies, and increasingly clinical investigation as well as preclinical applications. The third-generation lentiviral vector system has many advantages, including high packaging capacity, stable gene expression in both dividing and post-mitotic cells, and low immunogenicity in the recipient organism. Yet, the manufacture of these vectors is challenging, especially at high titers required for direct use in vivo, and further challenges are presented by the process of translating preclinical gene therapies toward manufacture of products for clinical investigation. The goals of this paper are to report the protocol for manufacturing high-titer third-generation lentivirus for preclinical testing and to provide detailed information on considerations for translating preclinical viral vector manufacture toward scaled-up platforms and processes in order to make gene therapies under Good Manufacturing Practice that are suitable for clinical trials. PMID:29212357

Controlled flight of a biologically inspired, insect-scale robot.

PubMed

Ma, Kevin Y; Chirarattananon, Pakpong; Fuller, Sawyer B; Wood, Robert J

2013-05-03

Flies are among the most agile flying creatures on Earth. To mimic this aerial prowess in a similarly sized robot requires tiny, high-efficiency mechanical components that pose miniaturization challenges governed by force-scaling laws, suggesting unconventional solutions for propulsion, actuation, and manufacturing. To this end, we developed high-power-density piezoelectric flight muscles and a manufacturing methodology capable of rapidly prototyping articulated, flexure-based sub-millimeter mechanisms. We built an 80-milligram, insect-scale, flapping-wing robot modeled loosely on the morphology of flies. Using a modular approach to flight control that relies on limited information about the robot's dynamics, we demonstrated tethered but unconstrained stable hovering and basic controlled flight maneuvers. The result validates a sufficient suite of innovations for achieving artificial, insect-like flight.

Measuring Scale Errors in a Laser Tracker’s Horizontal Angle Encoder Through Simple Length Measurement and Two-Face System Tests

PubMed Central

Muralikrishnan, B.; Blackburn, C.; Sawyer, D.; Phillips, S.; Bridges, R.

2010-01-01

We describe a method to estimate the scale errors in the horizontal angle encoder of a laser tracker in this paper. The method does not require expensive instrumentation such as a rotary stage or even a calibrated artifact. An uncalibrated but stable length is realized between two targets mounted on stands that are at tracker height. The tracker measures the distance between these two targets from different azimuthal positions (say, in intervals of 20° over 360°). Each target is measured in both front face and back face. Low order harmonic scale errors can be estimated from this data and may then be used to correct the encoder’s error map to improve the tracker’s angle measurement accuracy. We have demonstrated this for the second order harmonic in this paper. It is important to compensate for even order harmonics as their influence cannot be removed by averaging front face and back face measurements whereas odd orders can be removed by averaging. We tested six trackers from three different manufacturers. Two of those trackers are newer models introduced at the time of writing of this paper. For older trackers from two manufacturers, the length errors in a 7.75 m horizontal length placed 7 m away from a tracker were of the order of ± 65 μm before correcting the error map. They reduced to less than ± 25 μm after correcting the error map for second order scale errors. Newer trackers from the same manufacturers did not show this error. An older tracker from a third manufacturer also did not show this error. PMID:27134789

Use of inexpensive vegetable oils to ensure the long-term stability of sweet sorghum syrups for the manufacture of bioproducts

USDA-ARS?s Scientific Manuscript database

Fundamental processing needs identified by industry for the large-scale manufacture of biofuels and bioproducts from sweet sorghum (Sorghum bicolor L. Moench), include the long-term storage of 65 Brix syrups for year-round supply, efficient transport, and acceptable end-product yields. Sweet sorghu...

Input output scaling relations in Italian manufacturing firms

NASA Astrophysics Data System (ADS)

Bottazzi, Giulio; Grazzi, Marco; Secchi, Angelo

2005-09-01

Recent analyses on different database have proposed some regularities with respect to size and growth rates distribution of firms. In this work we explore some basic properties of the dynamics of productivity in Italian manufacturing firms. We investigate relations between different inputs and output examining the impact of productivity in shaping the pattern of corporates evolution.

A pilot-scale nonwoven roll goods manufacturing process reduces microbial burden to pharmacopeia acceptance levels for nonsterile hygiene applications

USDA-ARS?s Scientific Manuscript database

A total of seven source fiber types were selected for use in the manufacturing of nonwoven roll goods: polyester; polypropylene; rayon; greige cotton from two sources; mechanically cleaned greige cotton; and scoured and bleached cotton. The microbial burden of each source fiber was measured as a pr...

Metrology for Industry for use in the Manufacture of Grazing Incidence Beam Line Mirrors

DOE Office of Scientific and Technical Information (OSTI.GOV)

Metz, James P.; Parks, Robert E.

2014-12-01

The goal of this SBIR was to determine the slope sensitivity of Specular Reflection Deflectometry (SRD) and whether shearing methods had the sensitivity to be able to separate errors in the test equipment from slope error in the unit under test (UUT), or mirror. After many variations of test parameters it does not appear that SRD yields results much better than 1 μ radian RMS independent of how much averaging is done. Of course, a single number slope sensitivity over the full range of spatial scales is not a very insightful number in the same sense as a single numbermore » phase or height RMS value in interferometry does not tell the full story. However, the 1 μ radian RMS number is meaningful when contrasted with a sensitivity goal of better than 0.1 μ radian RMS. Shearing is a time proven method of separating the errors in a measurement from the actual shape of a UUT. It is accomplished by taking multiple measurements while moving the UUT relative to the test instrument. This process makes it possible to separate the two errors sources but only to a sensitivity of about 1 μ radian RMS. Another aspect of our conclusions is that this limit probably holds largely independent of the spatial scale of the test equipment. In the proposal for this work it was suggested that a test screen the full size of the UUT could be used to determine the slopes on scales of maybe 0.01 to full scale of the UUT while smaller screens and shorter focal length lenses could be used to measure shorter, or smaller, patches of slope. What we failed to take into consideration was that as the scale of the test equipment got smaller so too did the optical lever arm on which the slope was calculated. Although we did not do a test with a shorter focal length lens over a smaller sample area it is hard to argue with the logic that the slope sensitivity will be about the same independent of the spatial scale of the measurement assuming the test equipment is similarly scaled. On a more positive note, SRD does appear to be a highly flexible, easy to implement, rather inexpensive test for free form optics that require a dynamic range that exceeds that of interferometry. These optics are quite often specified to have more relaxed slope errors, on the order of 1 μ radian RMS or greater. It would be shortsighted to not recognize the value of this test method in the bigger picture.« less

Structural strengthening of rocket nozzle extension by means of laser metal deposition

NASA Astrophysics Data System (ADS)

Honoré, M.; Brox, L.; Hallberg, M.

2012-03-01

Commercial space operations strive to maximize the payload per launch in order to minimize the costs of each kg launched into orbit; this yields demand for ever larger launchers with larger, more powerful rocket engines. Volvo Aero Corporation in collaboration with Snecma and Astrium has designed and tested a new, upgraded Nozzle extension for the Vulcain 2 engine configuration, denoted Vulcain 2+ NE Demonstrator The manufacturing process for the welding of the sandwich wall and the stiffening structure is developed in close cooperation with FORCE Technology. The upgrade is intended to be available for future development programs for the European Space Agency's (ESA) highly successful commercial launch vehicle, the ARIANE 5. The Vulcain 2+ Nozzle Extension Demonstrator [1] features a novel, thin-sheet laser-welded configuration, with laser metal deposition built-up 3D-features for the mounting of stiffening structure, flanges and for structural strengthening, in order to cope with the extreme load- and thermal conditions, to which the rocket nozzle extension is exposed during launch of the 750 ton ARIANE 5 launcher. Several millimeters of material thickness has been deposited by laser metal deposition without disturbing the intricate flow geometry of the nozzle cooling channels. The laser metal deposition process has been applied on a full-scale rocket nozzle demonstrator, and in excess of 15 kilometers of filler wire has been successfully applied to the rocket nozzle. The laser metal deposition has proven successful in two full-throttle, full-scale tests, firing the rocket engine and nozzle in the ESA test facility P5 by DLR in Lampoldshausen, Germany.

Overview of the Photovoltaic Manufacturing Technology (PVMaT) project

NASA Astrophysics Data System (ADS)

Witt, C. E.; Mitchell, R. L.; Mooney, G. D.

1993-08-01

The Photovoltaic Manufacturing Technology (PVMaT) project is a historic government/industry photovoltaic (PV) manufacturing R&D partnership composed of joint efforts between the federal government (through the US Department of Energy) and members of the US PV industry. The project's ultimate goal is to ensure that the US industry retains and extends its world leadership role in the manufacture and commercial development of PV components and systems. PVMaT is designed to do this by helping the US PV industry improve manufacturing processes, accelerate manufacturing cost reductions for PV modules, improve commercial product performance, and lay the groundwork for a substantial scale-up of US-based PV manufacturing capacities. Phase 1 of the project, the problem identification phase, was completed in early 1991. Phase 2, the problem solution phase, which addresses process-specific problems of specific manufacturers, is now underway with an expected duration of 5 years. Phase 3 addresses R&D problems that are relatively common to a number of PV companies or the PV industry as a whole. These 'generic' problem areas are being addressed through a teamed research approach.

The presence of Enterococcus, coliforms and E. coli in a commercial yeast manufacturing process.

PubMed

O'Brien, S S; Lindsay, D; von Holy, A

2004-07-01

This study evaluated a typical commercial yeast manufacturing process for bacterial contamination. Product line samples of a commercial yeast manufacturing process and the corresponding seed yeast manufacturing process were obtained upstream from the final compressed and dry yeast products. All samples were analysed before (non-PI) and after preliminary incubation (PI) at 37 degrees C for 24 h. The PI procedure was incorporated for amplification of bacterial counts below the lower detection limit. Enterococcus, coliform and Escherichia coli counts were quantified by standard pour-plate techniques using selective media. Presence at all stages and progressive increases in counts of Enterococcus, coliforms and E. coli during processing in the commercial manufacturing operation suggested that the primary source of contamination of both compressed and dry yeast with these bacteria was the seed yeast manufacturing process and that contamination was amplified throughout the commercial yeast manufacturing process. This was confirmed by surveys of the seed yeast manufacturing process which indicated that contamination of the seed yeast with Enterococcus, coliforms and E. coli occurred during scale up of seed yeast biomass destined as inoculum for the commercial fermentation.

Noise reduction of a tilt-rotor aircraft including effects on weight and performance

NASA Technical Reports Server (NTRS)

Gibs, J.; Stepniewski, W. Z.; Spencer, R.; Kohler, G.

1973-01-01

Various methods for far-field noise reduction of a tilt-rotor acoustic signature and the performance and weight tradeoffs which result from modification of the noise sources are considered in this report. In order to provide a realistic approach for the investigation, the Boeing tilt-rotor flight research aircraft (Model 222), was selected as the baseline. This aircraft has undergone considerable engineering development. Its rotor has been manufactured and tested in the Ames full-scale wind tunnel. The study reflects the current state-of-the-art of aircraft design for far-field acoustic signature reduction and is not based solely on an engineering feasibility aircraft. This report supplements a previous study investigating reduction of noise signature through the management of the terminal flight trajectory.

Heat pipes for wing leading edges of hypersonic vehicles

NASA Technical Reports Server (NTRS)

Boman, B. L.; Citrin, K. M.; Garner, E. C.; Stone, J. E.

1990-01-01

Wing leading edge heat pipes were conceptually designed for three types of vehicle: an entry research vehicle, aero-space plane, and advanced shuttle. A full scale, internally instrumented sodium/Hastelloy X heat pipe was successfully designed and fabricated for the advanced shuttle application. The 69.4 inch long heat pipe reduces peak leading edge temperatures from 3500 F to 1800 F. It is internally instrumented with thermocouples and pressure transducers to measure sodium vapor qualities. Large thermal gradients and consequently large thermal stresses, which have the potential of limiting heat pipe life, were predicted to occur during startup. A test stand and test plan were developed for subsequent testing of this heat pipe. Heat pipe manufacturing technology was advanced during this program, including the development of an innovative technique for wick installation.

Experimental Flow Models for SSME Flowfield Characterization

NASA Technical Reports Server (NTRS)

Abel, L. C.; Ramsey, P. E.

1989-01-01

Full scale flow models with extensive instrumentation were designed and manufactured to provide data necessary for flow field characterization in rocket engines of the Space Shuttle Main Engine (SSME) type. These models include accurate flow path geometries from the pre-burner outlet through the throat of the main combustion chamber. The turbines are simulated with static models designed to provide the correct pressure drop and swirl for specific power levels. The correct turbopump-hot gas manifold interfaces were designed into the flow models to permit parametric/integration studies for new turbine designs. These experimental flow models provide a vehicle for understanding the fluid dynamics associated with specific engine issues and also fill the more general need for establishing a more detailed fluid dynamic base to support development and verification of advanced math models.

Towards a manufacturing ecosystem for integrated photonic sensors (Conference Presentation)

NASA Astrophysics Data System (ADS)

Miller, Benjamin L.

2017-03-01

Laboratory-scale demonstrations of optical biosensing employing structures compatible with CMOS fabrication, including waveguides, Mach-Zehnder interferometers, ring resonators, and photonic crystals, have provided ample validation of the promise of these technologies. However, to date there are relatively few examples of integrated photonic biosensors in the commercial sphere. The lack of successful translation from the laboratory to the marketplace is due in part to a lack of robust manufacturing processes for integrated photonics overall. This talk will describe efforts within the American Institute for Manufacturing Photonics (AIM Photonics), a public-private consortium funded by the Department of Defense, State governments, Universities, and Corporate partners to accelerate manufacturing of integrated photonic sensors.

Manufacturing methods of a composite cell case for a Ni-Cd battery

NASA Technical Reports Server (NTRS)

Bauer, J. L.; Bogner, R. S.; Lowe, E. P.; Orlowski, E.

1979-01-01

Graphite epoxy material for a nickel cadmium battery cell case has been evaluated and determined to perform in the simulated environment of the battery. The basic manufacturing method requires refinement to demonstrate production feasibility. The various facets of production scale-up, i.e., process and tooling development together with material and process control, have been integrated into a comprehensive manufacturing process that assures production reproducibility and product uniformity. Test results substantiate that a battery cell case produced from graphite epoxy pre-impregnated material utilizing internal pressure bag fabrication method is feasible.

Manufacturing’s Contribution to Pakistan’s Economic Expansion: Commodity - or Service-Led Growth

DTIC Science & Technology

1994-12-01

private sector from regulation and artificial price distortions. In addition, a complementary privatisation programme was launched with the aim of reducing the role of the public sector in manufacturing and services. As a side benefit, the programme was seen as alleviating the government’s financial and administrative burden and creating new opportunities for the private sector . While growth in large-scale manufacturing output has not accelerated in recent years (nor has its overall contribution to GDP growth increased), there is hope

Evaluation of cement-excelsior boards made from yellow-poplar and sweetgum

Treesearch

Andy W.C. Lee; Chung Y Hse

1993-01-01

Previous research conducted in the laboratory pointed out several hardwood species which were either superior, comparable, marginal, or unsuitable for manufacturing cement-excelsior board (CEB). In this study, forty full-sized boards were manufactured in a commercial production facility with the following species: yellow-poplar, sweetgum, southern pine, and sweetgum/...

Detecting delaminations and disbondings on full-scale wing composite panel by guided waves based SHM system

NASA Astrophysics Data System (ADS)

Monaco, E.; Boffa, N. D.; Memmolo, V.; Ricci, F.; Maio, L.

2016-04-01

A full-scale lower wing panel made of composite material has been designed, manufactured and sensorised within the European Funded research project named SARISTU. The authors contributed to the whole development of the system, from design to implementation as well as to the impacts campaign phase where Barely Visible and Visible Damages (BVID and VID) are to be artificially induced on the panel by a pneumatic impact machine. This work summarise part of the experimental results related to damages production, their assessment by C-SCAN as reference NDT method as well as damage detection of delimitations by a guided waves based SHM. The SHM system is made by customized piezoelectric patches secondary bonded on the wing plate acting both as guided waves sources and receivers. The paper will deal mostly with the experimental impact campaign and the signal analyses carried out to extract the metrics more sensitive to damages induced. Image reconstruction of the damages dimensions and shapes will be also described based mostly on the combination of metrics maps over the plate partial surfaces. Finally a comparison of damages maps obtained by the SHM approach and those obtained by "classic" C-SCAN will be presented analyzing briefly pros and cons of the two different approached as a combination to the most effective structural maintenance scenario of a commercial aircraft.

Mathematical modeling and full-scale shaking table tests for multi-curve buckling restrained braces

NASA Astrophysics Data System (ADS)

Tsai, C. S.; Lin, Yungchang; Chen, Wenshin; Su, H. C.

2009-09-01

Buckling restrained braces (BRBs) have been widely applied in seismic mitigation since they were introduced in the 1970s. However, traditional BRBs have several disadvantages caused by using a steel tube to envelope the mortar to prevent the core plate from buckling, such as: complex interfaces between the materials used, uncertain precision, and time consumption during the manufacturing processes. In this study, a new device called the multi-curve buckling restrained brace (MC-BRB) is proposed to overcome these disadvantages. The new device consists of a core plate with multiple neck portions assembled to form multiple energy dissipation segments, and the enlarged segment, lateral support elements and constraining elements to prevent the BRB from buckling. The enlarged segment located in the middle of the core plate can be welded to the lateral support and constraining elements to increase buckling resistance and to prevent them from sliding during earthquakes. Component tests and a series of shaking table tests on a full-scale steel structure equipped with MC-BRBs were carried out to investigate the behavior and capability of this new BRB design for seismic mitigation. The experimental results illustrate that the MC-BRB possesses a stable mechanical behavior under cyclic loadings and provides good protection to structures during earthquakes. Also, a mathematical model has been developed to simulate the mechanical characteristics of BRBs.

