Automated fiber placement composite manufacturing: The mission at MSFC's Productivity Enhancement Complex

NASA Technical Reports Server (NTRS)

Vickers, John H.; Pelham, Larry I.

1993-01-01

Automated fiber placement is a manufacturing process used for producing complex composite structures. It is a notable leap to the state-of-the-art in technology for automated composite manufacturing. The fiber placement capability was established at the Marshall Space Flight Center's (MSFC) Productivity Enhancement Complex in 1992 in collaboration with Thiokol Corporation to provide materials and processes research and development, and to fabricate components for many of the Center's Programs. The Fiber Placement System (FPX) was developed as a distinct solution to problems inherent to other automated composite manufacturing systems. This equipment provides unique capabilities to build composite parts in complex 3-D shapes with concave and other asymmetrical configurations. Components with complex geometries and localized reinforcements usually require labor intensive efforts resulting in expensive, less reproducible components; the fiber placement system has the features necessary to overcome these conditions. The mechanical systems of the equipment have the motion characteristics of a filament winder and the fiber lay-up attributes of a tape laying machine, with the additional capabilities of differential tow payout speeds, compaction and cut-restart to selectively place the correct number of fibers where the design dictates. This capability will produce a repeatable process resulting in lower cost and improved quality and reliability.

Mask manufacturing of advanced technology designs using multi-beam lithography (Part 1)

NASA Astrophysics Data System (ADS)

Green, Michael; Ham, Young; Dillon, Brian; Kasprowicz, Bryan; Hur, Ik Boum; Park, Joong Hee; Choi, Yohan; McMurran, Jeff; Kamberian, Henry; Chalom, Daniel; Klikovits, Jan; Jurkovic, Michal; Hudek, Peter

2016-10-01

As optical lithography is extended into 10nm and below nodes, advanced designs are becoming a key challenge for mask manufacturers. Techniques including advanced Optical Proximity Correction (OPC) and Inverse Lithography Technology (ILT) result in structures that pose a range of issues across the mask manufacturing process. Among the new challenges are continued shrinking Sub-Resolution Assist Features (SRAFs), curvilinear SRAFs, and other complex mask geometries that are counter-intuitive relative to the desired wafer pattern. Considerable capability improvements over current mask making methods are necessary to meet the new requirements particularly regarding minimum feature resolution and pattern fidelity. Advanced processes using the IMS Multi-beam Mask Writer (MBMW) are feasible solutions to these coming challenges. In this paper, we study one such process, characterizing mask manufacturing capability of 10nm and below structures with particular focus on minimum resolution and pattern fidelity.

Manufacturing Process Simulation of Large-Scale Cryotanks

NASA Technical Reports Server (NTRS)

Babai, Majid; Phillips, Steven; Griffin, Brian

2003-01-01

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 aide 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. As part of the SLI, The Boeing Company was awarded a basic period contract to research and propose options for both a metallic and a composite cryotank. Boeing then entered into a task agreement with the Marshall Space Flight Center to provide manufacturing simulation support. This paper highlights the accomplishments of this task agreement, while also introducing the capabilities of simulation software.

Manufacturing development for the SAFE 100 kW core

NASA Astrophysics Data System (ADS)

Carter, Robert; Roman, Jose; Salvail, Pat

2002-01-01

In stark contrast to what is sometimes considered the norm in traditional manufacturing processes, engineers at the Marshall Space Flight Center (MSFC) arc in the practice of altering the standard in an effort to realize other potential methods in core manufacturing. While remaining within the bounds of the materials database, we are researching into core manufacturing techniques that may have been overlooked in the past due to funding and/or time constraints. To augment proven core fabrication capabilities we are pursuing plating processes as another possible method for core build-up and assembly. Although brazing and a proprietary HIP cycle are used for module assembly (proven track record for stability and endurance), it is prudent to pursue secondary or backup methods of module and core assembly. For this reason heat tube manufacture and module assembly by means of plating is being investigated. Potentially, the plating processes will give engineers the ability to manufacture replacement modules for any module that might fail to perform nominally, and to assemble/disassemble a complete core in much less time than would be required for the conventional Braze-HIP process. Another area of improvement in core manufacturing capabilities is the installation of a sodium and lithium liquid metal heat pipe fill machine. This, along with the ability to Electron Beam Weld heat pipe seals and wet-in the pipes in the necessary vacuum atmosphere, will eliminate the need to ship potentially hazardous components outside for processing. In addition to developing core manufacturing techniques, the SAFE manufacturing team has been evaluating the thermal heat transfer characteristics, and manufacturability of several heat exchanger design concepts. .

Free-world microelectronic manufacturing equipment

NASA Astrophysics Data System (ADS)

Kilby, J. S.; Arnold, W. H.; Booth, W. T.; Cunningham, J. A.; Hutcheson, J. D.; Owen, R. W.; Runyan, W. R.; McKenney, Barbara L.; McGrain, Moira; Taub, Renee G.

1988-12-01

Equipment is examined and evaluated for the manufacture of microelectronic integrated circuit devices and sources for that equipment within the Free World. Equipment suitable for the following are examined: single-crystal silicon slice manufacturing and processing; required lithographic processes; wafer processing; device packaging; and test of digital integrated circuits. Availability of the equipment is also discussed, now and in the near future. Very adequate equipment for most stages of the integrated circuit manufacturing process is available from several sources, in different countries, although the best and most widely used versions of most manufacturing equipment are made in the United States or Japan. There is also an active market in used equipment, suitable for manufacture of capable integrated circuits with performance somewhat short of the present state of the art.

Automated array assembly, phase 2

NASA Technical Reports Server (NTRS)

Daiello, R. V.

1980-01-01

A manufacturing sequence which is capable of mass producing silicon solar cells is described. The sequence was arrived at after the evaluation of many processes and three related manufacturing sequences which are discussed.

Manufacturing Planning Guide

NASA Technical Reports Server (NTRS)

Waid, Michael

2011-01-01

Manufacturing process, milestones and inputs are unknowns to first-time users of the manufacturing facilities. The Manufacturing Planning Guide aids in establishing expectations for both NASA and non-NASA facility customers. The potential audience for this guide includes both internal and commercial spaceflight hardware/software developers. It is intended to assist their project engineering personnel in manufacturing planning and execution. Material covered includes a roadmap of the manufacturing process, roles and responsibilities of facility and user, major milestones, facility capabilities, and inputs required by the facility. Samples of deliverables, products, and inputs necessary to define test scope, cost, and schedule are included as an appendix to the guide.

Six sigma: process of understanding the control and capability of ranitidine hydrochloride tablet.

PubMed

Chabukswar, Ar; Jagdale, Sc; Kuchekar, Bs; Joshi, Vd; Deshmukh, Gr; Kothawade, Hs; Kuckekar, Ab; Lokhande, Pd

2011-01-01

The process of understanding the control and capability (PUCC) is an iterative closed loop process for continuous improvement. It covers the DMAIC toolkit in its three phases. PUCC is an iterative approach that rotates between the three pillars of the process of understanding, process control, and process capability, with each iteration resulting in a more capable and robust process. It is rightly said that being at the top is a marathon and not a sprint. The objective of the six sigma study of Ranitidine hydrochloride tablets is to achieve perfection in tablet manufacturing by reviewing the present robust manufacturing process, to find out ways to improve and modify the process, which will yield tablets that are defect-free and will give more customer satisfaction. The application of six sigma led to an improved process capability, due to the improved sigma level of the process from 1.5 to 4, a higher yield, due to reduced variation and reduction of thick tablets, reduction in packing line stoppages, reduction in re-work by 50%, a more standardized process, with smooth flow and change in coating suspension reconstitution level (8%w/w), a huge cost reduction of approximately Rs.90 to 95 lakhs per annum, an improved overall efficiency by 30% approximately, and improved overall quality of the product.

Six Sigma: Process of Understanding the Control and Capability of Ranitidine Hydrochloride Tablet

PubMed Central

Chabukswar, AR; Jagdale, SC; Kuchekar, BS; Joshi, VD; Deshmukh, GR; Kothawade, HS; Kuckekar, AB; Lokhande, PD