Hybrid 3D printing by bridging micro/nano processes

NASA Astrophysics Data System (ADS)

Yoon, Hae-Sung; Jang, Ki-Hwan; Kim, Eunseob; Lee, Hyun-Taek; Ahn, Sung-Hoon

2017-06-01

A hybrid 3D printing process was developed for multiple-material/freeform nano-scale manufacturing. The process consisted of aerodynamically focused nanoparticle (AFN) printing, micro-machining, focused ion beam milling, and spin-coating. Theoretical and experimental investigations were carried out to improve the compatibility of each of the processes, enabling bridging of various different techniques. The resulting hybrid process could address the limitations of individual processes, enabling improved process scaling and dimensional degrees of freedom, without losing the advantages of the existing processes. The minimum structure width can be reduced to 50 nm using undercut structures. In addition, AFN printing employs particle impact for adhesion, and various inorganic materials are suitable for printing, including metals and functional ceramics. Using the developed system, we fabricated bi-material cantilevers for applications as a thermal actuator. The mechanical and thermal properties of the structure were investigated using an in situ measurement system, and irregular thermal phenomena due to the fabrication process were analyzed. We expect that this work will lead to improvements in the area of customized nano-scale manufacturing, as well as further improvements in manufacturing technology by combining different fabrication techniques.

Failure mechanism of the polymer infiltration of carbon nanotube forests

NASA Astrophysics Data System (ADS)

Buchheim, Jakob; Park, Hyung Gyu

2016-11-01

Polymer melt infiltration is one of the feasible methods for manufacturing filter membranes out of carbon nanotubes (CNTs) on large scales. Practically, however, its process suffers from low yields, and the mechanism behind this failure is rather poorly understood. Here, we investigate a failure mechanism of polymer melt infiltration of vertical aligned (VA-) CNTs. In penetrating the VA-CNT interstices, polymer melts exert a capillarity-induced attractive force laterally on CNTs at the moving meniscus, leading to locally agglomerated macroscale bunches. Such a large configurational change can deform and distort individual CNTs so much as to cause buckling or breakdown of the alignment. In view of membrane manufacturing, this irreversible distortion of nanotubes is detrimental, as it could block the transport path of the membranes. The failure mechanism of the polymer melt infiltration is largely attributed to steric hindrance and an energy penalty of confined polymer chains. Euler beam theory and scaling analysis affirm that CNTs with low aspect ratio, thick walls and sparse distribution can maintain their vertical alignment. Our results can enrich a mechanistic understanding of the polymer melt infiltration process and offer guidelines to the facile large-scale manufacturing of the CNT-polymer filter membranes.

Vapor Phase Hydrogen Peroxide Sanitization of an Isolator for Aseptic Filling of Monoclonal Antibody Drug Product - Hydrogen Peroxide Uptake and Impact on Protein Quality.

PubMed

Hubbard, Aaron; Reodl, Thomas; Hui, Ada; Knueppel, Stephanie; Eppler, Kirk; Lehnert, Siegfried; Maa, Yuh-Fun

2018-03-15

A monoclonal antibody drug product (DP) manufacturing process was transferred to a different production site, where aseptic filling took place within an isolator that was sanitized using vapor phase hydrogen peroxide (VPHP). A quality-by-design approach was applied for study design to understand the impact of VPHP uptake in the isolator on DP quality. A combination of small-scale and manufacturing-scale studies was performed to evaluate the sensitivity of the monoclonal antibody to hydrogen peroxide (H2O2) as well as VPHP uptake mechanisms during the filling process. The acceptable H2O2 level was determined to be 100 ng/mL for the antibody in the H2O2 spiking study; protein oxidation was observed above this threshold. The most prominent sources of VPHP uptake were identified to be via the silicone tubing assembly (associated with the peristaltic pumps) and open, filled vials. Silicone tubing, an effective depot to H2O2, could absorb VPHP during different stages of the filling process and discharge H2O2 into the DP solution during filling interruptions. A small-scale isolator model, established to simulate manufacturing-scale conditions, was a useful tool in understanding H2O2 uptake in relation to tubing dimensions and VPHP concentration in the isolator air (or atmosphere). Although the tubing assembly had absorbed a substantial amount of VPHP during the decontamination phase, the majority of H2O2 could be removed during tubing cleaning and sterilization in the subsequent isolator aeration phase, demonstrating that H2O2 in the DP solution is taken up primarily via atmospheric VPHP residues in the isolator during filling. Picarro sensor monitoring suggested that the validated VPHP aeration process generates reproducible residual VPHP profiles in isolator air, thus allowing small-scale studies to provide more relevant recommendations on tubing size and interruption time limits for commercial manufacturing. The recommended process parameters were demonstrated to be acceptable and rendered no product quality impact as demonstrated in six consecutive manufacturing batches in the process validation campaign. Overall, this case study would provide process development scientists/engineers an in-depth understanding of the VPHP process and a science-based approach to mitigating DP quality impact. Copyright © 2018, Parenteral Drug Association.

Modular Hydropower Engineering and Pilot Scale Manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Chesser, Phillip C.

Emrgy has developed, prototyped and tested a modular hydropower system for renewable energy generation. ORNL worked with Emrgy to demonstrate the use of additive manufacturing in the production of the hydrofoils and spokes for the hydrokinetic system. Specifically, during Phase 1 of this effort, ORNL printed and finished machined patterns for both the hydrofoils and spokes that were subsequently used in a sand casting manufacturing process. Emrgy utilized the sand castings for a pilot installation in Denver, CO, where the parts represented an 80% cost savings from the previous prototype build that was manufactured using subtractive manufacturing. In addition, themore » castings were completed with ORNL’s newly developed AlCeMg alloy that will be tested for performance improvements including higher corrosion resistance in a water application than the 6160 alloy used previously« less

16 CFR 233.3 - Advertising retail prices which have been established or suggested by manufacturers (or other...

Code of Federal Regulations, 2011 CFR

2011-01-01

... at least in the principal retail outlets which do not conduct their business on a discount basis. It... insignificant) sales are made in the advertiser's trade area (the area in which he does business). Conversely... hand, a manufacturer or other distributor who does business on a large regional or national scale...

16 CFR 233.3 - Advertising retail prices which have been established or suggested by manufacturers (or other...

Code of Federal Regulations, 2014 CFR

2014-01-01

... at least in the principal retail outlets which do not conduct their business on a discount basis. It... insignificant) sales are made in the advertiser's trade area (the area in which he does business). Conversely... hand, a manufacturer or other distributor who does business on a large regional or national scale...

16 CFR 233.3 - Advertising retail prices which have been established or suggested by manufacturers (or other...

Code of Federal Regulations, 2012 CFR

2012-01-01

... at least in the principal retail outlets which do not conduct their business on a discount basis. It... insignificant) sales are made in the advertiser's trade area (the area in which he does business). Conversely... hand, a manufacturer or other distributor who does business on a large regional or national scale...

16 CFR 233.3 - Advertising retail prices which have been established or suggested by manufacturers (or other...

Code of Federal Regulations, 2013 CFR

2013-01-01

... at least in the principal retail outlets which do not conduct their business on a discount basis. It... insignificant) sales are made in the advertiser's trade area (the area in which he does business). Conversely... hand, a manufacturer or other distributor who does business on a large regional or national scale...

2001 Industry Studies: Electronics

DTIC Science & Technology

2001-01-01

Center, Dallas, TX Northrop Grumman Corp, Electronic Sensors & Systems, Baltimore, MD International Acer Incorporated, Hsin Chu, Taiwan Aerospace...manufacturing. Many of the large-scale fabrication foundries are offshore in such countries as Taiwan, Singapore and Malaysia .5 - 5 - The largest market for...done in the US. However, more of the actual mass manufacturing of the chips are done in Taiwan, Singapore, and Malaysia . A new semiconductor facility

Department of Defense Acquisition of Vaccine Production. Volume 1

DTIC Science & Technology

2000-12-01

and by Science Applications International Corporation (SAIC) under a contract with the Office of the Director, Defense Research and Engineering...development clinical trials, manufacturing, and development; requires application of state-of- testing the-art research capability to problem solving...trials, vaccine recommending usage manufacturing scale, and logistics bodies (e.g., AFEB, ACIP) License application Prepare and submit -100 volume

Issues in nanocomposite ceramic engineering: focus on processing and properties of alumina-based composites.

PubMed

Palmero, Paola; Kern, Frank; Sommer, Frank; Lombardi, Mariangela; Gadow, Rainer; Montanaro, Laura

2014-12-30

Ceramic nanocomposites, containing at least one phase in the nanometric dimension, have received special interest in recent years. They have, in fact, demonstrated increased performance, reliability and lifetime with respect to monolithic ceramics. However, a successful approach to the production of tailored composite nanostructures requires the development of innovative concepts at each step of manufacturing, from the synthesis of composite nanopowders, to their processing and sintering.This review aims to deepen understanding of some of the critical issues associated with the manufacturing of nanocomposite ceramics, focusing on alumina-based composite systems. Two case studies are presented and briefly discussed. The former illustrates the benefits, in terms of sintered microstructure and related mechanical properties, resulting from the application of an engineering approach to a laboratory-scale protocol for the elaboration of nanocomposites in the system alumina-ZrO2-YAG (yttrium aluminium garnet). The latter illustrates the manufacturing of alumina-based composites for large-scale applications such as cutting tools, carried out by an injection molding process. The need for an engineering approach to be applied in all processing steps is demonstrated also in this second case study, where a tailored manufacturing process is required to obtain the desired results.

First light of an external occulter testbed at flight Fresnel numbers

NASA Astrophysics Data System (ADS)

Kim, Yunjong; Sirbu, Dan; Hu, Mia; Kasdin, Jeremy; Vanderbei, Robert J.; Harness, Anthony; Shaklan, Stuart

2017-01-01

Many approaches have been suggested over the last couple of decades for imaging Earth-like planets. One of the main candidates for creating high-contrast for future Earth-like planets detection is an external occulter. The external occulter is a spacecraft flown along the line-of-sight of a space telescope to suppress starlight and enable high-contrast direct imaging of exoplanets. The occulter is typically tens of meters in diameter and the separation from the telescope is of the order of tens of thousands of kilometers. Optical testing of a full-scale external occulter on the ground is impossible because of the long separations. Therefore, laboratory verification of occulter designs is necessary to validate the optical models used to design and predict occulter performance. At Princeton, we have designed and built a testbed that allows verification of scaled occulter designs whose suppressed shadow is mathematically identical to that of space occulters. The goal of this experiment is to demonstrate a pupil plane suppression of better than 1e-9 with a corresponding image plane contrast of better than 1e-11. The occulter testbed uses a 77.2 m optical propagation distance to realize the flight Fresnel number of 14.5. The scaled mask is placed at 27.2 m from the artificial source and the camera is located 50.0 m from the scaled mask. We will use an etched silicon mask, manufactured by the Microdevices Lab(MDL) of the Jet Propulsion Laboratory(JPL), as the occulter. Based on conversations with MDL, we expect that 0.5 μm feature size is an achievable resolution in the mask manufacturing process and is therefore likely the indicator of the best possible performance. The occulter is illuminated by a diverging laser beam to reduce the aberrations from the optics before the occulter. Here, we present first light result of a sample design operating at a flight Fresnel number and the experimental setup of the testbed. We compare the experimental results with simulations that predict the ultimate contrast performance.

Space Industrialization: The Mirage of Abundance.

ERIC Educational Resources Information Center

Deudney, Daniel

1982-01-01

Large-scale space industrialization is not a viable solution to the population, energy, and resource problems of earth. The expense and technological difficulties involved in the development and maintenance of space manufacturing facilities, space colonies, and large-scale satellites for solar power are discussed. (AM)

A Theoretical Investigation of Composite Overwrapped Pressure Vessel (COPV) Mechanics Applied to NASA Full Scale Tests

NASA Technical Reports Server (NTRS)

Greene, N.; Thesken, J. C.; Murthy, P. L. N.; Phoenix, S. L.; Palko, J.; Eldridge, J.; Sutter, J.; Saulsberry, R.; Beeson, H.

2006-01-01

A theoretical investigation of the factors controlling the stress rupture life of the National Aeronautics and Space Agency's (NASA) composite overwrapped pressure vessels (COPVs) continues. Kevlar(TradeMark) fiber overwrapped tanks are of particular concern due to their long usage and the poorly understood stress rupture process in Kevlar(TradeMark) filaments. Existing long term data show that the rupture process is a function of stress, temperature and time. However, due to the presence of a load sharing liner, the manufacturing induced residual stresses and the complex mechanical response, the state of actual fiber stress in flight hardware and test articles is not clearly known. This paper is a companion to the experimental investigation reported in [1] and develops a theoretical framework necessary to design full-scale pathfinder experiments and accurately interpret the experimentally observed deformation and failure mechanisms leading up to static burst in COPVs. The fundamental mechanical response of COPVs is described using linear elasticity and thin shell theory and discussed in comparison to existing experimental observations. These comparisons reveal discrepancies between physical data and the current analytical results and suggest that the vessel's residual stress state and the spatial stress distribution as a function of pressure may be completely different from predictions based upon existing linear elastic analyses. The 3D elasticity of transversely isotropic spherical shells demonstrates that an overly compliant transverse stiffness relative to membrane stiffness can account for some of this by shifting a thin shell problem well into the realm of thick shell response. The use of calibration procedures are demonstrated as calibrated thin shell model results and finite element results are shown to be in good agreement with the experimental results. The successes reported here have lead to continuing work with full scale testing of larger NASA COPV hardware.

Complex shaped boron carbides from negative additive manufacturing

DOE PAGES

Lu, Ryan; Chandrasekaran, Swetha; Du Frane, Wyatt L.; ...

2018-03-13

In this paper, complex shaped boron carbide with carbon (B 4C/C) at near-full densities were achieved for the first time using negative additive manufacturing techniques via gelcasting. Negative additive manufacturing involves 3D printing of sacrificial molds used for casting negative copies. B 4C powder distributions and rheology of suspensions were optimized to successfully cast complex shapes. In addition to demonstrating scalability of these complex geometries, hierarchically meso-porous structures were also shown to be possible from this technique. Resorcinol-Formaldehyde (RF) polymer was selected as the gelling agent and can also pyrolyze into a carbon aerogel network to act as the sinteringmore » aid for B 4C. Finally, due to the highly effective distribution of in situ carbon for the B 4C matrix, near-full sintered density of 97–98% of theoretical maximum density was achieved.« less

Complex shaped boron carbides from negative additive manufacturing

DOE Office of Scientific and Technical Information (OSTI.GOV)

Lu, Ryan; Chandrasekaran, Swetha; Du Frane, Wyatt L.

In this paper, complex shaped boron carbide with carbon (B 4C/C) at near-full densities were achieved for the first time using negative additive manufacturing techniques via gelcasting. Negative additive manufacturing involves 3D printing of sacrificial molds used for casting negative copies. B 4C powder distributions and rheology of suspensions were optimized to successfully cast complex shapes. In addition to demonstrating scalability of these complex geometries, hierarchically meso-porous structures were also shown to be possible from this technique. Resorcinol-Formaldehyde (RF) polymer was selected as the gelling agent and can also pyrolyze into a carbon aerogel network to act as the sinteringmore » aid for B 4C. Finally, due to the highly effective distribution of in situ carbon for the B 4C matrix, near-full sintered density of 97–98% of theoretical maximum density was achieved.« less

The manufacture and use of sludge test materials for R and D purposes in the treatment and processing of magnox based sludge

DOE Office of Scientific and Technical Information (OSTI.GOV)

Blackburn, D.R.; Thompson, E.J.

2013-07-01

Among the Intermediate Level Waste materials in store and awaiting treatment and processing in the UK are quantities of magnesium hydroxide sludge. This sludge is a product of radioactive Magnox Swarf which arose from the de-canning of used magnox fuel element rods. As the Swarf was stored underwater, a corrosion reaction occurred over the course of time between the magnox and the water resulting in a magnesium hydroxide based sludge. The differing conditions and materials present in the various storage areas means that the sludge can range in consistency from that of a slurry through to a thick clay. Sludgemore » test materials are required to underpin and validate the research and development equipment and processes that are to be used to treat the waste material. Necessary restrictions imposed on the sampling and testing of the radioactive waste means that the available data on the properties and behaviour of the sludge is limited. The raw materials used to create the sludge test materials are based upon magnesium hydroxide so that as far as possible the chemical behaviour will be similar to that of the waste material. The most representative sludge test material is manufactured by the corrosion of non-radioactive magnox or magnesium. However, time constraints make it impractical to supply this material in sufficient quantities for full scale validation trials. An alternative is to use sludge manufactured from commercially available magnesium hydroxide. The particle shape of commercially available materials differs from corrosion product magnesium hydroxide which means that properties such as the rheological behaviour cannot be replicated. Nevertheless, valuable trial data can be obtained, giving a greater degree of confidence in the waste treatment process than would be possible if only the more representative but less available corrosion product materials were to be used. Key test material parameters used in the trials have been identified as the particle size distribution and the sludge thickness (measured as yield shear strength). Other properties including cohesion, adhesion and rheological behaviour are also considered. The use of different mixers for sludge manufacture has the potential to affect the behavioural properties and a brief description of each of these mixers is included. The scale of mixing has been found to make a significant difference to the ageing. A chemical impurity in the commercially available materials has been successfully exploited, so that sludge mixed at comparatively low yield shear strengths can thicken into the consistency of clay. This aids manufacture and allows large quantities of thick material to be produced relatively easily. (authors)« less

Modeling the performance and cost of lithium-ion batteries for electric-drive vehicles.