2011-01-01

The process of understanding the control and capability (PUCC) is an iterative closed loop process for continuous improvement. It covers the DMAIC toolkit in its three phases. PUCC is an iterative approach that rotates between the three pillars of the process of understanding, process control, and process capability, with each iteration resulting in a more capable and robust process. It is rightly said that being at the top is a marathon and not a sprint. The objective of the six sigma study of Ranitidine hydrochloride tablets is to achieve perfection in tablet manufacturing by reviewing the present robust manufacturing process, to find out ways to improve and modify the process, which will yield tablets that are defect-free and will give more customer satisfaction. The application of six sigma led to an improved process capability, due to the improved sigma level of the process from 1.5 to 4, a higher yield, due to reduced variation and reduction of thick tablets, reduction in packing line stoppages, reduction in re-work by 50%, a more standardized process, with smooth flow and change in coating suspension reconstitution level (8%w/w), a huge cost reduction of approximately Rs.90 to 95 lakhs per annum, an improved overall efficiency by 30% approximately, and improved overall quality of the product. PMID:21607050

Supportability Technologies for Future Exploration Missions

NASA Technical Reports Server (NTRS)

Watson, Kevin; Thompson, Karen

2007-01-01

Future long-duration human exploration missions will be challenged by resupply limitations and mass and volume constraints. Consequently, it will be essential that the logistics footprint required to support these missions be minimized and that capabilities be provided to make them highly autonomous from a logistics perspective. Strategies to achieve these objectives include broad implementation of commonality and standardization at all hardware levels and across all systems, repair of failed hardware at the lowest possible hardware level, and manufacture of structural and mechanical replacement components as needed. Repair at the lowest hardware levels will require the availability of compact, portable systems for diagnosis of failures in electronic systems and verification of system functionality following repair. Rework systems will be required that enable the removal and replacement of microelectronic components with minimal human intervention to minimize skill requirements and training demand for crews. Materials used in the assembly of electronic systems (e.g. solders, fluxes, conformal coatings) must be compatible with the available repair methods and the spacecraft environment. Manufacturing of replacement parts for structural and mechanical applications will require additive manufacturing systems that can generate near-net-shape parts from the range of engineering alloys employed in the spacecraft structure and in the parts utilized in other surface systems. These additive manufacturing processes will need to be supported by real-time non-destructive evaluation during layer-additive processing for on-the-fly quality control. This will provide capabilities for quality control and may serve as an input for closed-loop process control. Additionally, non-destructive methods should be available for material property determination. These nondestructive evaluation processes should be incorporated with the additive manufacturing process - providing an in-process capability to ensure that material deposited during layer-additive processing meets required material property criteria.

Large-area copper indium diselenide (CIS) process, control and manufacturing

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

Gillespie, T.J.; Lanning, B.R.; Marshall, C.H.

1997-12-31

Lockheed Martin Astronautics (LMA) has developed a large-area (30x30cm) sequential CIS manufacturing approach amenable to low-cost photovoltaics (PV) production. A prototype CIS manufacturing system has been designed and built with compositional uniformity (Cu/In ratio) verified within {+-}4 atomic percent over the 30x30cm area. CIS device efficiencies have been measured by the National Renewable Energy Laboratory (NREL) at 7% on a flexible non-sodium-containing substrate and 10% on a soda-lime-silica (SLS) glass substrate. Critical elements of the manufacturing capability include the CIS sequential process selection, uniform large-area material deposition, and in-situ process control. Details of the process and large-area manufacturing approach aremore » discussed and results presented.« less

The use of Tecnomatix software to simulate the manufacturing flows in an industrial enterprise producing hydrostatic components

NASA Astrophysics Data System (ADS)

Petrila, S.; Brabie, G.; Chirita, B.

2016-08-01

The analysis performed on manufacturing flows within industrial enterprises producing hydrostatic components twos made on a number of factors that influence smooth running of production such: distance between pieces, waiting time from one surgery to another; time achievement of setups on CNC machines; tool changing in case of a large number of operators and manufacturing complexity of large files [2]. To optimize the manufacturing flow it was used the software Tecnomatix. This software represents a complete portfolio of manufacturing solutions digital manufactured by Siemens. It provides innovation by linking all production methods of a product from process design, process simulation, validation and ending the manufacturing process. Among its many capabilities to create a wide range of simulations, the program offers various demonstrations regarding the behavior manufacturing cycles. This program allows the simulation and optimization of production systems and processes in several areas such as: car suppliers, production of industrial equipment; electronics manufacturing, design and production of aerospace and defense parts.

An Introduction to Intelligent Processing Programs Developed by the Air Force Manufacturing Technology Directorate

NASA Technical Reports Server (NTRS)

Sampson, Paul G.; Sny, Linda C.

1992-01-01

The Air Force has numerous on-going manufacturing and integration development programs (machine tools, composites, metals, assembly, and electronics) which are instrumental in improving productivity in the aerospace industry, but more importantly, have identified strategies and technologies required for the integration of advanced processing equipment. An introduction to four current Air Force Manufacturing Technology Directorate (ManTech) manufacturing areas is provided. Research is being carried out in the following areas: (1) machining initiatives for aerospace subcontractors which provide for advanced technology and innovative manufacturing strategies to increase the capabilities of small shops; (2) innovative approaches to advance machine tool products and manufacturing processes; (3) innovative approaches to advance sensors for process control in machine tools; and (4) efforts currently underway to develop, with the support of industry, the Next Generation Workstation/Machine Controller (Low-End Controller Task).

Improvements in Operational Readiness by Distributing Manufacturing Capability in the Supply Chain through Additive Manufacturing

DTIC Science & Technology

2017-12-01

inefficiencies of a more complex system. Additional time may also be due to the longer distances traveled . The fulfillment time for a requisition to...Approved OMB No. 0704-0188 Public reporting burden for this collection of information is estimated to average 1 hour per response, including the time ...advanced manufacturing methods with additive manufacturing. This work decomposes the additive manufacturing processes into 11 primary functions. The time

A review of micro-powder injection moulding as a microfabrication technique

NASA Astrophysics Data System (ADS)

Attia, Usama M.; Alcock, Jeffrey R.

2011-04-01

Micro-powder injection moulding (µPIM) is a fast-developing micro-manufacturing technique for the production of metal and ceramic components. Shape complexity, dimensional accuracy, replication fidelity, material variety combined with high-volume capabilities are some of the key advantages of the technology. This review assesses the capabilities and limitations of µPIM as a micro-manufacturing technique by reviewing the latest developments in the area and by considering potential improvements. The basic elements of the process chain, variant processes and simulation attempts are discussed and evaluated. Challenges and research gaps are highlighted, and potential areas for improvement are presented.

Apparatus and method for converting biomass to feedstock for biofuel and biochemical manufacturing processes

DOEpatents

Kania, John; Qiao, Ming; Woods, Elizabeth M.; Cortright, Randy D.; Myren, Paul

2015-12-15

The present invention includes improved systems and methods for producing biomass-derived feedstocks for biofuel and biochemical manufacturing processes. The systems and methods use components that are capable of transferring relatively high concentrations of solid biomass utilizing pressure variations between vessels, and allows for the recovery and recycling of heterogeneous catalyst materials.

Critical operations capabilities in a high cost environment: a multiple case study

NASA Astrophysics Data System (ADS)

Sansone, C.; Hilletofth, P.; Eriksson, D.

2018-04-01

Operations capabilities have been a popular research area for many years and several frameworks have been proposed in the literature. The current frameworks do not take specific contexts into consideration, for instance a high cost environment. This research gap is of particular interest since a manufacturing relocation process has been ongoing the last decades, leading to a huge amount of manufacturing being moved from high to low cost environments. The purpose of this study is to identify critical operations capabilities in a high cost environment. The two research questions were: What are the critical operations capabilities dimensions in a high cost environment? What are the critical operations capabilities in a high cost environment? A multiple case study was conducted and three Swedish manufacturing firms were selected. The study was based on the investigation of an existing framework of operations capabilities. The main dimensions of operations capabilities included in the framework were: cost, quality, delivery, flexibility, service, innovation and environment. Each of the dimensions included two or more operations capabilities. The findings confirmed the validity of the framework and its usefulness in a high cost environment and a new operations capability was revealed (employee flexibility).

An Interoperability Framework and Capability Profiling for Manufacturing Software

NASA Astrophysics Data System (ADS)

Matsuda, M.; Arai, E.; Nakano, N.; Wakai, H.; Takeda, H.; Takata, M.; Sasaki, H.