DOE Office of Scientific and Technical Information (OSTI.GOV)

Nelson, P. A.

2011-10-20

This report details the Battery Performance and Cost model (BatPaC) developed at Argonne National Laboratory for lithium-ion battery packs used in automotive transportation. The model designs the battery for a specified power, energy, and type of vehicle battery. The cost of the designed battery is then calculated by accounting for every step in the lithium-ion battery manufacturing process. The assumed annual production level directly affects each process step. The total cost to the original equipment manufacturer calculated by the model includes the materials, manufacturing, and warranty costs for a battery produced in the year 2020 (in 2010 US$). At themore » time this report is written, this calculation is the only publically available model that performs a bottom-up lithium-ion battery design and cost calculation. Both the model and the report have been publically peer-reviewed by battery experts assembled by the U.S. Environmental Protection Agency. This report and accompanying model include changes made in response to the comments received during the peer-review. The purpose of the report is to document the equations and assumptions from which the model has been created. A user of the model will be able to recreate the calculations and perhaps more importantly, understand the driving forces for the results. Instructions for use and an illustration of model results are also presented. Almost every variable in the calculation may be changed by the user to represent a system different from the default values pre-entered into the program. The distinct advantage of using a bottom-up cost and design model is that the entire power-to-energy space may be traversed to examine the correlation between performance and cost. The BatPaC model accounts for the physical limitations of the electrochemical processes within the battery. Thus, unrealistic designs are penalized in energy density and cost, unlike cost models based on linear extrapolations. Additionally, the consequences on cost and energy density from changes in cell capacity, parallel cell groups, and manufacturing capabilities are easily assessed with the model. New proposed materials may also be examined to translate bench-scale values to the design of full-scale battery packs providing realistic energy densities and prices to the original equipment manufacturer. The model will be openly distributed to the public in the year 2011. Currently, the calculations are based in a Microsoft{reg_sign} Office Excel spreadsheet. Instructions are provided for use; however, the format is admittedly not user-friendly. A parallel development effort has created an alternate version based on a graphical user-interface that will be more intuitive to some users. The version that is more user-friendly should allow for wider adoption of the model.« less

Additive direct-write microfabrication for MEMS: A review

NASA Astrophysics Data System (ADS)

Teh, Kwok Siong

2017-12-01

Direct-write additive manufacturing refers to a rich and growing repertoire of well-established fabrication techniques that builds solid objects directly from computer- generated solid models without elaborate intermediate fabrication steps. At the macroscale, direct-write techniques such as stereolithography, selective laser sintering, fused deposition modeling ink-jet printing, and laminated object manufacturing have significantly reduced concept-to-product lead time, enabled complex geometries, and importantly, has led to the renaissance in fabrication known as the maker movement. The technological premises of all direct-write additive manufacturing are identical—converting computer generated three-dimensional models into layers of two-dimensional planes or slices, which are then reconstructed sequentially into threedimensional solid objects in a layer-by-layer format. The key differences between the various additive manufacturing techniques are the means of creating the finished layers and the ancillary processes that accompany them. While still at its infancy, direct-write additive manufacturing techniques at the microscale have the potential to significantly lower the barrier-of-entry—in terms of cost, time and training—for the prototyping and fabrication of MEMS parts that have larger dimensions, high aspect ratios, and complex shapes. In recent years, significant advancements in materials chemistry, laser technology, heat and fluid modeling, and control systems have enabled additive manufacturing to achieve higher resolutions at the micrometer and nanometer length scales to be a viable technology for MEMS fabrication. Compared to traditional MEMS processes that rely heavily on expensive equipment and time-consuming steps, direct-write additive manufacturing techniques allow for rapid design-to-prototype realization by limiting or circumventing the need for cleanrooms, photolithography and extensive training. With current direct-write additive manufacturing technologies, it is possible to fabricate unsophisticated micrometer scale structures at adequate resolutions and precisions using materials that range from polymers, metals, ceramics, to composites. In both academia and industry, direct-write additive manufacturing offers extraordinary promises to revolutionize research and development in microfabrication and MEMS technologies. Importantly, direct-write additive manufacturing could appreciably augment current MEMS fabrication technologies, enable faster design-to-product cycle, empower new paradigms in MEMS designs, and critically, encourage wider participation in MEMS research at institutions or for individuals with limited or no access to cleanroom facilities. This article aims to provide a limited review of the current landscape of direct-write additive manufacturing techniques that are potentially applicable for MEMS microfabrication.

Equipment characterization to mitigate risks during transfers of cell culture manufacturing processes.

PubMed

Sieblist, Christian; Jenzsch, Marco; Pohlscheidt, Michael

2016-08-01

The production of monoclonal antibodies by mammalian cell culture in bioreactors up to 25,000 L is state of the art technology in the biotech industry. During the lifecycle of a product, several scale up activities and technology transfers are typically executed to enable the supply chain strategy of a global pharmaceutical company. Given the sensitivity of mammalian cells to physicochemical culture conditions, process and equipment knowledge are critical to avoid impacts on timelines, product quantity and quality. Especially, the fluid dynamics of large scale bioreactors versus small scale models need to be described, and similarity demonstrated, in light of the Quality by Design approach promoted by the FDA. This approach comprises an associated design space which is established during process characterization and validation in bench scale bioreactors. Therefore the establishment of predictive models and simulation tools for major operating conditions of stirred vessels (mixing, mass transfer, and shear force.), based on fundamental engineering principles, have experienced a renaissance in the recent years. This work illustrates the systematic characterization of a large variety of bioreactor designs deployed in a global manufacturing network ranging from small bench scale equipment to large scale production equipment (25,000 L). Several traditional methods to determine power input, mixing, mass transfer and shear force have been used to create a data base and identify differences for various impeller types and configurations in operating ranges typically applied in cell culture processes at manufacturing scale. In addition, extrapolation of different empirical models, e.g. Cooke et al. (Paper presented at the proceedings of the 2nd international conference of bioreactor fluid dynamics, Cranfield, UK, 1988), have been assessed for their validity in these operational ranges. Results for selected designs are shown and serve as examples of structured characterization to enable fast and agile process transfers, scale up and troubleshooting.

Research on advanced transportation systems

NASA Astrophysics Data System (ADS)

Nagai, Hirokazu; Hashimoto, Ryouhei; Nosaka, Masataka; Koyari, Yukio; Yamada, Yoshio; Noda, Keiichirou; Shinohara, Suetsugu; Itou, Tetsuichi; Etou, Takao; Kaneko, Yutaka

1992-08-01

An overview of the researches on advanced space transportation systems is presented. Conceptual study is conducted on fly back boosters with expendable upper stage rocket systems assuming a launch capacity of 30 tons and returning to the launch site by the boosters, and prospect of their feasibility is obtained. Reviews are conducted on subjects as follows: (1) trial production of 10 tons sub scale engines for the purpose of acquiring hardware data and picking up technical problems for full scale 100 tons thrust engines using hydrocarbon fuels; (2) development techniques for advanced liquid propulsion systems from the aspects of development schedule, cost; (3) review of conventional technologies, and common use of component; (4) oxidant switching propulsion systems focusing on feasibility of Liquefied Air Cycle Engine (LACE) and Compressed Air Cycle Engine (CACE); (5) present status of slosh hydrogen manufacturing, storage, and handling; (6) construction of small high speed dynamometer for promoting research on mini pump development; (7) hybrid solid boosters under research all over the world as low-cost and clean propulsion systems; and (8) high performance solid propellant for upper stage and lower stage propulsion systems.

ITER-FEAT vacuum vessel and blanket design features and implications for the R&D programme

NASA Astrophysics Data System (ADS)

Ioki, K.; Dänner, W.; Koizumi, K.; Krylov, V. A.; Cardella, A.; Elio, F.; Onozuka, M.; ITER Joint Central Team; ITER Home Teams

2001-03-01

A configuration in which the vacuum vessel (VV) fits tightly to the plasma aids the passive plasma vertical stability, and ferromagnetic material in the VV reduces the toroidal field ripple. The blanket modules are supported directly by the VV. A full scale VV sector model has provided critical information related to fabrication technology and for testing the magnitude of welding distortions and achievable tolerances. This R&D validated the fundamental feasibility of the double wall VV design. The blanket module configuration consists of a shield body to which a separate first wall is mounted. The separate first wall has a facet geometry consisting of multiple flat panels, where 3-D machining will not be required. A configuration with deep slits minimizes the induced eddy currents and loads. The feasibility and robustness of solid hot isostatic pressing joining were demonstrated in the R&D by manufacturing and testing several small and medium scale mock-ups and finally two prototypes. Remote handling tests and assembly tests of a blanket module have demonstrated the basic feasibility of its installation and removal.

Examination of the Work Organization Assessment Questionnaire in public sector workers.

PubMed

Wynne-Jones, Gwenllian; Varnava, Alice; Buck, Rhiannon; Karanika-Murray, Maria; Griffiths, Amanda; Phillips, Ceri; Cox, Tom; Kahn, Sayeed; Main, Chris J

2009-05-01

To investigate the utility of the Work and Organization Assessment Questionnaire (WOAQ) for public sector data. A cross-sectional survey was performed in public sector organizations measuring demographics, work characteristics, work perceptions (WOAQ), sickness absence, and work performance. Confirmatory factor analysis of the WOAQ showed that factor structure derived for the manufacturing sector, for which the questionnaire was developed, could be replicated moderately well with public sector data. The study then considered whether a better more specific fit for public sector data was possible. Principal components analysis of the public sector data identified a two-factor structure linked to four of the five scales of the WOAQ assessing Management and Work Design, and Work Culture. These two factors may offer a context-sensitive scoring method for the WOAQ in public sector populations. These two factors were found to have good internal consistency, and correlated with the full WOAQ scales and the measures of performance and absence. The WOAQ is a useful and potentially transferable tool. The modified scoring may be used to assess work and organizational factors in the public sector.

Analysis and evaluation in the production process and equipment area of the low-cost solar array project

NASA Technical Reports Server (NTRS)

Goldman, H.; Wolf, M.

1979-01-01

The energy consumed in manufacturing silicon solar cell modules was calculated for the current process, as well as for 1982 and 1986 projected processes. In addition, energy payback times for the above three sequences are shown. The module manufacturing energy was partitioned two ways. In one way, the silicon reduction, silicon purification, sheet formation, cell fabrication, and encapsulation energies were found. In addition, the facility, equipment, processing material and direct material lost-in-process energies were appropriated in junction formation processes and full module manufacturing sequences. A brief methodology accounting for the energy of silicon wafers lost-in-processing during cell manufacturing is described.

Development of Probabilistic Structural Analysis Integrated with Manufacturing Processes

NASA Technical Reports Server (NTRS)

Pai, Shantaram S.; Nagpal, Vinod K.

2007-01-01

An effort has been initiated to integrate manufacturing process simulations with probabilistic structural analyses in order to capture the important impacts of manufacturing uncertainties on component stress levels and life. Two physics-based manufacturing process models (one for powdered metal forging and the other for annular deformation resistance welding) have been linked to the NESSUS structural analysis code. This paper describes the methodology developed to perform this integration including several examples. Although this effort is still underway, particularly for full integration of a probabilistic analysis, the progress to date has been encouraging and a software interface that implements the methodology has been developed. The purpose of this paper is to report this preliminary development.

Application of Contact Mode AFM to Manufacturing Processes

NASA Astrophysics Data System (ADS)

Giordano, Michael A.; Schmid, Steven R.

A review of the application of contact mode atomic force microscopy (AFM) to manufacturing processes is presented. A brief introduction to common experimental techniques including hardness, scratch, and wear testing is presented, with a discussion of challenges in the extension of manufacturing scale investigations to the AFM. Differences between the macro- and nanoscales tests are discussed, including indentation size effects and their importance in the simulation of processes such as grinding. The basics of lubrication theory are presented and friction force microscopy is introduced as a method of investigating metal forming lubrication on the nano- and microscales that directly simulates tooling/workpiece asperity interactions. These concepts are followed by a discussion of their application to macroscale industrial manufacturing processes and direct correlations are made.

Adaptive Multi-scale PHM for Robotic Assembly Processes

PubMed Central

Choo, Benjamin Y.; Beling, Peter A.; LaViers, Amy E.; Marvel, Jeremy A.; Weiss, Brian A.

2017-01-01

Adaptive multiscale prognostics and health management (AM-PHM) is a methodology designed to support PHM in smart manufacturing systems. As a rule, PHM information is not used in high-level decision-making in manufacturing systems. AM-PHM leverages and integrates component-level PHM information with hierarchical relationships across the component, machine, work cell, and production line levels in a manufacturing system. The AM-PHM methodology enables the creation of actionable prognostic and diagnostic intelligence up and down the manufacturing process hierarchy. Decisions are made with the knowledge of the current and projected health state of the system at decision points along the nodes of the hierarchical structure. A description of the AM-PHM methodology with a simulated canonical robotic assembly process is presented. PMID:28664161

Development of novel IVD assays: a manufacturer's perspective.

PubMed

Metcalfe, Thomas A

2010-01-01

IVD manufacturers are heavily reliant on novel IVD assays to fuel their growth and drive innovation within the industry. They represent a key part of the IVD industry's value proposition to customers and the healthcare industry in general, driving product differentiation, helping to create demand for new systems and generating incremental revenue. However, the discovery of novel biomarkers and their qualification for a specific clinical purpose is a high risk undertaking and the large, risky investments associated with doing this on a large scale are incompatible with IVD manufacturer's business models. This article describes the sources of novel IVD assays, the processes for discovering and qualifying novel assays and the reliance of IVD manufacturers on collaborations and in-licensing to source new IVD assays for their platforms.

Attributes and Behaviors of Performance-Centered Systems.

ERIC Educational Resources Information Center

Gery, Gloria

1995-01-01

Examines attributes, characteristics, and behaviors of performance-centered software packages that are emerging in the consumer software marketplace and compares them with large-scale systems software being designed by internal information systems staffs and vendors of large-scale software designed for financial, manufacturing, processing, and…

Recombinant protein vaccines produced in insect cells.

PubMed

Cox, Manon M J

2012-02-27

The baculovirus-insect cell expression system is a well known tool for the production of complex proteins. The technology is also used for commercial manufacture of various veterinary and human vaccines. This review paper provides an overview of how this technology can be applied to produce a multitude of vaccine candidates. The key advantage of this recombinant protein manufacturing platform is that a universal "plug and play" process may be used for producing a broad range of protein-based prophylactic and therapeutic vaccines for both human and veterinary use while offering the potential for low manufacturing costs. Large scale mammalian cell culture facilities previously established for the manufacturing of monoclonal antibodies that have now become obsolete due to yield improvement could be deployed for the manufacturing of these vaccines. Alternatively, manufacturing capacity could be established in geographic regions that do not have any vaccine production capability. Dependent on health care priorities, different vaccines could be manufactured while maintaining the ability to rapidly convert to producing pandemic influenza vaccine when the need arises. Copyright © 2012 Elsevier Ltd. All rights reserved.

Modeling process-structure-property relationships for additive manufacturing

NASA Astrophysics Data System (ADS)

Yan, Wentao; Lin, Stephen; Kafka, Orion L.; Yu, Cheng; Liu, Zeliang; Lian, Yanping; Wolff, Sarah; Cao, Jian; Wagner, Gregory J.; Liu, Wing Kam

2018-02-01

This paper presents our latest work on comprehensive modeling of process-structure-property relationships for additive manufacturing (AM) materials, including using data-mining techniques to close the cycle of design-predict-optimize. To illustrate the processstructure relationship, the multi-scale multi-physics process modeling starts from the micro-scale to establish a mechanistic heat source model, to the meso-scale models of individual powder particle evolution, and finally to the macro-scale model to simulate the fabrication process of a complex product. To link structure and properties, a highefficiency mechanistic model, self-consistent clustering analyses, is developed to capture a variety of material response. The model incorporates factors such as voids, phase composition, inclusions, and grain structures, which are the differentiating features of AM metals. Furthermore, we propose data-mining as an effective solution for novel rapid design and optimization, which is motivated by the numerous influencing factors in the AM process. We believe this paper will provide a roadmap to advance AM fundamental understanding and guide the monitoring and advanced diagnostics of AM processing.

Cell therapy-processing economics: small-scale microfactories as a stepping stone toward large-scale macrofactories.