ISO/TC184/SC5/WG4 is working on ISO16100: Manufacturing software capability profiling for interoperability. This paper reports on a manufacturing software interoperability framework and a capability profiling methodology which were proposed and developed through this international standardization activity. Within the context of manufacturing application, a manufacturing software unit is considered to be capable of performing a specific set of function defined by a manufacturing software system architecture. A manufacturing software interoperability framework consists of a set of elements and rules for describing the capability of software units to support the requirements of a manufacturing application. The capability profiling methodology makes use of the domain-specific attributes and methods associated with each specific software unit to describe capability profiles in terms of unit name, manufacturing functions, and other needed class properties. In this methodology, manufacturing software requirements are expressed in terns of software unit capability profiles.

Flexible Biomanufacturing Processes that Address the Needs of the Future.

PubMed

Diel, Bernhard; Manzke, Christian; Peuker, Thorsten

2014-01-01

: As the age of the blockbuster drug recedes, the business model for the biopharmaceutical industry is evolving at an ever-increasing pace. The personalization of medicine, the emergence of biosimilars and biobetters, and the need to provide vaccines globally are just some of the factors forcing biomanufacturers to rethink how future manufacturing capability is implemented. One thing is clear: the traditional manufacturing strategy of constructing large-scale, purpose-built, capital-intensive facilities will no longer meet the industry's emerging production and economic requirements. Therefore, the authors of this chapter describe the new approach for designing and implementing flexible production processes for monoclonal antibodies and focus on the points to consider as well as the lessons learned from past experience in engineering such systems. A conceptual integrated design is presented that can be used as a blueprint for next-generation biomanufacturing facilities. In addition, this chapter discusses the benefits of the new approach with respect to flexibility, cost, and schedule. The concept presented here can be applied to other biopharmaceutical manufacturing processes and facilities, including-but not limited to-vaccine manufacturing, multiproduct and/or multiprocess capability, clinical manufacturing, and so on.

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

NASA's In-Space Manufacturing Project: Materials and Manufacturing Process Development Update

NASA Technical Reports Server (NTRS)

Prater, Tracie; Bean, Quincy; Werkheiser, Niki; Ledbetter, Frank

2017-01-01

The mission of NASA's In-Space Manufacturing (ISM) project is to identify, design, and implement on-demand, sustainable manufacturing solutions for fabrication, maintenance and repair during exploration missions. ISM has undertaken a phased strategy of incrementally increasing manufacturing capabilities to achieve this goal. The ISM project began with the development of the first 3D printer for the International Space Station. To date, the printer has completed two phases of flight operations. Results from phase I specimens indicated some differences in material properties between ground-processed and ISS-processed specimens, but results of follow-on analyses of these parts and a ground-based study with an equivalent printer strongly indicate that this variability is likely attributable to differences in manufacturing process settings between the ground and flight prints rather than microgravity effects on the fused deposition modeling (FDM) process. Analysis of phase II specimens from the 3D Printing in Zero G tech demo, which shed further light on the sources of material variability, will be presented. The ISM project has also developed a materials characterization plan for the Additive Manufacturing Facility, the follow-on commercial multimaterial 3D printing facility developed for ISS by Made in Space. This work will yield a suite of characteristic property values that can inform use of AMF by space system designers. Other project activities include development of an integrated 3D printer and recycler, known as the Refabricator, by Tethers Unlimited, which will be operational on ISS in 2018. The project also recently issued a broad area announcement for a multimaterial fabrication laboratory, which may include in-space manufacturing capabilities for metals, electronics, and polymeric materials, to be deployed on ISS in the 2022 timeframe.

2015 Army Science Planning and Strategy Meeting Series: Outcomes and Conclusions

DTIC Science & Technology

2017-12-21

modeling and nanoscale characterization tools to enable efficient design of hybridized manufacturing ; realtime, multiscale computational capability...to enable predictive analytics for expeditionary on-demand manufacturing • Discovery of design principles to enable programming advanced genetic...goals, significant research is needed to mature the fundamental materials science, processing and manufacturing sciences, design methodologies, data

Process capability determination of new and existing equipment

NASA Technical Reports Server (NTRS)

Mcclelland, H. T.; Su, Penwen

1994-01-01

The objective of this paper is to illustrate a method of determining the process capability of new or existing equipment. The method may also be modified to apply to testing laboratories. Long term changes in the system may be determined by periodically making new test parts or submitting samples from the original set to the testing laboratory. The technique described has been developed through a series of projects in special topics manufacturing courses and graduate student projects. It will be implemented as a standard experiment in an advanced manufacturing course in a new Manufacturing Engineering program at the University of Wisconsin-Stout campus. Before starting a project of this nature, it is important to decide on the exact question to be answered. In this case, it is desired to know what variation can be reasonably expected in the next part, feature, or test result produced. Generally, this question is answered by providing the process capability or the average value of a measured characteristic of the part or process plus or minus three standard deviations. There are two general cases to be considered: the part or test is made in large quantities with little change, or the process is flexible and makes a large variety of parts. Both cases can be accommodated; however, the emphasis in this report is on short run situations.

High-Volume Production of Lightweight Multijunction Solar Cells

NASA Technical Reports Server (NTRS)

Youtsey, Christopher

2015-01-01

MicroLink Devices, Inc., has transitioned its 6-inch epitaxial lift-off (ELO) solar cell fabrication process into a manufacturing platform capable of sustaining large-volume production. This Phase II project improves the ELO process by reducing cycle time and increasing the yield of large-area devices. In addition, all critical device fabrication processes have transitioned to 6-inch production tool sets designed for volume production. An emphasis on automated cassette-to-cassette and batch processes minimizes operator dependence and cell performance variability. MicroLink Devices established a pilot production line capable of at least 1,500 6-inch wafers per month at greater than 80 percent yield. The company also increased the yield and manufacturability of the 6-inch reclaim process, which is crucial to reducing the cost of the cells.

Space Technology Mission Directorate: Game Changing Development

NASA Technical Reports Server (NTRS)

Gaddis, Stephen W.

2015-01-01

NASA and the aerospace community have deep roots in manufacturing technology and innovation. Through it's Game Changing Development Program and the Advanced Manufacturing Technology Project NASA develops and matures innovative, low-cost manufacturing processes and products. Launch vehicle propulsion systems are a particular area of interest since they typically comprise a large percentage of the total vehicle cost and development schedule. NASA is currently working to develop and utilize emerging technologies such as additive manufacturing (i.e. 3D printing) and computational materials and processing tools that could dramatically improve affordability, capability, and reduce schedule for rocket propulsion hardware.

Advances in solid dosage form manufacturing technology.

PubMed

Andrews, Gavin P

2007-12-15

Currently, the pharmaceutical and healthcare industries are moving through a period of unparalleled change. Major multinational pharmaceutical companies are restructuring, consolidating, merging and more importantly critically assessing their competitiveness to ensure constant growth in an ever-more demanding market where the cost of developing novel products is continuously increasing. The pharmaceutical manufacturing processes currently in existence for the production of solid oral dosage forms are associated with significant disadvantages and in many instances provide many processing problems. Therefore, it is well accepted that there is an increasing need for alternative processes to dramatically improve powder processing, and more importantly to ensure that acceptable, reproducible solid dosage forms can be manufactured. Consequently, pharmaceutical companies are beginning to invest in innovative processes capable of producing solid dosage forms that better meet the needs of the patient while providing efficient manufacturing operations. This article discusses two emerging solid dosage form manufacturing technologies, namely hot-melt extrusion and fluidized hot-melt granulation.

In-Space Manufacturing Baseline Property Development

NASA Technical Reports Server (NTRS)

Stockman, Tom; Schneider, Judith; Prater, Tracie; Bean, Quincy; Werkheiser, Nicki

2016-01-01

The In-Space Manufacturing (ISM) project at NASA Marshall Space Flight Center currently operates a 3D FDM (fused deposition modeling) printer onboard the International Space Station. In order to enable utilization of this capability by designer, the project needs to establish characteristic material properties for materials produced using the process. This is difficult for additive manufacturing since standards and specifications do not yet exist for these technologies. Due to availability of crew time, there are limitations to the sample size which in turn limits the application of the traditional design allowables approaches to develop a materials property database for designers. In this study, various approaches to development of material databases were evaluated for use by designers of space systems who wish to leverage in-space manufacturing capabilities. This study focuses on alternative statistical techniques for baseline property development to support in-space manufacturing.

Overview of the production of sintered SiC optics and optical sub-assemblies

NASA Astrophysics Data System (ADS)

Williams, S.; Deny, P.