PubMed

Harrison, Richard P; Medcalf, Nicholas; Rafiq, Qasim A

2018-03-01

Manufacturing methods for cell-based therapies differ markedly from those established for noncellular pharmaceuticals and biologics. Attempts to 'shoehorn' these into existing frameworks have yielded poor outcomes. Some excellent clinical results have been realized, yet emergence of a 'blockbuster' cell-based therapy has so far proved elusive.  The pressure to provide these innovative therapies, even at a smaller scale, remains. In this process, economics research paper, we utilize cell expansion research data combined with operational cost modeling in a case study to demonstrate the alternative ways in which a novel mesenchymal stem cell-based therapy could be provided at small scale. This research outlines the feasibility of cell microfactories but highlighted that there is a strong pressure to automate processes and split the quality control cost-burden over larger production batches. The study explores one potential paradigm of cell-based therapy provisioning as a potential exemplar on which to base manufacturing strategy.

Predictive models of lyophilization process for development, scale-up/tech transfer and manufacturing.

PubMed

Zhu, Tong; Moussa, Ehab M; Witting, Madeleine; Zhou, Deliang; Sinha, Kushal; Hirth, Mario; Gastens, Martin; Shang, Sherwin; Nere, Nandkishor; Somashekar, Shubha Chetan; Alexeenko, Alina; Jameel, Feroz

2018-07-01

Scale-up and technology transfer of lyophilization processes remains a challenge that requires thorough characterization of the laboratory and larger scale lyophilizers. In this study, computational fluid dynamics (CFD) was employed to develop computer-based models of both laboratory and manufacturing scale lyophilizers in order to understand the differences in equipment performance arising from distinct designs. CFD coupled with steady state heat and mass transfer modeling of the vial were then utilized to study and predict independent variables such as shelf temperature and chamber pressure, and response variables such as product resistance, product temperature and primary drying time for a given formulation. The models were then verified experimentally for the different lyophilizers. Additionally, the models were applied to create and evaluate a design space for a lyophilized product in order to provide justification for the flexibility to operate within a certain range of process parameters without the need for validation. Published by Elsevier B.V.

MODELING OF ION-EXCHANGE FOR CESIUM REMOVAL FROM DISSOLVED SALTCAKE IN SRS TANKS 1-3, 37 AND 41

DOE Office of Scientific and Technical Information (OSTI.GOV)

Smith, F

2007-08-15

This report presents an evaluation of the expected performance of engineered Crystalline Silicotitanate (CST) and spherical Resorcinol-Formaldehyde (RF) ion exchange resin for the removal of cesium from dissolved saltcake in SRS Tanks 1-3, 37 and 41. The application presented in this report reflects the expected behavior of engineered CST IE-911 and spherical RF resin manufactured at the intermediate-scale (approximately 100 gallon batch size; batch 5E-370/641). It is generally believed that scale-up to production-scale in RF resin manufacturing will result in similarly behaving resin batches whose chemical selectivity is unaffected while total capacity per gram of resin may vary. As such,more » the predictions provided within this report should provide reasonable estimates of production-scale column performance. Two versions of the RF cesium isotherm were used. The older version provides a conservative estimate of the resin capacity while the newer version more accurately fits the most recent experimental data.« less

An Integrated Computational Materials Engineering Method for Woven Carbon Fiber Composites Preforming Process

DOE Office of Scientific and Technical Information (OSTI.GOV)

Zhang, Weizhao; Ren, Huaqing; Wang, Zequn

2016-10-19

An integrated computational materials engineering method is proposed in this paper for analyzing the design and preforming process of woven carbon fiber composites. The goal is to reduce the cost and time needed for the mass production of structural composites. It integrates the simulation methods from the micro-scale to the macro-scale to capture the behavior of the composite material in the preforming process. In this way, the time consuming and high cost physical experiments and prototypes in the development of the manufacturing process can be circumvented. This method contains three parts: the micro-scale representative volume element (RVE) simulation to characterizemore » the material; the metamodeling algorithm to generate the constitutive equations; and the macro-scale preforming simulation to predict the behavior of the composite material during forming. The results show the potential of this approach as a guidance to the design of composite materials and its manufacturing process.« less

Facts controllers and HVDC enhance power transmission (A manufacturer`s perspective)

DOE Office of Scientific and Technical Information (OSTI.GOV)

Juette, G.; Renz, K.

1995-12-31

Various types of FACTS as well as HVDC have been available for some time. New ones have been developed recently. Their respective benefits are well proven and have been made known. System studies have to be done to make full use of FACTS and HVDC problem solving capabilities. Siemens is offering digital models for correct representation of several FACTS devices and HVDC in widely used time-based simulation study programs. The manufacturers are doing their homework. It is up to the utility industry to make use of it now!

Flat conductor cable design, manufacture, and installation

NASA Technical Reports Server (NTRS)

Angele, W.; Hankins, J. D.

1973-01-01

Pertinent information for hardware selection, design, manufacture, and quality control necessary for flat conductor cable interconnecting harness application is presented. Comparisons are made between round wire cable and flat conductor cable. The flat conductor cable interconnecting harness systems show major cost, weight, and space savings, plus increased system performance and reliability. The design application section includes electrical characteristics, harness design and development, and a full treatise on EMC considerations. Manufacturing and quality control sections pertain primarily to the developed conductor-contact connector system and special flat conductor cable to round wire cable transitions.

Study of multi-functional precision optical measuring system for large scale equipment

NASA Astrophysics Data System (ADS)

Jiang, Wei; Lao, Dabao; Zhou, Weihu; Zhang, Wenying; Jiang, Xingjian; Wang, Yongxi

2017-10-01

The effective application of high performance measurement technology can greatly improve the large-scale equipment manufacturing ability. Therefore, the geometric parameters measurement, such as size, attitude and position, requires the measurement system with high precision, multi-function, portability and other characteristics. However, the existing measuring instruments, such as laser tracker, total station, photogrammetry system, mostly has single function, station moving and other shortcomings. Laser tracker needs to work with cooperative target, but it can hardly meet the requirement of measurement in extreme environment. Total station is mainly used for outdoor surveying and mapping, it is hard to achieve the demand of accuracy in industrial measurement. Photogrammetry system can achieve a wide range of multi-point measurement, but the measuring range is limited and need to repeatedly move station. The paper presents a non-contact opto-electronic measuring instrument, not only it can work by scanning the measurement path but also measuring the cooperative target by tracking measurement. The system is based on some key technologies, such as absolute distance measurement, two-dimensional angle measurement, automatically target recognition and accurate aiming, precision control, assembly of complex mechanical system and multi-functional 3D visualization software. Among them, the absolute distance measurement module ensures measurement with high accuracy, and the twodimensional angle measuring module provides precision angle measurement. The system is suitable for the case of noncontact measurement of large-scale equipment, it can ensure the quality and performance of large-scale equipment throughout the process of manufacturing and improve the manufacturing ability of large-scale and high-end equipment.

Sustainable design and manufacturing of multifunctional polymer nanocomposite coatings: A multiscale systems approach

NASA Astrophysics Data System (ADS)

Xiao, Jie

Polymer nanocomposites have a great potential to be a dominant coating material in a wide range of applications in the automotive, aerospace, ship-making, construction, and pharmaceutical industries. However, how to realize design sustainability of this type of nanostructured materials and how to ensure the true optimality of the product quality and process performance in coating manufacturing remain as a mountaintop area. The major challenges arise from the intrinsic multiscale nature of the material-process-product system and the need to manipulate the high levels of complexity and uncertainty in design and manufacturing processes. This research centers on the development of a comprehensive multiscale computational methodology and a computer-aided tool set that can facilitate multifunctional nanocoating design and application from novel function envisioning and idea refinement, to knowledge discovery and design solution derivation, and further to performance testing in industrial applications and life cycle analysis. The principal idea is to achieve exceptional system performance through concurrent characterization and optimization of materials, product and associated manufacturing processes covering a wide range of length and time scales. Multiscale modeling and simulation techniques ranging from microscopic molecular modeling to classical continuum modeling are seamlessly coupled. The tight integration of different methods and theories at individual scales allows the prediction of macroscopic coating performance from the fundamental molecular behavior. Goal-oriented design is also pursued by integrating additional methods for bio-inspired dynamic optimization and computational task management that can be implemented in a hierarchical computing architecture. Furthermore, multiscale systems methodologies are developed to achieve the best possible material application towards sustainable manufacturing. Automotive coating manufacturing, that involves paint spay and curing, is specifically discussed in this dissertation. Nevertheless, the multiscale considerations for sustainable manufacturing, the novel concept of IPP control, and the new PPDE-based optimization method are applicable to other types of manufacturing, e.g., metal coating development through electroplating. It is demonstrated that the methodological development in this dissertation can greatly facilitate experimentalists in novel material invention and new knowledge discovery. At the same time, they can provide scientific guidance and reveal various new opportunities and effective strategies for sustainable manufacturing.

10 CFR 431.445 - Determination of small electric motor efficiency.

Code of Federal Regulations, 2014 CFR

2014-01-01

...) General requirements. The average full-load efficiency of each basic model of small electric motor must be... this section, provided, however, that an AEDM may be used to determine the average full-load efficiency of one or more of a manufacturer's basic models only if the average full-load efficiency of at least...

10 CFR 431.445 - Determination of small electric motor efficiency.

Code of Federal Regulations, 2013 CFR

2013-01-01

...) General requirements. The average full-load efficiency of each basic model of small electric motor must be... this section, provided, however, that an AEDM may be used to determine the average full-load efficiency of one or more of a manufacturer's basic models only if the average full-load efficiency of at least...

Capital intensity of photovoltaics manufacturing: Barrier to scale and opportunity for innovation

DOE Office of Scientific and Technical Information (OSTI.GOV)

Powell, Douglas M.; Fu, Ran; Horowitz, Kelsey

In this study, using a bottom-up cost model, we assess the impact of initial factory capital expenditure (capex) on photovoltaic (PV) module minimum sustainable price (MSP) and industry-wide trends. We find capex to have two important impacts on PV manufacturing. First, capex strongly influences the per-unit MSP of a c-Si module: we calculate that the capex-related elements sum to 22% of MSP for an integrated wafer, cell, and module manufacturer. This fraction provides a significant opportunity to reduce MSP toward the U.S. DOE SunShot module price target through capex innovation.

Time Lapse of World’s Largest 3-D Printed Object

DOE Office of Scientific and Technical Information (OSTI.GOV)

None

2016-08-29

Researchers at the MDF have 3D-printed a large-scale trim tool for a Boeing 777X, the world’s largest twin-engine jet airliner. The additively manufactured tool was printed on the Big Area Additive Manufacturing, or BAAM machine over a 30-hour period. The team used a thermoplastic pellet comprised of 80% ABS plastic and 20% carbon fiber from local material supplier. The tool has proven to decrease time, labor, cost and errors associated with traditional manufacturing techniques and increased energy savings in preliminary testing and will undergo further, long term testing.

Further Structural Intelligence for Sensors Cluster Technology in Manufacturing

PubMed Central

Mekid, Samir

2006-01-01

With the ever increasing complex sensing and actuating tasks in manufacturing plants, intelligent sensors cluster in hybrid networks becomes a rapidly expanding area. They play a dominant role in many fields from macro and micro scale. Global object control and the ability to self organize into fault-tolerant and scalable systems are expected for high level applications. In this paper, new structural concepts of intelligent sensors and networks with new intelligent agents are presented. Embedding new functionalities to dynamically manage cooperative agents for autonomous machines are interesting key enabling technologies most required in manufacturing for zero defects production.

Infrared Time Lapse of World’s Largest 3D-Printed Object

DOE Office of Scientific and Technical Information (OSTI.GOV)

None

Researchers at Oak Ridge National Laboratory have 3D-printed a large-scale trim tool for a Boeing 777X, the world’s largest twin-engine jet airliner. The additively manufactured tool was printed on the Big Area Additive Manufacturing, or BAAM machine over a 30-hour period. The team used a thermoplastic pellet comprised of 80% ABS plastic and 20% carbon fiber from local material supplier. The tool has proven to decrease time, labor, cost and errors associated with traditional manufacturing techniques and increased energy savings in preliminary testing and will undergo further, long term testing.

Capital intensity of photovoltaics manufacturing: Barrier to scale and opportunity for innovation

DOE PAGES

Powell, Douglas M.; Fu, Ran; Horowitz, Kelsey; ...

2015-09-07

In this study, using a bottom-up cost model, we assess the impact of initial factory capital expenditure (capex) on photovoltaic (PV) module minimum sustainable price (MSP) and industry-wide trends. We find capex to have two important impacts on PV manufacturing. First, capex strongly influences the per-unit MSP of a c-Si module: we calculate that the capex-related elements sum to 22% of MSP for an integrated wafer, cell, and module manufacturer. This fraction provides a significant opportunity to reduce MSP toward the U.S. DOE SunShot module price target through capex innovation.

Design and Evaluation of Log-To-Dimension Manufacturing Systems Using System Simulation

Treesearch

Wenjie Lin; D. Earl Kline; Philip A. Araman; Janice K. Wiedenbeck

1995-01-01

In a recent study of alternative dimension manufacturing systems that produce green hardwood dimension directly fromlogs, it was observed that for Grade 2 and 3 red oak logs, up to 78 and 76 percent of the log scale volume could be converted into clear dimension parts. The potential high yields suggest that this processing system can be a promising technique for...

Manufacturing considerations for AMLCD cockpit displays

NASA Astrophysics Data System (ADS)

Luo, Fang-Chen

1995-06-01

AMLCD cockpit displays need to meet more stringent requirements compared with AMLCD commercial displays in areas such as environmental conditions, optical performance and device reliability. Special considerations are required for the manufacturing of AMLCD cockpit displays in each process step to address these issues. Some examples are: UV stable polarizers, wide-temperature LC material, strong LC glue seal, ESS test system, gray scale voltage EEPROM, etc.

Concise Review: Guidance in Developing Commercializable Autologous/Patient-Specific Cell Therapy Manufacturing

PubMed Central

Armant, Myriam; Brandwein, Harvey; Burger, Scott; Campbell, Andrew; Carpenito, Carmine; Clarke, Dominic; Fong, Timothy; Karnieli, Ohad; Niss, Knut; Van't Hof, Wouter; Wagey, Ravenska

2013-01-01

Cell therapy is poised to play an enormous role in regenerative medicine. However, little guidance is being made available to academic and industrial entities in the start-up phase. In this technical review, members of the International Society for Cell Therapy provide guidance in developing commercializable autologous and patient-specific manufacturing strategies from the perspective of process development. Special emphasis is placed on providing guidance to small academic or biotech researchers as to what simple questions can be addressed or answered at the bench in order to make their cell therapy products more feasible for commercial-scale production. We discuss the processes that are required for scale-out at the manufacturing level, and how many questions can be addressed at the bench level. The goal of this review is to provide guidance in the form of topics that can be addressed early in the process of development to better the chances of the product being successful for future commercialization. PMID:24101671

DOE Office of Scientific and Technical Information (OSTI.GOV)

Hung, Cheng-Hung

The main objective of this project was to develop a low-cost integrated substrate for rigid OLED solid-state lighting produced at a manufacturing scale. The integrated substrates could include combinations of soda lime glass substrate, light extraction layer, and an anode layer (i.e., Transparent Conductive Oxide, TCO). Over the 3 + year course of the project, the scope of work was revised to focus on the development of a glass substrates with an internal light extraction (IEL) layer. A manufacturing-scale float glass on-line particle embedding process capable of producing an IEL glass substrate having a thickness of less than 1.7mm andmore » an area larger than 500mm x 400mm was demonstrated. Substrates measuring 470mm x 370mm were used in the OLED manufacturing process for fabricating OLED lighting panels in single pixel devices as large as 120.5mm x 120.5mm. The measured light extraction efficiency (calculated as external quantum efficiency, EQE) for on-line produced IEL samples (>50%) met the project’s initial goal.« less

Progress of the Photovoltaic Technology Incubator Project Towards an Enhanced U.S. Manufacturing Base: Preprint

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ullal, H.; Mitchell, R.; Keyes, B.

In this paper, we report on the major accomplishments of the U.S. Department of Energy's (DOE) Solar Energy Technologies Program (SETP) Photovoltaic (PV) Technology Incubator project. The Incubator project facilitates a company's transition from developing a solar cell or PV module prototype to pilot- and large-scale U.S. manufacturing. The project targets small businesses that have demonstrated proof-of-concept devices or processes in the laboratory. Their success supports U.S. Secretary of Energy Steven Chu's SunShot Initiative, which seeks to achieve PV technologies that are cost-competitive without subsidies at large scale with fossil-based energy sources by the end of this decade. The Incubatormore » Project has enhanced U.S. PV manufacturing capacity and created more than 1200 clean energy jobs, resulting in an increase in American economic competitiveness. The investment raised to date by these PV Incubator companies as a result of DOE's $ 59 million investment totals nearly $ 1.3 billion.« less

Progress of the PV Technology Incubator Project Towards an Enhanced U.S. Manufacturing Base

DOE Office of Scientific and Technical Information (OSTI.GOV)

Ullal, H.; Mitchell, R.; Keyes, B.

In this paper, we report on the major accomplishments of the U.S. Department of Energy's (DOE) Solar Energy Technologies Program (SETP) Photovoltaic (PV) Technology Incubator project. The Incubator project facilitates a company's transition from developing a solar cell or PV module prototype to pilot- and large-scale U.S. manufacturing. The project targets small businesses that have demonstrated proof-of-concept devices or processes in the laboratory. Their success supports U.S. Secretary of Energy Steven Chu's SunShot Initiative, which seeks to achieve PV technologies that are cost-competitive without subsidies at large scale with fossil-based energy sources by the end of this decade. The Incubatormore » Project has enhanced U.S. PV manufacturing capacity and created more than 1200 clean energy jobs, resulting in an increase in American economic competitiveness. The investment raised to date by these PV Incubator companies as a result of DOE's $ 59 million investment total nearly $ 1.3 billion.« less

Real time and accelerated stability studies of Tetanus toxoid manufactured in public sector facilities of Pakistan.

PubMed

Parveen, Ghazala; Hussain, Shahzad; Malik, Farnaz; Begum, Anwar; Mahmood, Sidra; Raza, Naeem

2013-11-01

Tetanus is an acute illness represented by comprehensive increased inflexibility and spastic spasms of skeletal muscles. The poor quality tetanus toxoid vaccine can raise the prevalence of neonatal tetanus. WHO has taken numerous steps to assist national regulatory authorities and vaccine manufacturers to ensure its quality and efficacy. It has formulated international principles for stability evaluation of each vaccine, which are available in the form of recommendations and guidelines. The aim of present study was to ensure the stability of tetanus vaccines produced by National Institute of Health, Islamabad, Pakistan by employing standardized methods to ensure constancy of tetanus toxoid at elevated temperature, if during storage/transportation cold chain may not be maintained in hot weather. A total of three batches filled during full-scale production were tested. All Stability studies determination were performed on final products stored at 2-8°C and elevated temperatures in conformance with the ICH Guideline of Stability Testing of Biological Products. These studies gave comparison between real time shelf-life stability and accelerated stability studies. The findings indicate long﷓term thermo stability and prove that this tetanus vaccine can remain efficient under setting of routine use when suggested measures for storage and handling are followed in true spirit.

Starshades for Exoplanet Imaging and Characterization

NASA Astrophysics Data System (ADS)

Kasdin, N. J.; Vanderbei, R. J.; Shaklan, S.; Lisman, D.; Thomson, M.; Cady, E.; Macintosh, B.; Sirbu, D.; Lo, A.

2014-01-01

An external occulter is a satellite employing a large screen, or starshade, that flies in formation with a spaceborne telescope to provide the starlight suppression needed for detecting and characterizing exoplanets. Among the advantages of using an occulter are the broadband allowed for characterization and the removal of light before entering the observatory, greatly relaxing the requirements on the telescope and instrument. In this presentation I will explain how star shades achieve high contrast through precise design and control of their shape and how we develop an error budget to establish requirements on the manufacturing and control. Raising the technology readiness level of starshades requires a sequence of activities to verify approaches to manufacturing, deployment, test, and analysis. The SAT-TDEM program has been instrumental in raising the readiness level of the most critical technology. In particular, I will show the results of our first TDEM in 2010-2012 that verified a full scale petal could be built and measured to the needed accuracy for 10 orders of magnitude of contrast. Our second TDEM in 2012-2014 verified that a starshade could be deployed and the petals could be placed to the required position to better than 1 mm. Finally, laboratory experiments have verified the optical modeling used to predict starshade performance to better than 1e-10.

Synthesis of Two-Dimensional Materials for Capacitive Energy Storage

DOE Office of Scientific and Technical Information (OSTI.GOV)

Mendoza-Sánchez, Beatriz; Gogotsi, Yury

The unique properties and great variety of two-dimensional (2D) nanomaterials make them highly attractive for energy storage applications. Here, an insight into the progress made towards the application of 2D nanomaterials for capacitive energy storage is provided. Moreover, synthesis methods, and electrochemical performance of various classes of 2D nanomaterials, particularly based on graphene, transition metal oxides, dichalcogenides, and carbides, are presented. Some factors that directly influence capacitive performance are discussed throughout the text and include nanosheet composition, morphology and texture, electrode architecture, and device configuration. Recent progress in the fabrication of 2D-nanomaterials-based microsupercapacitors and flexible and free-standing supercapacitors is presented.more » The main electrode manufacturing techniques with emphasis on scalability and cost-effectiveness are discussed, and include laser scribing, printing, and roll-to-roll manufacture. Some various issues that prevent the use of the full energy-storage potential of 2D nanomaterials and how they have been tackled are discussed, and include nanosheet aggregation and the low electrical conductivity of some 2D nanomaterials. In particular, the design of hybrid and hierarchical 2D and 3D structures based on 2D nanomaterials is presented. Other challenges and opportunities are discussed and include: control of nanosheets size and thickness, chemical and electrochemical instability, and scale-up of electrode films.« less

Synthesis of Two-Dimensional Materials for Capacitive Energy Storage

DOE PAGES

Mendoza-Sánchez, Beatriz; Gogotsi, Yury

2016-06-02

The unique properties and great variety of two-dimensional (2D) nanomaterials make them highly attractive for energy storage applications. Here, an insight into the progress made towards the application of 2D nanomaterials for capacitive energy storage is provided. Moreover, synthesis methods, and electrochemical performance of various classes of 2D nanomaterials, particularly based on graphene, transition metal oxides, dichalcogenides, and carbides, are presented. Some factors that directly influence capacitive performance are discussed throughout the text and include nanosheet composition, morphology and texture, electrode architecture, and device configuration. Recent progress in the fabrication of 2D-nanomaterials-based microsupercapacitors and flexible and free-standing supercapacitors is presented.more » The main electrode manufacturing techniques with emphasis on scalability and cost-effectiveness are discussed, and include laser scribing, printing, and roll-to-roll manufacture. Some various issues that prevent the use of the full energy-storage potential of 2D nanomaterials and how they have been tackled are discussed, and include nanosheet aggregation and the low electrical conductivity of some 2D nanomaterials. In particular, the design of hybrid and hierarchical 2D and 3D structures based on 2D nanomaterials is presented. Other challenges and opportunities are discussed and include: control of nanosheets size and thickness, chemical and electrochemical instability, and scale-up of electrode films.« less

Field-programmable lab-on-a-chip based on microelectrode dot array architecture.

PubMed

Wang, Gary; Teng, Daniel; Lai, Yi-Tse; Lu, Yi-Wen; Ho, Yingchieh; Lee, Chen-Yi

2014-09-01

The fundamentals of electrowetting-on-dielectric (EWOD) digital microfluidics are very strong: advantageous capability in the manipulation of fluids, small test volumes, precise dynamic control and detection, and microscale systems. These advantages are very important for future biochip developments, but the development of EWOD microfluidics has been hindered by the absence of: integrated detector technology, standard commercial components, on-chip sample preparation, standard manufacturing technology and end-to-end system integration. A field-programmable lab-on-a-chip (FPLOC) system based on microelectrode dot array (MEDA) architecture is presented in this research. The MEDA architecture proposes a standard EWOD microfluidic component called 'microelectrode cell', which can be dynamically configured into microfluidic components to perform microfluidic operations of the biochip. A proof-of-concept prototype FPLOC, containing a 30 × 30 MEDA, was developed by using generic integrated circuits computer aided design tools, and it was manufactured with standard low-voltage complementary metal-oxide-semiconductor technology, which allows smooth on-chip integration of microfluidics and microelectronics. By integrating 900 droplet detection circuits into microelectrode cells, the FPLOC has achieved large-scale integration of microfluidics and microelectronics. Compared to the full-custom and bottom-up design methods, the FPLOC provides hierarchical top-down design approach, field-programmability and dynamic manipulations of droplets for advanced microfluidic operations.

Demonstration of no-VOC/no-HAP wood furniture coating system

DOE Office of Scientific and Technical Information (OSTI.GOV)

Huang, E.W.; Guan, R.; McCrillis, R.C.

1997-12-31

The United States Environmental Protection Agency has contracted with AeroVironment Environmental Services, Inc. and its subcontractor, Adhesive Coating Co., to develop and demonstrate a no-VOC (volatile organic compound)/no-HAP (hazardous air pollutant) wood furniture coating system. The objectives of this project are to develop a new wood coating system that is sufficiently mature for demonstration and to develop a technology transfer plan to get the product into public use. The performance characteristics of this new coating system are excellent in terms of adhesion, drying times, gloss, hardness, mar resistance, level of solvents, and stain resistance. Workshops will be held to providemore » detailed information to wood furniture manufacturers on what is required to change to the new coating system. Topics such as spray gun selection, spray techniques, coating repair procedures, drying times and procedures, and spray equipment cleaning materials and techniques will be presented. A cost analysis, including costs of materials, capital outlay, and labor will be conducted comparing costs to finish furniture with the new system to systems currently used. Film performance, coating materials cost per unit production, productivity, manufacturing changes, and emission levels will be compared in the workshops, based on data gathered during the in-plant, full scale demonstrations.« less

Real-time product attribute control to manufacture antibodies with defined N-linked glycan levels.

PubMed

Zupke, Craig; Brady, Lowell J; Slade, Peter G; Clark, Philip; Caspary, R Guy; Livingston, Brittney; Taylor, Lisa; Bigham, Kyle; Morris, Arvia E; Bailey, Robert W

2015-01-01

Pressures for cost-effective new therapies and an increased emphasis on emerging markets require technological advancements and a flexible future manufacturing network for the production of biologic medicines. The safety and efficacy of a product is crucial, and consistent product quality is an essential feature of any therapeutic manufacturing process. The active control of product quality in a typical biologic process is challenging because of measurement lags and nonlinearities present in the system. The current study uses nonlinear model predictive control to maintain a critical product quality attribute at a predetermined value during pilot scale manufacturing operations. This approach to product quality control ensures a more consistent product for patients, enables greater manufacturing efficiency, and eliminates the need for extensive process characterization by providing direct measures of critical product quality attributes for real time release of drug product. © 2015 American Institute of Chemical Engineers.

Enhancing cell and gene therapy manufacture through the application of advanced fluorescent optical sensors (Review).

PubMed

Harrison, Richard P; Chauhan, Veeren M

2017-12-15

Cell and gene therapies (CGTs) are examples of future therapeutics that can be used to cure or alleviate the symptoms of disease, by repairing damaged tissue or reprogramming defective genetic information. However, despite the recent advancements in clinical trial outcomes, the path to wide-scale adoption of CGTs remains challenging, such that the emergence of a "blockbuster" therapy has so far proved elusive. Manufacturing solutions for these therapies require the application of scalable and replicable cell manufacturing techniques, which differ markedly from the existing pharmaceutical incumbent. Attempts to adopt this pharmaceutical model for CGT manufacture have largely proved unsuccessful. The most significant challenges facing CGT manufacturing are process analytical testing and quality control. These procedures would greatly benefit from improved sensory technologies that allow direct measurement of critical quality attributes, such as pH, oxygen, lactate and glucose. In turn, this would make manufacturing more robust, replicable and standardized. In this review, the present-day state and prospects of CGT manufacturing are discussed. In particular, the authors highlight the role of fluorescent optical sensors, focusing on their strengths and weaknesses, for CGT manufacture. The review concludes by discussing how the integration of CGT manufacture and fluorescent optical sensors could augment future bioprocessing approaches.

Robotic insects: Manufacturing, actuation, and power considerations

NASA Astrophysics Data System (ADS)

Wood, Robert

2015-12-01

As the characteristic size of a flying robot decreases, the challenges for successful flight revert to basic questions of fabrication, actuation, fluid mechanics, stabilization, and power - whereas such questions have in general been answered for larger aircraft. When developing a robot on the scale of a housefly, all hardware must be developed from scratch as there is nothing "off-the-shelf" which can be used for mechanisms, sensors, or computation that would satisfy the extreme mass and power limitations. With these challenges in mind, this talk will present progress in the essential technologies for insect-like robots with an emphasis on multi-scale manufacturing methods, high power density actuation, and energy-efficient power distribution.

Industrial-scale spray layer-by-layer assembly for production of biomimetic photonic systems.

PubMed

Krogman, K C; Cohen, R E; Hammond, P T; Rubner, M F; Wang, B N

2013-12-01

Layer-by-layer assembly is a powerful and flexible thin film process that has successfully reproduced biomimetic photonic systems such as structural colour. While most of the seminal work has been carried out using slow and ultimately unscalable immersion assembly, recent developments using spray layer-by-layer assembly provide a platform for addressing challenges to scale-up and manufacturability. A series of manufacturing systems has been developed to increase production throughput by orders of magnitude, making commercialized structural colour possible. Inspired by biomimetic photonic structures we developed and demonstrated a heat management system that relies on constructive reflection of near infrared radiation to bring about dramatic reductions in heat content.

Development of high performance refractory fibers with enhanced insulating properties and longer service lifetimes

DOE Office of Scientific and Technical Information (OSTI.GOV)

Martin, P.C.; DePoorter, G.L.; Munoz, D.R.

1991-02-01

We have initiated a three phase investigation of the development of high performance refractory fibers with enhanced insulating properties and longer usable lifetimes. This report presents the results of the first phase of the study, performed from Aug. 1989 through Feb. 1991, which shows that significant energy saving are possible through the use of high temperature insulating fibers that better retain their efficient insulating properties during the service lifetime of the fibers. The remaining phases of this program include the pilot scale development and then full scale production feasibility development and evaluation of enhanced high temperature refractory insulting fibers. Thismore » first proof of principle phase of the program presents a summary of the current use patterns of refractory fibers, a laboratory evaluation of the high temperature performance characteristics of selected typical refractory fibers and an analysis of the potential energy savings through the use of enhanced refractory fibers. The current use patterns of refractory fibers span a wide range of industries and high temperature furnaces within those industries. The majority of high temperature fiber applications are in furnaces operating between 2000 and 26000{degrees}F. The fibers used in furnaces operating within this range provide attractive thermal resistance and low thermal storage at reasonable cost. A series of heat treatment studies performed for this phase of the program has shown that the refractory fibers, as initially manufactured, have attractive thermal conductivities for high temperature applications but the fibers go through rapid devitrification and subsequent crystal growth upon high temperature exposure. Development of improved fibers, maintaining the favorable characteristics of the existing as-manufactured fibers, could save between 1 and 4% of the energy consumed in high temperature furnaces using refractory fibers.« less

General Overview of the ODC Elimination Effort of the RSRM Program

NASA Technical Reports Server (NTRS)

Evans, Kurt; Golde, Rick; McCool, Alex (Technical Monitor)

2001-01-01

The purpose of the ODC Elimination Program of the Space Shuttle RSRM Program is to eliminate the usage of 1, 1, 1 trichloroethane (TCA) in all RSRM (Reusable Solid Rocket Motor) manufacturing processes. This program consists of the following phases and objectives: Phase 0 - Convert to greaseless shipping of metal components. Phase 1 - Eliminate TCA vapor degreasing and usage in propellant cleaning operations. Phase 2 - Eliminate TCA usage for hand cleaning operations. Each phase reduces peak TCA consumption (about 1.4 million pounds in 1989) by about 29, 61, and 10 percent, respectively. Phase 0 was completed in 1992, Phase 1 in 1997, and Phase 2 is in progress (about 75% complete). TCA replacement objectives are accomplished by are a series of subscale, full-scale, and static testing outlined by the NASA-funded, ODC Elimination Program.

Evaluating the impact of LED bulb development on the economic viability of ultraviolet technology for disinfection.

PubMed

Ibrahim, Mohamed A S; MacAdam, Jitka; Autin, Olivier; Jefferson, Bruce

2014-01-01

Ultraviolet (UV) technologies have been very successful in disinfection applications due to their ability to inactivate microorganisms without producing harmful disinfection by-products. However, there have been a number of concerns associated with the use of conventional UV systems such as hazardous mercury content, high capital investment and reduced electrical efficiency. These concerns have set limitations for the use of UV processes. The study evaluates the development of light emitting diode (LED) technology as an alternative UV source over the last 5 years, analyses the projections provided by the researchers and UV LED manufacturers and presents the information in a cost model with the aim to predict the timeline at which UV LED will compete with traditional UV low pressure high output technology in the commercial market at full-scale residential and industrial disinfection applications.

Composite Crew Module: Primary Structure

NASA Technical Reports Server (NTRS)

Kirsch, Michael T.

2011-01-01

In January 2007, the NASA Administrator and Associate Administrator for the Exploration Systems Mission Directorate chartered the NASA Engineering and Safety Center to design, build, and test a full-scale crew module primary structure, using carbon fiber reinforced epoxy based composite materials. The overall goal of the Composite Crew Module project was to develop a team from the NASA family with hands-on experience in composite design, manufacturing, and testing in anticipation of future space exploration systems being made of composite materials. The CCM project was planned to run concurrently with the Orion project's baseline metallic design within the Constellation Program so that features could be compared and discussed without inducing risk to the overall Program. This report discusses the project management aspects of the project including team organization, decision making, independent technical reviews, and cost and schedule management approach.

75 FR 14572 - Notice of Petitions by Firms for Determination of Eligibility To Apply for Trade Adjustment...

Federal Register 2010, 2011, 2012, 2013, 2014

2010-03-26

... thereof, and to a decrease in sales or production of each petitioning firm. List of Petitions Received by... Manufacturing of Bedding Support Products, Co., Inc. Commerce, CA 90040. Bed Frames, Bed Rails, Rollaway Beds... Manufacturing 4116 First Avenue, 3/9/2010 Full line of steel display hardware Corp. Brooklyn, NY 11232...