2005-08-01

The following is an overview on sintered silicon carbide (SSiC) material properties and processing requirements for the manufacturing of components for advanced technology optical systems. The overview will compare SSiC material properties to typical materials used for optics and optical structures. In addition, it will review manufacturing processes required to produce optical components in detail by process step. The process overview will illustrate current manufacturing process and concepts to expand the process size capability. The overview will include information on the substantial capital equipment employed in the manufacturing of SSIC. This paper will also review common in-process inspection methodology and design rules. The design rules are used to improve production yield, minimize cost, and maximize the inherent benefits of SSiC for optical systems. Optimizing optical system designs for a SSiC manufacturing process will allow systems designers to utilize SSiC as a low risk, cost competitive, and fast cycle time technology for next generation optical systems.

Overlay Tolerances For VLSI Using Wafer Steppers

NASA Astrophysics Data System (ADS)

Levinson, Harry J.; Rice, Rory

1988-01-01

In order for VLSI circuits to function properly, the masking layers used in the fabrication of those devices must overlay each other to within the manufacturing tolerance incorporated in the circuit design. The capabilities of the alignment tools used in the masking process determine the overlay tolerances to which circuits can be designed. It is therefore of considerable importance that these capabilities be well characterized. Underestimation of the overlay accuracy results in unnecessarily large devices, resulting in poor utilization of wafer area and possible degradation of device performance. Overestimation will result in significant yield loss because of the failure to conform to the tolerances of the design rules. The proper methodology for determining the overlay capabilities of wafer steppers, the most commonly used alignment tool for the production of VLSI circuits, is the subject of this paper. Because cost-effective manufacturing process technology has been the driving force of VLSI, the impact on productivity is a primary consideration in all discussions. Manufacturers of alignment tools advertise the capabilities of their equipment. It is notable that no manufacturer currently characterizes his aligners in a manner consistent with the requirements of producing very large integrated circuits, as will be discussed. This has resulted in the situation in which the evaluation and comparison of the capabilities of alignment tools require the attention of a lithography specialist. Unfortunately, lithographic capabilities must be known by many other people, particularly the circuit designers and the managers responsible for the financial consequences of the high prices of modern alignment tools. All too frequently, the designer or manager is confronted with contradictory data, one set coming from his lithography specialist, and the other coming from a sales representative of an equipment manufacturer. Since the latter generally attempts to make his merchandise appear as attractive as possible, the lithographer is frequently placed in the position of having to explain subtle issues in order to justify his decisions. It is the purpose of this paper to provide that explanation.

Potential application of the consistency approach for vaccine potency testing.

PubMed

Arciniega, J; Sirota, L A

2012-01-01

The Consistency Approach offers the possibility of reducing the number of animals used for a potency test. However, it is critical to assess the effect that such reduction may have on assay performance. Consistency of production, sometimes referred to as consistency of manufacture or manufacturing, is an old concept implicit in regulation, which aims to ensure the uninterrupted release of safe and effective products. Consistency of manufacture can be described in terms of process capability, or the ability of a process to produce output within specification limits. For example, the standard method for potency testing of inactivated rabies vaccines is a multiple-dilution vaccination challenge test in mice that gives a quantitative, although highly variable estimate. On the other hand, a single-dilution test that does not give a quantitative estimate, but rather shows if the vaccine meets the specification has been proposed. This simplified test can lead to a considerable reduction in the number of animals used. However, traditional indices of process capability assume that the output population (potency values) is normally distributed, which clearly is not the case for the simplified approach. Appropriate computation of capability indices for the latter case will require special statistical considerations.

In-Space Manufacturing: Pioneering a Sustainable Path to Mars

NASA Technical Reports Server (NTRS)

Werkheiser, Niki

2015-01-01

In order to provide meaningful impacts to exploration technology needs, the In-Space Manufacturing (ISM) Initiative must influence exploration systems design now. In-space manufacturing offers: dramatic paradigm shift in the development and creation of space architectures; efficiency gain and risk reduction for low Earth orbit and deep space exploration; and "pioneering" approach to maintenance, repair, and logistics leading to sustainable, affordable supply chain model. In order to develop application-based capabilities in time to support NASA budget and schedule, ISM must be able to leverage the significant commercial developments, which requires innovative, agile collaborative mechanisms (contracts, challenges, SBIR's, etc.); and NASA-unique investments to focus primarily on adapting the technologies and processes to the microgravity environment. We must do the foundational work - it is the critical path for taking these technologies from lab curiosities to institutionalized capabilities: characterize, certify, institutionalize, design for Additive Manufacturing (AM). Ideally, International Space Station (ISS) U.S. lab rack or partial rack space should be identified for in-space manufacturing utilization in order to continue technology development of a suite of capabilities required for exploration missions, as well as commercialization on ISS.