A Integrated Circuit for a Biomedical Capacitive Pressure Transducer

NASA Astrophysics Data System (ADS)

Smith, Michael John Sebastian

Medical research has an urgent need for a small, accurate, stable, low-power, biocompatible and inexpensive pressure sensor with a zero to full-scale range of 0-300 mmHg. An integrated circuit (IC) for use with a capacitive pressure transducer was designed, built and tested. The random pressure measurement error due to resolution and non-linearity is (+OR-)0.4 mmHg (at mid-range with a full -scale of 300 mmHg). The long-term systematic error due to falling battery voltage is (+OR-)0.6 mmHg. These figures were calculated from measurements of temperature, supply dependence and non-linearity on completed integrated circuits. The sensor IC allows measurement of temperature to (+OR-)0.1(DEGREES)C to allow for temperature compensation of the transducer. Novel micropower circuit design of the system components enabled these levels of accuracy to be reached. Capacitance is measured by a new ratiometric scheme employing an on -chip reference capacitor. This method greatly reduces the effects of voltage supply, temperature and manufacturing variations on the sensor circuit performance. The limits on performance of the bandgap reference circuit fabricated with a standard bipolar process using ion-implanted resistors were determined. Measurements confirm the limits of temperature stability as approximately (+OR-)300 ppm/(DEGREES)C. An exact analytical expression for the period of the Schmitt trigger oscillator, accounting for non-constant capacitor charging current, was formulated. Experiments to test agreement with theory showed that prediction of the oscillator period was very accurate. The interaction of fundamental and practical limits on the scaling of the transducer size was investigated including a correction to previous theoretical analysis of jitter in an RC oscillator. An areal reduction of 4 times should be achievable.

Simulation research on the process of large scale ship plane segmentation intelligent workshop

NASA Astrophysics Data System (ADS)

Xu, Peng; Liao, Liangchuang; Zhou, Chao; Xue, Rui; Fu, Wei

2017-04-01

Large scale ship plane segmentation intelligent workshop is a new thing, and there is no research work in related fields at home and abroad. The mode of production should be transformed by the existing industry 2.0 or part of industry 3.0, also transformed from "human brain analysis and judgment + machine manufacturing" to "machine analysis and judgment + machine manufacturing". In this transforming process, there are a great deal of tasks need to be determined on the aspects of management and technology, such as workshop structure evolution, development of intelligent equipment and changes in business model. Along with them is the reformation of the whole workshop. Process simulation in this project would verify general layout and process flow of large scale ship plane section intelligent workshop, also would analyze intelligent workshop working efficiency, which is significant to the next step of the transformation of plane segmentation intelligent workshop.

Biosimilarity Versus Manufacturing Change: Two Distinct Concepts.

PubMed

Declerck, Paul; Farouk-Rezk, Mourad; Rudd, Pauline M

2016-02-01

As products of living cells, biologics are far more complicated than small molecular-weight drugs not only with respect to size and structural complexity but also their sensitivity to manufacturing processes and post-translational changes. Most of the information on the manufacturing process of biotherapeutics is proprietary and hence not fully accessible to the public. This information gap represents a key challenge for biosimilar developers and plays a key role in explaining the differences in regulatory pathways required to demonstrate biosimilarity versus those required to ensure that a change in manufacturing process did not have implications on safety and efficacy. Manufacturing process changes are frequently needed for a variety of reasons including response to regulatory requirements, up scaling production, change in facility, change in raw materials, improving control of quality (consistency) or optimising production efficiency. The scope of the change is usually a key indicator of the scale of analysis required to evaluate the quality. In most cases, where the scope of the process change is limited, only quality and analytical studies should be sufficient while comparative clinical studies can be required in case of major changes (e.g., cell line changes). Biosimilarity exercises have been addressed differently by regulators on the understanding that biosimilar developers start with fundamental differences being a new cell line and also a knowledge gap of the innovator's processes, including culture media, purification processes, and potentially different formulations, and are thus required to ensure that differences from innovators do not result in differences in efficacy and safety.

Optimized method for manufacturing large aspheric surfaces

NASA Astrophysics Data System (ADS)

Zhou, Xusheng; Li, Shengyi; Dai, Yifan; Xie, Xuhui

2007-12-01

Aspheric optics are being used more and more widely in modern optical systems, due to their ability of correcting aberrations, enhancing image quality, enlarging the field of view and extending the range of effect, while reducing the weight and volume of the system. With optical technology development, we have more pressing requirement to large-aperture and high-precision aspheric surfaces. The original computer controlled optical surfacing (CCOS) technique cannot meet the challenge of precision and machining efficiency. This problem has been thought highly of by researchers. Aiming at the problem of original polishing process, an optimized method for manufacturing large aspheric surfaces is put forward. Subsurface damage (SSD), full aperture errors and full band of frequency errors are all in control of this method. Lesser SSD depth can be gained by using little hardness tool and small abrasive grains in grinding process. For full aperture errors control, edge effects can be controlled by using smaller tools and amendment model with material removal function. For full band of frequency errors control, low frequency errors can be corrected with the optimized material removal function, while medium-high frequency errors by using uniform removing principle. With this optimized method, the accuracy of a K9 glass paraboloid mirror can reach rms 0.055 waves (where a wave is 0.6328μm) in a short time. The results show that the optimized method can guide large aspheric surface manufacturing effectively.

Utilizing global data to estimate analytical performance on the Sigma scale: A global comparative analysis of methods, instruments, and manufacturers through external quality assurance and proficiency testing programs.

PubMed

Westgard, Sten A

2016-06-01

To assess the analytical performance of instruments and methods through external quality assessment and proficiency testing data on the Sigma scale. A representative report from five different EQA/PT programs around the world (2 US, 1 Canadian, 1 UK, and 1 Australasian) was accessed. The instrument group standard deviations were used as surrogate estimates of instrument imprecision. Performance specifications from the US CLIA proficiency testing criteria were used to establish a common quality goal. Then Sigma-metrics were calculated to grade the analytical performance. Different methods have different Sigma-metrics for each analyte reviewed. Summary Sigma-metrics estimate the percentage of the chemistry analytes that are expected to perform above Five Sigma, which is where optimized QC design can be implemented. The range of performance varies from 37% to 88%, exhibiting significant differentiation between instruments and manufacturers. Median Sigmas for the different manufacturers in three analytes (albumin, glucose, sodium) showed significant differentiation. Chemistry tests are not commodities. Quality varies significantly from manufacturer to manufacturer, instrument to instrument, and method to method. The Sigma-assessments from multiple EQA/PT programs provide more insight into the performance of methods and instruments than any single program by itself. It is possible to produce a ranking of performance by manufacturer, instrument and individual method. Laboratories seeking optimal instrumentation would do well to consult this data as part of their decision-making process. To confirm that these assessments are stable and reliable, a longer term study should be conducted that examines more results over a longer time period. Copyright © 2016 The Canadian Society of Clinical Chemists. Published by Elsevier Inc. All rights reserved.

Comprehensive hands-on training for influenza vaccine manufacturing: a WHO-BARDA-BTEC partnership for global workforce development.

PubMed

Ruiz, Jennifer; Gilleskie, Gary L; Brown, Patty; Burnett, Bruce; Carbonell, Ruben G

2014-01-01

The critical need for enhancing influenza pandemic preparedness in many developing nations has led the World Health Organization (WHO) and the Biomedical Advanced Research and Development Authority (BARDA), part of the U.S. Department of Health and Human Services (HHS), to develop an international influenza vaccine capacity-building program. Among the critical limitations faced by many of these nations is lack of access to training programs for staff supporting operations within vaccine production facilities. With support from BARDA, the Biomanufacturing Training and Education Center (BTEC) at North Carolina State University has addressed this need for training by developing and delivering a comprehensive training program, consisting of three courses: Fundamentals of cGMP Influenza Vaccine Manufacturing, Advanced Upstream Processes for Influenza Vaccine Manufacturing, and Advanced Downstream Processes for Influenza Vaccine Manufacturing. The courses cover process design, transfer, and execution at manufacturing scale, quality systems, and regulations covering both manufacturing and approval of pandemic vaccines. The Fundamentals course focuses on the concepts, equipment, applicable regulations, and procedures commonly used to produce influenza vaccine. The two Advanced courses focus on process design, scale up, validation, and new technologies likely to improve efficiency of vaccine production. All three courses rely on a combination of classroom instruction and hands-on training in BTEC's various laboratories. Each course stands alone, and participants may take one or more of the three courses. Overall participant satisfaction with the courses has been high, and follow-up surveys show that participants actively transferred the knowledge they gained to the workplace. Future plans call for BTEC to continue offering the three courses and to create an online version of several modules of the Fundamentals course. Copyright © 2014 Wiley Periodicals, Inc.

Gram-scale production of plasmid pUDK-HGF with current good manufacturing practices for gene therapy of critical limb ischemia.

PubMed

Hu, ChunSheng; Cheng, XiaoChen; Lu, YuXin; Wu, ZuZe; Zhang, QingLin

2016-11-16

The demand of a plasmid encoding human hepatocyte growth factor gene (pUDK-HGF) in large quantities at high purity and concentration has increased for gene therapy of critical limb ischemia (CLI) in clinical trials. In this article, we produced pUDK-HGF in compliance with current good manufacturing practices at gram scale. The process included a 50-L batch fermentation, continuous alkaline lysis, and integrated three-step chromatography on Sepharose 6 Fast Flow, PlasmidSelect Xtra, and Source 15Q. The production process has been scaled up to yield 4.24 ± 0.41 g of pharmaceutical pUDK-HGF from 1.0 kg bacterial cell paste and the overall yield reached range from 58.37 to 66.70%. The final pUDK-HGF product exhibited high purity with supercoiled percentage of > 95.8% and undetectable residual RNA, contaminated protein, and bacterial endotoxin. The phase I clinical study indicates that intramuscular injection of pUDK-HGF is safe, well tolerated, and may provide symptomatic relief to CLI patients. These results show that our manufacturing process of pUDK-HGF is efficient in producing pharmaceutical-grade plasmid DNA and is safe for clinical applications.

Standardization of fluorine-18 manufacturing processes: new scientific challenges for PET.

PubMed

Hjelstuen, Ole K; Svadberg, Anders; Olberg, Dag E; Rosser, Mark

2011-08-01

In [(18)F]fluoride chemistry, the minute amounts of radioactivity taking part in a radiolabeling reaction are easily outnumbered by other reactants. Surface areas become comparably larger and more influential than in standard fluorine chemistry, while leachables, extractables, and other components that normally are considered small impurities can have a considerable influence on the efficiency of the reaction. A number of techniques exist to give sufficient (18)F-tracer for a study in a pre-clinical or clinical system, but the chemical and pharmaceutical understanding has significant gaps when it comes to scaling up or making the reaction more efficient. Automation and standardization of [(18)F]fluoride PET tracers is a prerequisite for reproducible manufacturing across multiple PET centers. So far, large-scale, multi-site manufacture has been established only for [(18)F]FDG, but several new tracers are emerging. In general terms, this transition from small- to large-scale production has disclosed several scientific challenges that need to be addressed. There are still areas of limited knowledge in the fundamental [(18)F]fluoride chemistry. The role of pharmaceutical factors that could influence the (18)F-radiosynthesis and the gaps in precise chemistry knowledge are discussed in this review based on a normal synthesis pattern. Copyright © 2011 Elsevier B.V. All rights reserved.

Designing of network planning system for small-scale manufacturing

NASA Astrophysics Data System (ADS)

Kapulin, D. V.; Russkikh, P. A.; Vinnichenko, M. V.

2018-05-01

The paper presents features of network planning in small-scale discrete production. The procedure of explosion of the production order, considering multilevel representation, is developed. The software architecture is offered. Approbation of the network planning system is carried out. This system allows carrying out dynamic updating of the production plan.

COMMODITY SCALE SYNTHESIS OF 1-METHYLIMIDAZOLE BASED IONIC LIQUIDS USING A SPINNING TUBE-IN-TUBE REACTOR

EPA Science Inventory

The continuous large-scale preparation of several 1-methylimidazole based ionic liquids was carried out using a Spinning Tube-in-Tube (STT) reactor (manufactured by Kreido Laboratories). This reactor, which embodies and facilitates the use of Green Chemistry principles and Proce...

Middle and small manufacture enterprise e-commerce application systems research

NASA Astrophysics Data System (ADS)

Zhu, Mingqiang

2017-04-01

With the extensive application of electronic commerce in manufacturing enterprises, e-commerce the influence of operation is increasingly becoming the focus of academic and business circles on the basis, this paper probes into the influence of e-commerce on the operation of the enterprise for the manufacturing enterprises to correctly understand the performance of e-commerce to provide a little help. The article first analyses e-commerce new environment on medium manufacturing enterprise requires, current medium manufacturing enterprise achieved e-commerce has many difficult, should e-commerce correctly awareness, and full planning, and points step implementation, and e-commerce and enterprise integration, and construction features of e-commerce platform, and procurement and supply chain of collaborative management, and attention customer management, and variety e-commerce of mode mixed, and flexible effective operations, and logistics socialization, views, focus on small and medium manufacturing enterprises in e-commerce applications to be innovative in design, production and management of agile and flexible production strategies.

Utilization of curve offsets in additive manufacturing

NASA Astrophysics Data System (ADS)

Haseltalab, Vahid; Yaman, Ulas; Dolen, Melik

2018-05-01

Curve offsets are utilized in different fields of engineering and science. Additive manufacturing, which lately becomes an explicit requirement in manufacturing industry, utilizes curve offsets widely. One of the necessities of offsetting is for scaling which is required if there is shrinkage after the fabrication or if the surface quality of the resulting part is unacceptable. Therefore, some post-processing is indispensable. But the major application of curve offsets in additive manufacturing processes is for generating head trajectories. In a point-wise AM process, a correct tool-path in each layer can reduce lots of costs and increase the surface quality of the fabricated parts. In this study, different curve offset generation algorithms are analyzed to show their capabilities and disadvantages through some test cases and improvements on their drawbacks are suggested.

Neponset River Basin Massachusetts, Flood Plain Management Study.

DTIC Science & Technology

1982-03-01

extensive water power. There are in the southern village, two rolling mills, for the manufacture of copper bolts and sheathing, on a large scale; two...furnaces for refining copper , and casting bells and brass cannon (operated by Paul Revere): forges and furnaces for the manufacture of iron wheels and...Dedha Granodiorite, Westwood Granite, Sharon Syenite, and Blue Rills Granite Porphyry . Crushed Stone. The Mattapan Volcanic Complex and Westwood

Life Cycle Assessment of Titania Perovskite Solar Cell Technology for Sustainable Design and Manufacturing.

PubMed

Zhang, Jingyi; Gao, Xianfeng; Deng, Yelin; Li, Bingbing; Yuan, Chris

2015-11-01

Perovskite solar cells have attracted enormous attention in recent years due to their low cost and superior technical performance. However, the use of toxic metals, such as lead, in the perovskite dye and toxic chemicals in perovskite solar cell manufacturing causes grave concerns for its environmental performance. To understand and facilitate the sustainable development of perovskite solar cell technology from its design to manufacturing, a comprehensive environmental impact assessment has been conducted on titanium dioxide nanotube based perovskite solar cells by using an attributional life cycle assessment approach, from cradle to gate, with manufacturing data from our laboratory-scale experiments and upstream data collected from professional databases and the literature. The results indicate that the perovskite dye is the primary source of environmental impact, associated with 64.77% total embodied energy and 31.38% embodied materials consumption, contributing to more than 50% of the life cycle impact in almost all impact categories, although lead used in the perovskite dye only contributes to about 1.14% of the human toxicity potential. A comparison of perovskite solar cells with commercial silicon and cadmium-tellurium solar cells reveals that perovskite solar cells could be a promising alternative technology for future large-scale industrial applications. © 2015 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Active full-shell grazing-incidence optics

NASA Astrophysics Data System (ADS)

Roche, Jacqueline M.; Elsner, Ronald F.; Ramsey, Brian D.; O'Dell, Stephen L.; Kolodziejczak, Jeffrey J.; Weisskopf, Martin C.; Gubarev, Mikhail V.

2016-09-01

MSFC has a long history of developing full-shell grazing-incidence x-ray optics for both narrow (pointed) and wide field (surveying) applications. The concept presented in this paper shows the potential to use active optics to switch between narrow and wide-field geometries, while maintaining large effective area and high angular resolution. In addition, active optics has the potential to reduce errors due to mounting and manufacturing lightweight optics. The design presented corrects low spatial frequency error and has significantly fewer actuators than other concepts presented thus far in the field of active x-ray optics. Using a finite element model, influence functions are calculated using active components on a full-shell grazing-incidence optic. Next, the ability of the active optic to effect a change of optical prescription and to correct for errors due to manufacturing and mounting is modeled.

Research on the full life cycle management system of smart electric energy meter

NASA Astrophysics Data System (ADS)

Chen, Xiangqun; Huang, Rui; Shen, Liman; Guo, Dingying; Xiong, Dezhi; Xiao, Xiangqi; Liu, Mouhai; Renheng, Xu

2018-02-01

At present, China’s smart electric energy meter life management is started from the procurement and acceptance. The related monitoring and management of the manufacturing sector has not yet been carried out. This article applies RFID technology and network cloud platform to full life cycle management system of smart electric energy meters, builds this full life cycle management system including design and manufacturing, process control, measurement and calibration testing, storage management, user acceptance, site operation, maintenance scrap and other aspects. Exploring smart electric energy meters on-line and off-line communication by the application of active RFID communication functions, and the actual functional application such as local data exchange and instrument calibration. This system provides technical supports on power demand side management and the improvement of smart electric energy meter reliability evaluation system.

Active Full-Shell Grazing-Incidence Optics

NASA Technical Reports Server (NTRS)

Davis, Jacqueline M.; Elsner, Ronald F.; Ramsey, Brian D.; O'Dell, Stephen L.; Kolodziejczak, Jeffery; Weisskopf, Martin C.; Gubarev, Mikhail V.

2016-01-01

MSFC has a long history of developing full-shell grazing-incidence x-ray optics for both narrow (pointed) and wide field (surveying) applications. The concept presented in this paper shows the potential to use active optics to switch between narrow and wide-field geometries, while maintaining large effective area and high angular resolution. In addition, active optics has the potential to reduce errors due to mounting and manufacturing lightweight optics. The design presented corrects low spatial frequency error and has significantly fewer actuators than other concepts presented thus far in the field of active x-ray optics. Using a finite element model, influence functions are calculated using active components on a full-shell grazing-incidence optic. Next, the ability of the active optic to effect a change of optical prescription and to correct for errors due to manufacturing and mounting is modeled.

A case study on topology optimized design for additive manufacturing

NASA Astrophysics Data System (ADS)

Gebisa, A. W.; Lemu, H. G.

2017-12-01

Topology optimization is an optimization method that employs mathematical tools to optimize material distribution in a part to be designed. Earlier developments of topology optimization considered conventional manufacturing techniques that have limitations in producing complex geometries. This has hindered the topology optimization efforts not to fully be realized. With the emergence of additive manufacturing (AM) technologies, the technology that builds a part layer upon a layer directly from three dimensional (3D) model data of the part, however, producing complex shape geometry is no longer an issue. Realization of topology optimization through AM provides full design freedom for the design engineers. The article focuses on topologically optimized design approach for additive manufacturing with a case study on lightweight design of jet engine bracket. The study result shows that topology optimization is a powerful design technique to reduce the weight of a product while maintaining the design requirements if additive manufacturing is considered.

Full-Scale Test and Analysis of a PRSEUS Fuselage Panel to Assess Damage-Containment Features

NASA Technical Reports Server (NTRS)

Bergan, Andrew; Bakuckas, John G.; Lovejoy, Andrew E.; Jegley, Dawn C.; Linton, Kim A.; Korkosz, Gregory; Awerbuch, Jonathan; Tan, Tein-Min

2011-01-01

Stitched composite technology has the potential to substantially decrease structural weight through enhanced damage containment capabilities. The most recent generation of stitched composite technology, the Pultruded Rod Stitched Efficient Unitized Structure (PRSEUS) concept, has been shown to successfully arrest damage at the sub-component level through tension testing of a three stringer panel with damage in the form of a two-bay notch. In a joint effort undertaken by the National Aeronautics and Space Administration (NASA), the Federal Aviation Administration (FAA), and the Boeing Company, further studies are being conducted to characterize the damage containment features of the PRSEUS concept. A full-scale residual strength test will be performed on a fuselage panel to determine if the load capacity will meet strength, deformation, and damage tolerance requirements. A curved panel was designed, fabricated, and prepared for residual strength testing. A pre-test Finite Element Model (FEM) was developed using design allowables from previous test programs to predict test panel deformation characteristics and margins of safety. Three phases of testing with increasing damage severity include: (1) as manufactured; (2) barely visible impact damage (BVID) and visible impact damage (VID); and (3) discrete source damage (DSD) where the panel will be loaded to catastrophic failure. This paper presents the background information, test plan, and experimental procedure. This paper is the first of several future articles reporting the test preparations, results, and analysis conducted in the test program.

Biomanufacturing process analytical technology (PAT) application for downstream processing: Using dissolved oxygen as an indicator of product quality for a protein refolding reaction.

PubMed

Pizarro, Shelly A; Dinges, Rachel; Adams, Rachel; Sanchez, Ailen; Winter, Charles

2009-10-01

Process analytical technology (PAT) is an initiative from the US FDA combining analytical and statistical tools to improve manufacturing operations and ensure regulatory compliance. This work describes the use of a continuous monitoring system for a protein refolding reaction to provide consistency in product quality and process performance across batches. A small-scale bioreactor (3 L) is used to understand the impact of aeration for refolding recombinant human vascular endothelial growth factor (rhVEGF) in a reducing environment. A reverse-phase HPLC assay is used to assess product quality. The goal in understanding the oxygen needs of the reaction and its impact to quality, is to make a product that is efficiently refolded to its native and active form with minimum oxidative degradation from batch to batch. Because this refolding process is heavily dependent on oxygen, the % dissolved oxygen (DO) profile is explored as a PAT tool to regulate process performance at commercial manufacturing scale. A dynamic gassing out approach using constant mass transfer (k(L)a) is used for scale-up of the aeration parameters to manufacturing scale tanks (2,000 L, 15,000 L). The resulting DO profiles of the refolding reaction show similar trends across scales and these are analyzed using rpHPLC. The desired product quality attributes are then achieved through alternating air and nitrogen sparging triggered by changes in the monitored DO profile. This approach mitigates the impact of differences in equipment or feedstock components between runs, and is directly inline with the key goal of PAT to "actively manage process variability using a knowledge-based approach." (c) 2009 Wiley Periodicals, Inc.

Manufacture and performance of full size structural flakeboards from Douglas-fir forest residues

Treesearch

J. Dobbin McNatt

1978-01-01

The Forest Products Laboratory manufactured and assessed the performance of 4- by 8-foot structural flakeboard panels from Douglas-fir forest residues after target performance goals were developed. The 42 pcf, three- layer boards were 1/2 inch thick with high quality disk cut flakes for the faces and lower quality flakes processed through a ring flaker in the core....

Assessment of the State-of-the-Art in the Design and Manufacturing of Large Composite Structure

NASA Technical Reports Server (NTRS)

Harris, C. E.

2001-01-01

This viewgraph presentation gives an assessment of the state-of-the-art in the design and manufacturing of large component structures, including details on the use of continuous fiber reinforced polymer matrix composites (CFRP) in commercial and military aircraft and in space launch vehicles. Project risk mitigation plans must include a building-block test approach to structural design development, manufacturing process scale-up development tests, and pre-flight ground tests to verify structural integrity. The potential benefits of composite structures justifies NASA's investment in developing the technology. Advanced composite structures technology is enabling to virtually every Aero-Space Technology Enterprise Goal.

Scale-up of 2G wire manufacturing at American Superconductor Corporation

NASA Astrophysics Data System (ADS)

Fleshler, S.; Buczek, D.; Carter, B.; Cedrone, P.; DeMoranville, K.; Gannon, J.; Inch, J.; Li, X.; Lynch, J.; Otto, A.; Podtburg, E.; Roy, D.; Rupich, M.; Sathyamurthy, S.; Schreiber, J.; Thieme, C.; Thompson, E.; Tucker, D.; Nagashima, K.; Ogata, M.

2009-10-01

American Superconductor Corporation (AMSC) has developed the base technology and a manufacturing line for initial volume production of low-cost second generation high temperature superconductor (2G HTS) wire for commercial and military applications. The manufacturing line is based on reel-to-reel processing of wide HTS strips using rolling assisted bi-axially textured substrate (RABiTS™) for the template and Metal Organic Deposition (MOD) for the HTS layer. AMSC’s wide strip process is a low cost manufacturing technology since multiple wires are produced in a single manufacturing pass by slitting the wide strip to narrower width in the last stage of the manufacturing process. Industry standard 4.4 mm wide wires are produced by laminating metallic foils, such as copper, stainless steel or any other material, to the HTS insert wire, and are chosen to tailor the electrical, thermal and mechanical properties of the wire for specific applications. The laminated, 4.4 mm wide wires are known as “344 superconductors.” In this paper, we summarize the status of AMSC’s manufacturing capability, the performance of the wire presently being produced, as well as the cost and technical advantages of AMSC’s manufacturing approach. In addition, future direction for research and development to improve electrical performance is presented.

Microscopic full-field three-dimensional strain measurement during the mechanical testing of additively manufactured porous biomaterials.

PubMed

Genovese, Katia; Leeflang, Sander; Zadpoor, Amir A

2017-05-01

A custom-designed micro-digital image correlation system was used to track the evolution of the full-surface three-dimensional strain field of Ti6Al4V additively manufactured lattice samples under mechanical loading. The high-magnification capabilities of the method allowed to resolve the strain distribution down to the strut level and disclosed a highly heterogeneous mechanical response of the lattice structure with local strain concentrations well above the nominal global strain level. In particular, we quantified that strain heterogeneity appears at a very early stage of the deformation process and increases with load, showing a strain accumulation pattern with a clear correlation to the later onset of the fracture. The obtained results suggest that the unique opportunities offered by the proposed experimental method, in conjunction with analytical and computational models, could serve to provide novel important information for the rational design of additively manufactured porous biomaterials. Copyright © 2017 Elsevier Ltd. All rights reserved.

Advances in the manufacture of MIP nanoparticles.

PubMed

Poma, Alessandro; Turner, Anthony P F; Piletsky, Sergey A

2010-12-01

Molecularly imprinted polymers (MIPs) are prepared by creating a three-dimensional polymeric matrix around a template molecule. After the matrix is removed, complementary cavities with respect to shape and functional groups remain. MIPs have been produced for applications in in vitro diagnostics, therapeutics and separations. However, this promising technology still lacks widespread application because of issues related to large-scale production and optimization of the synthesis. Recent developments in the area of MIP nanoparticles might offer solutions to several problems associated with performance and application. This review discusses various approaches used in the preparation of MIP nanoparticles, focusing in particular on the issues associated with large-scale manufacture and implications for the performance of synthesized nanomaterials. Copyright © 2010 Elsevier Ltd. All rights reserved.

40 CFR 86.338-79 - Exhaust measurement accuracy.

Code of Federal Regulations, 2010 CFR

2010-07-01

... percent of full-scale chart deflection during the measurement of the emissions for each mode. The... percent of full-scale if the full-scale value is 155 ppm (or ppm C) or less. (2) Option. For CO analysis the analyzer's response may be less than 15 percent of full scale if the full-scale value is 5500 ppm...

Prepreg effects on honeycomb composite manufacturing

NASA Astrophysics Data System (ADS)

Martin, Cary Joseph

Fiber reinforced composites offer many advantages over traditional materials and are widely utilized in aerospace applications. Advantages include a high stiffness to weight ratio and excellent fatigue resistance. However, the pace of new implementation is slow. The manufacturing processes used to transform composite intermediates into final products are poorly understood and are a source of much variability. This limits new implementation and increases the manufacturing costs of existing designs. One such problem is honeycomb core crush, in which a core-stiffened structure collapses during autoclave manufacture, making the structure unusable and increasing the overall manufacturing cost through increased scrap rates. Consequently, the major goal of this research was to investigate the scaling of core crush from prepreg process-structure-property relations to commercial composite manufacture. The material dependent nature of this defect was of particular interest. A methodology and apparatus were developed to measure the frictional resistance of prepreg materials under typical processing conditions. Through a characterization of commercial and experimental prepregs, it was found that core crush behavior was the result of differences in prepreg frictional resistance. This frictional resistance was related to prepreg morphology and matrix rheology and elasticity. Resin composition and prepreg manufacturing conditions were also found to affect manufacturing behavior. Mechanical and dimensional models were developed and demonstrated utility for predicting this crushing behavior. Collectively, this work explored and identified the process-structure-property relations as they relate to the manufacture of composite materials and suggested several avenues by which manufacturing-robust materials may be developed.

A Review of the Potential of Bio-Ethanol in New Zealand

ERIC Educational Resources Information Center

Acharya, Vishesh; Young, Brent R.

2008-01-01

This article presents a study of the techno-economical feasibility of manufacturing biofuel ethanol at small scale from agricultural sources in New Zealand. It investigates possible agricultural products and wastes as potential feedstock and looks at laboratory-scale fermentation trials to determine their ethanol yields. The ethanol requirement to…

Very large scale monoclonal antibody purification: the case for conventional unit operations.

PubMed

Kelley, Brian

2007-01-01

Technology development initiatives targeted for monoclonal antibody purification may be motivated by manufacturing limitations and are often aimed at solving current and future process bottlenecks. A subject under debate in many biotechnology companies is whether conventional unit operations such as chromatography will eventually become limiting for the production of recombinant protein therapeutics. An evaluation of the potential limitations of process chromatography and filtration using today's commercially available resins and membranes was conducted for a conceptual process scaled to produce 10 tons of monoclonal antibody per year from a single manufacturing plant, a scale representing one of the world's largest single-plant capacities for cGMP protein production. The process employs a simple, efficient purification train using only two chromatographic and two ultrafiltration steps, modeled after a platform antibody purification train that has generated 10 kg batches in clinical production. Based on analyses of cost of goods and the production capacity of this very large scale purification process, it is unlikely that non-conventional downstream unit operations would be needed to replace conventional chromatographic and filtration separation steps, at least for recombinant antibodies.

Nanotechnologies for Composite Structures- From Nanocomposites to Multifunctional Nano-Enabled Fibre Reinforced Composites for Spacecrafts

NASA Astrophysics Data System (ADS)

Kostopoulos, Vassilis; Vavouliotis, Antonios; Baltopoulos, Athanasios; Sotiririadis, George; Masouras, Athanasios; Pambaguian, Laurent

2014-06-01

The past decade, extensive efforts have been invested in understanding the nano-scale and revealing the capabilities offered by nanotechnology products to structural materials. Nevertheless, a major issue faced lately more seriously due to the interest of industry is on how to incorporate these nano-species into the final composite structure through existing manufacturing processes and infrastructure. In this work, we present the experience obtained from the latest nanotechnology research activities supported by ESA. The paper focuses on prepreg composite manufacturing technology and addresses:- Approaches for nano-enabling of composites- Up-scaling strategies towards final structures- Latest results on performance of nano-enabledfiber reinforced compositesSeveral approaches for the utilization of nanotechnology products in structural composite structures have been proposed and are reviewed, in short along with respective achieved results. A variety of nano-fillers has been proposed and employed, individually or in combination in hybrid forms, to approach the desired performance. A major part of the work deals with the up-scaling routes of these technologies to reach final products and industrial scales and processes while meeting end-user performance.

A Scalable System for Production of Functional Pancreatic Progenitors from Human Embryonic Stem Cells

PubMed Central

Schulz, Thomas C.; Young, Holly Y.; Agulnick, Alan D.; Babin, M. Josephine; Baetge, Emmanuel E.; Bang, Anne G.; Bhoumik, Anindita; Cepa, Igor; Cesario, Rosemary M.; Haakmeester, Carl; Kadoya, Kuniko; Kelly, Jonathan R.; Kerr, Justin; Martinson, Laura A.; McLean, Amanda B.; Moorman, Mark A.; Payne, Janice K.; Richardson, Mike; Ross, Kelly G.; Sherrer, Eric S.; Song, Xuehong; Wilson, Alistair Z.; Brandon, Eugene P.; Green, Chad E.; Kroon, Evert J.; Kelly, Olivia G.; D’Amour, Kevin A.; Robins, Allan J.

2012-01-01

Development of a human embryonic stem cell (hESC)-based therapy for type 1 diabetes will require the translation of proof-of-principle concepts into a scalable, controlled, and regulated cell manufacturing process. We have previously demonstrated that hESC can be directed to differentiate into pancreatic progenitors that mature into functional glucose-responsive, insulin-secreting cells in vivo. In this study we describe hESC expansion and banking methods and a suspension-based differentiation system, which together underpin an integrated scalable manufacturing process for producing pancreatic progenitors. This system has been optimized for the CyT49 cell line. Accordingly, qualified large-scale single-cell master and working cGMP cell banks of CyT49 have been generated to provide a virtually unlimited starting resource for manufacturing. Upon thaw from these banks, we expanded CyT49 for two weeks in an adherent culture format that achieves 50–100 fold expansion per week. Undifferentiated CyT49 were then aggregated into clusters in dynamic rotational suspension culture, followed by differentiation en masse for two weeks with a four-stage protocol. Numerous scaled differentiation runs generated reproducible and defined population compositions highly enriched for pancreatic cell lineages, as shown by examining mRNA expression at each stage of differentiation and flow cytometry of the final population. Islet-like tissue containing glucose-responsive, insulin-secreting cells was generated upon implantation into mice. By four- to five-months post-engraftment, mature neo-pancreatic tissue was sufficient to protect against streptozotocin (STZ)-induced hyperglycemia. In summary, we have developed a tractable manufacturing process for the generation of functional pancreatic progenitors from hESC on a scale amenable to clinical entry. PMID:22623968

Enhanced clinical-scale manufacturing of TCR transduced T-cells using closed culture system modules.

PubMed

Jin, Jianjian; Gkitsas, Nikolaos; Fellowes, Vicki S; Ren, Jiaqiang; Feldman, Steven A; Hinrichs, Christian S; Stroncek, David F; Highfill, Steven L

2018-01-24

Genetic engineering of T-cells to express specific T cell receptors (TCR) has emerged as a novel strategy to treat various malignancies. More widespread utilization of these types of therapies has been somewhat constrained by the lack of closed culture processes capable of expanding sufficient numbers of T-cells for clinical application. Here, we evaluate a process for robust clinical grade manufacturing of TCR gene engineered T-cells. TCRs that target human papillomavirus E6 and E7 were independently tested. A 21 day process was divided into a transduction phase (7 days) and a rapid expansion phase (14 days). This process was evaluated using two healthy donor samples and four samples obtained from patients with epithelial cancers. The process resulted in ~ 2000-fold increase in viable nucleated cells and high transduction efficiencies (64-92%). At the end of culture, functional assays demonstrated that these cells were potent and specific in their ability to kill tumor cells bearing target and secrete large quantities of interferon and tumor necrosis factor. Both phases of culture were contained within closed or semi-closed modules, which include automated density gradient separation and cell culture bags for the first phase and closed GREX culture devices and wash/concentrate systems for the second phase. Large-scale manufacturing using modular systems and semi-automated devices resulted in highly functional clinical-grade TCR transduced T-cells. This process is now in use in actively accruing clinical trials and the NIH Clinical Center and can be utilized at other cell therapy manufacturing sites that wish to scale-up and optimize their processing using closed systems.

Manufacturing Process Simulation of Large-Scale Cryotanks

NASA Technical Reports Server (NTRS)

Babai, Majid; Phillips, Steven; Griffin, Brian; Munafo, Paul M. (Technical Monitor)

2002-01-01

NASA's Space Launch Initiative (SLI) is an effort to research and develop the technologies needed to build a second-generation reusable launch vehicle. It is required that this new launch vehicle be 100 times safer and 10 times cheaper to operate than current launch vehicles. Part of the SLI includes the development of reusable composite and metallic cryotanks. The size of these reusable tanks is far greater than anything ever developed and exceeds the design limits of current manufacturing tools. Several design and manufacturing approaches have been formulated, but many factors must be weighed during the selection process. Among these factors are tooling reachability, cycle times, feasibility, and facility impacts. The manufacturing process simulation capabilities available at NASA's Marshall Space Flight Center have played a key role in down selecting between the various manufacturing approaches. By creating 3-D manufacturing process simulations, the varying approaches can be analyzed in a virtual world before any hardware or infrastructure is built. This analysis can detect and eliminate costly flaws in the various manufacturing approaches. The simulations check for collisions between devices, verify that design limits on joints are not exceeded, and provide cycle times which aid in the development of an optimized process flow. In addition, new ideas and concerns are often raised after seeing the visual representation of a manufacturing process flow. The output of the manufacturing process simulations allows for cost and safety comparisons to be performed between the various manufacturing approaches. This output helps determine which manufacturing process options reach the safety and cost goals of the SLI.

Roll-to-Roll Advanced Materials Manufacturing DOE Lab Consortium - FY16 Annual Report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Daniel, Claus; Wood, III, David L.; Krumdick, Gregory

2016-12-01

A DOE laboratory consortium comprised of ORNL, ANL, NREL and LBNL, coordinating with Kodak’s Eastman Business Park (Kodak) and other selected industry partners, was formed to address enhancing battery electrode performance and R2R manufacturing challenges. The objective of the FY 2016 seed project was to develop a materials genome synthesis process amenable to R2R manufacturing and to provide modeling, simulation, processing, and manufacturing techniques that demonstrate the feasibility of process controls and scale-up potential for improved battery electrodes. The research efforts were to predict and measure changes and results in electrode morphology and performance based on process condition changes; tomore » evaluate mixed, active, particle size deposition and drying for novel electrode materials; and to model various process condition changes and the resulting morphology and electrode performance.« less

Manufacture of tumor- and virus-specific T lymphocytes for adoptive cell therapies

PubMed Central

Wang, X; Rivière, I

2015-01-01

Adoptive transfer of tumor-infiltrating lymphocytes (TILs) and genetically engineered T lymphocytes expressing chimeric antigen receptors (CARs) or conventional alpha/beta T-cell receptors (TCRs), collectively termed adoptive cell therapy (ACT), is an emerging novel strategy to treat cancer patients. Application of ACT has been constrained by the ability to isolate and expand functional tumor-reactive T cells. The transition of ACT from a promising experimental regimen to an established standard of care treatment relies largely on the establishment of safe, efficient, robust and cost-effective cell manufacturing protocols. The manufacture of cellular products under current good manufacturing practices (cGMPs) has a critical role in the process. Herein, we review current manufacturing methods for the large-scale production of clinical-grade TILs, virus-specific and genetically modified CAR or TCR transduced T cells in the context of phase I/II clinical trials as well as the regulatory pathway to get these complex personalized cellular products to the clinic. PMID:25721207

Manufacture of tumor- and virus-specific T lymphocytes for adoptive cell therapies.

PubMed

Wang, X; Rivière, I

2015-03-01

Adoptive transfer of tumor-infiltrating lymphocytes (TILs) and genetically engineered T lymphocytes expressing chimeric antigen receptors (CARs) or conventional alpha/beta T-cell receptors (TCRs), collectively termed adoptive cell therapy (ACT), is an emerging novel strategy to treat cancer patients. Application of ACT has been constrained by the ability to isolate and expand functional tumor-reactive T cells. The transition of ACT from a promising experimental regimen to an established standard of care treatment relies largely on the establishment of safe, efficient, robust and cost-effective cell manufacturing protocols. The manufacture of cellular products under current good manufacturing practices (cGMPs) has a critical role in the process. Herein, we review current manufacturing methods for the large-scale production of clinical-grade TILs, virus-specific and genetically modified CAR or TCR transduced T cells in the context of phase I/II clinical trials as well as the regulatory pathway to get these complex personalized cellular products to the clinic.

Ultrasonic NDE Simulation for Composite Manufacturing Defects

NASA Technical Reports Server (NTRS)

Leckey, Cara A. C.; Juarez, Peter D.

2016-01-01

The increased use of composites in aerospace components is expected to continue into the future. The large scale use of composites in aerospace necessitates the development of composite-appropriate nondestructive evaluation (NDE) methods to quantitatively characterize defects in as-manufactured parts and damage incurred during or post manufacturing. Ultrasonic techniques are one of the most common approaches for defect/damage detection in composite materials. One key technical challenge area included in NASA's Advanced Composite's Project is to develop optimized rapid inspection methods for composite materials. Common manufacturing defects in carbon fiber reinforced polymer (CFRP) composites include fiber waviness (in-plane and out-of-plane), porosity, and disbonds; among others. This paper is an overview of ongoing work to develop ultrasonic wavefield based methods for characterizing manufacturing waviness defects. The paper describes the development and implementation of a custom ultrasound simulation tool that is used to model ultrasonic wave interaction with in-plane fiber waviness (also known as marcelling). Wavefield data processing methods are applied to the simulation data to explore possible routes for quantitative defect characterization.

Additive Manufacturing for Highly Efficient Window Inserts CRADA Report

DOE Office of Scientific and Technical Information (OSTI.GOV)

Roschli, Alex C.; Chesser, Phillip C.; Love, Lonnie J.

ORNL partnered with the Mackinac Technology Company to demonstrate how additive manufacturing can be used to create highly energy efficient window inserts for retrofit in pre-existing buildings. Many early iterations of the window inserts were fabricated using carbon fiber reinforced thermoplastics and polycarbonate films as a stand in for the low-e coated films produced by the Mackinac Technology Company. After demonstration of the proof of concept, i.e. custom window inserts with tensioned film, the materials used for the manufacture of the frames was more closely examined. Hollow particle-filled syntactic foam and low-density polymer composites formed by expandable microspheres were exploredmore » as the materials used to additively manufacture the frames of the inserts. It was concluded that low-cost retrofit window inserts in custom sizes could be easily fabricated using large scale additive manufacturing. Furthermore, the syntactic and expanded foams developed and tested satisfy the mechanical performance requirements for the application.« less

Emulsified systems based on glyceryl monostearate and potassium cetyl phosphate: scale-up and characterization of physical properties.

PubMed

Baby, André Rolim; Santoro, Diego Monegatto; Velasco, Maria Valéria Robles; Dos Reis Serra, Cristina Helena

2008-09-01

Introducing a pharmaceutical product on the market involves several stages of research. The scale-up stage comprises the integration of previous phases of development and their integration. This phase is extremely important since many process limitations which do not appear on the small scale become significant on the transposition to a large one. Since scientific literature presents only a few reports about the characterization of emulsified systems involving their scaling-up, this research work aimed at evaluating physical properties of non-ionic and anionic emulsions during their manufacturing phases: laboratory stage and scale-up. Prototype non-ionic (glyceryl monostearate) and anionic (potassium cetyl phosphate) emulsified systems had the physical properties by the determination of the droplet size (D[4,3], mum) and rheology profile. Transposition occurred from a batch of 500-50,000g. Semi-industrial manufacturing involved distinct conditions: intensity of agitation and homogenization. Comparing the non-ionic and anionic systems, it was observed that anionic emulsifiers generated systems with smaller droplet size and higher viscosity in laboratory scale. Besides that, for the concentrations tested, augmentation of the glyceryl monostearate emulsifier content provided formulations with better physical characteristics. For systems with potassium cetyl phosphate, droplet size increased with the elevation of the emulsifier concentration, suggesting inadequate stability. The scale-up provoked more significant alterations on the rheological profile and droplet size on the anionic systems than the non-ionic.

High-shear granulation as a manufacturing method for cocrystal granules.

PubMed

Rehder, Sönke; Christensen, Niels Peter Aae; Rantanen, Jukka; Rades, Thomas; Leopold, Claudia S

2013-11-01

Cocrystal formation allows the tailoring of physicochemical as well as of mechanical properties of an API. However, there is a lack of large-scale manufacturing methods of cocrystals. Therefore, the objective of this work was to examine the suitability of high-shear wet granulation as a manufacturing method for cocrystal granules on a batch scale. Furthermore, the cocrystal granules were characterized regarding their mechanical properties as well as their dissolution behavior. High-shear wet granulation was found to be a feasible manufacturing method for cocrystal granules. Cocrystal formation depended on the exposure time of the solids to the granulation liquid (water), the amount of liquid, the impeller speed of the granulator, and on the excipients (hydroxyl propylcellulose, microcrystalline cellulose, calcium hydrogenphosphate) used in the formulation. Storage stability was strongly influenced by the excipients, since in presence of calcium hydrogenphosphate, the poorly water-soluble salt calcium tartrate monohydrate was formed at high relative humidity. Interestingly, compactability was increased by cocrystal formation compared to that of the reference granules (piracetam and the respective excipients). The drug release was slightly decreased by cocrystal formation, most likely due to the lower solubility of the cocrystal. In the presence of calcium hydrogenphosphate however, no influence of cocrystal formation on either compactability or on drug release were observed, compared with the reference tablets. It was concluded that high-shear wet granulation is a valuable, however complex, manufacturing method for cocrystals. Cocrystal formation may influence compactability and drug release and thus affect drug performance and should be investigated during pre-formulation. Copyright © 2013 Elsevier B.V. All rights reserved.

Design and Fabrication of Full Wheatstone-Bridge-Based Angular GMR Sensors.

PubMed

Yan, Shaohua; Cao, Zhiqiang; Guo, Zongxia; Zheng, Zhenyi; Cao, Anni; Qi, Yue; Leng, Qunwen; Zhao, Weisheng

2018-06-05

Since the discovery of the giant magnetoresistive (GMR) effect, GMR sensors have gained much attention in last decades due to their high sensitivity, small size, and low cost. The full Wheatstone-bridge-based GMR sensor is most useful in terms of the application point of view. However, its manufacturing process is usually complex. In this paper, we present an efficient and concise approach to fabricate a full Wheatstone-bridge-based angular GMR sensor by depositing one GMR film stack, utilizing simple patterned processes, and a concise post-annealing procedure based on a special layout. The angular GMR sensor is of good linear performance and achieves a sensitivity of 0.112 mV/V/Oe at the annealing temperature of 260 °C in the magnetic field range from -50 to +50 Oe. This work provides a design and method for GMR-sensor manufacturing that is easy for implementation and suitable for mass production.

Vaccine production, distribution, access and uptake

PubMed Central

Smith, Jon; Lipsitch, Marc; Almond, Jeffrey W.

2011-01-01

Making human vaccines available on a global scale requires the use of complex production methods, meticulous quality control and reliable distribution channels that ensure the products are potent and effective at their point of use. The technologies involved in manufacturing different types of vaccines may strongly influence vaccine cost, ease of industrial scale-up, stability and ultimately world-wide availability. Manufacturing complexity is compounded by the need for different formulations for different countries and age groups. Reliable vaccine production in appropriate quantities and at affordable prices is the cornerstone of developing global vaccination policies. However, ensuring optimal access and uptake also requires strong partnerships between private manufacturers, regulatory authorities and national and international public health services. For vaccines whose supplies are limited, either due to rapidly emerging diseases or longer-term mismatch of supply and demand, prioritizing target groups can increase vaccine impact. Focusing on influenza vaccines as an example that well illustrates many of the relevant points, this article considers current production, distribution, access and other factors that ultimately impact on vaccine uptake and population-level effectiveness. PMID:21664680

Vaccine production, distribution, access, and uptake.

PubMed

Smith, Jon; Lipsitch, Marc; Almond, Jeffrey W

2011-07-30

For human vaccines to be available on a global scale, complex production methods, meticulous quality control, and reliable distribution channels are needed to ensure that the products are potent and effective at the point of use. The technologies used to manufacture different types of vaccines can strongly affect vaccine cost, ease of industrial scale-up, stability, and, ultimately, worldwide availability. The complexity of manufacturing is compounded by the need for different formulations in different countries and age-groups. Reliable vaccine production in appropriate quantities and at affordable prices is the cornerstone of developing global vaccination policies. However, to ensure optimum access and uptake, strong partnerships are needed between private manufacturers, regulatory authorities, and national and international public health services. For vaccines whose supply is insufficient to meet demand, prioritisation of target groups can increase the effect of these vaccines. In this report, we draw from our experience of vaccine development and focus on influenza vaccines as an example to consider production, distribution, access, and other factors that affect vaccine uptake and population-level effectiveness. Copyright © 2011 Elsevier Ltd. All rights reserved.

All-solid-state lithium-ion and lithium metal batteries - paving the way to large-scale production

NASA Astrophysics Data System (ADS)

Schnell, Joscha; Günther, Till; Knoche, Thomas; Vieider, Christoph; Köhler, Larissa; Just, Alexander; Keller, Marlou; Passerini, Stefano; Reinhart, Gunther

2018-04-01

Challenges and requirements for the large-scale production of all-solid-state lithium-ion and lithium metal batteries are herein evaluated via workshops with experts from renowned research institutes, material suppliers, and automotive manufacturers. Aiming to bridge the gap between materials research and industrial mass production, possible solutions for the production chains of sulfide and oxide based all-solid-state batteries from electrode fabrication to cell assembly and quality control are presented. Based on these findings, a detailed comparison of the production processes for a sulfide based all-solid-state battery with conventional lithium-ion cell production is given, showing that processes for composite electrode fabrication can be adapted with some effort, while the fabrication of the solid electrolyte separator layer and the integration of a lithium metal anode will require completely new processes. This work identifies the major steps towards mass production of all-solid-state batteries, giving insight into promising manufacturing technologies and helping stakeholders, such as machine engineering, cell producers, and original equipment manufacturers, to plan the next steps towards safer batteries with increased storage capacity.

Large-scale adenovirus and poxvirus-vectored vaccine manufacturing to enable clinical trials.

PubMed

Kallel, Héla; Kamen, Amine A

2015-05-01

Efforts to make vaccines against infectious diseases and immunotherapies for cancer have evolved to utilize a variety of heterologous expression systems such as viral vectors. These vectors are often attenuated or engineered to safely deliver genes encoding antigens of different pathogens. Adenovirus and poxvirus vectors are among the viral vectors that are most frequently used to develop prophylactic vaccines against infectious diseases as well as therapeutic cancer vaccines. This mini-review describes the trends and processes in large-scale production of adenovirus and poxvirus vectors to meet the needs of clinical applications. We briefly describe the general principles for the production and purification of adenovirus and poxvirus viral vectors. Currently, adenovirus and poxvirus vector manufacturing methods rely on well-established cell culture technologies. Several improvements have been evaluated to increase the yield and to reduce the overall manufacturing cost, such as cultivation at high cell densities and continuous downstream processing. Additionally, advancements in vector characterization will greatly facilitate the development of novel vectored vaccine candidates. Copyright © 2015 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

Solar Photochemical Synthesis: From the Beginnings of Organic Photochemistry to the Solar Manufacturing of Commodity Chemicals.

PubMed

Oelgemöller, Michael

2016-09-14

Natural sunlight offers a cost-efficient and sustainable energy source for photochemical reactions. In contrast to the lengthy and small-scale "flask in the sun" procedures of the past, modern solar concentrator systems nowadays significantly shorten reaction times and enable technical-scale operations. After a brief historical introduction, this review presents the most important solar reactor types and their successful application in preparative solar syntheses. The examples demonstrate that solar manufacturing of fine chemicals is technically feasible and environmentally sustainable. After over 100 years, Ciamician's prophetic vision of "the photochemistry of the future" as a clean and green manufacturing methodology has yet to be realized. At the same time, his warning "for nature is not in a hurry but mankind is" is still valid today. It is hoped that this review will lead to a renewed interest in this truly enlightening technology, that it will stimulate photochemists and photochemical engineers to "go back to the roots onto the roofs" and that it will ultimately result in industrial applications in the foreseeable future.