Martin Marietta, Y-12 Plant Laboratory Partnership Program Plan

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

Koger, J.

1995-02-10

The Y-12 Plant currently embraces three mission areas; stockpile surveillance, maintaining production capability, and storage of special nuclear materials. The Y-12 Plant also contributes to the nations` economic strength by partnering with industry in deploying technology. This partnering has been supported to a great extent through the Technology Transfer Initiative (TTI) directed by DOE/Defense Programs (DP-14). The Oak Ridge Centers for Manufacturing Technology (ORCMT) was established to draw upon the manufacturing and fabrication capabilities at the Y-12 Plant to coordinate and support collaborative efforts, between DP and the domestic industrial sector, toward the development of technologies which offer mutual benefitmore » to both DOE/DP programs and the private sector. Most of the needed technologies for the ``Factory of the Future`` (FOF) are being pursued as core areas at the Y-12 Plant. As a result, 85% of DP-14 projects already support the FOF. The unique capabilities of ORCMT can be applied to a wide range of manufacturing problems to enhance the capabilities of the US industrial base and its economic outcome. The ORCMT has an important role to play in DOE`s Technology Transfer initiative because its capabilities are focused on applied manufacturing and technology deployment which has a more near-term impact on private sector competitiveness. The Y-12 Plant uses the ORCMT to help maintain its own core competencies for the FOF by challenging its engineers and capabilities with technical problems from industry. Areas of strength at the Y-12 Plant that could impact the FOF include modeling of processes and advanced materials; intelligent inspection systems with standardized operator interfaces, analysis software, and part programming language; electronic transfer of designs and features; existing computer-based concurrent engineering; and knowledge-based forming process.« less

Laser dimpling process parameters selection and optimization using surrogate-driven process capability space

NASA Astrophysics Data System (ADS)

Ozkat, Erkan Caner; Franciosa, Pasquale; Ceglarek, Dariusz

2017-08-01

Remote laser welding technology offers opportunities for high production throughput at a competitive cost. However, the remote laser welding process of zinc-coated sheet metal parts in lap joint configuration poses a challenge due to the difference between the melting temperature of the steel (∼1500 °C) and the vapourizing temperature of the zinc (∼907 °C). In fact, the zinc layer at the faying surface is vapourized and the vapour might be trapped within the melting pool leading to weld defects. Various solutions have been proposed to overcome this problem over the years. Among them, laser dimpling has been adopted by manufacturers because of its flexibility and effectiveness along with its cost advantages. In essence, the dimple works as a spacer between the two sheets in lap joint and allows the zinc vapour escape during welding process, thereby preventing weld defects. However, there is a lack of comprehensive characterization of dimpling process for effective implementation in real manufacturing system taking into consideration inherent changes in variability of process parameters. This paper introduces a methodology to develop (i) surrogate model for dimpling process characterization considering multiple-inputs (i.e. key control characteristics) and multiple-outputs (i.e. key performance indicators) system by conducting physical experimentation and using multivariate adaptive regression splines; (ii) process capability space (Cp-Space) based on the developed surrogate model that allows the estimation of a desired process fallout rate in the case of violation of process requirements in the presence of stochastic variation; and, (iii) selection and optimization of the process parameters based on the process capability space. The proposed methodology provides a unique capability to: (i) simulate the effect of process variation as generated by manufacturing process; (ii) model quality requirements with multiple and coupled quality requirements; and (iii) optimize process parameters under competing quality requirements such as maximizing the dimple height while minimizing the dimple lower surface area.

Integrated Process Modeling-A Process Validation Life Cycle Companion.

PubMed

Zahel, Thomas; Hauer, Stefan; Mueller, Eric M; Murphy, Patrick; Abad, Sandra; Vasilieva, Elena; Maurer, Daniel; Brocard, Cécile; Reinisch, Daniela; Sagmeister, Patrick; Herwig, Christoph

2017-10-17

During the regulatory requested process validation of pharmaceutical manufacturing processes, companies aim to identify, control, and continuously monitor process variation and its impact on critical quality attributes (CQAs) of the final product. It is difficult to directly connect the impact of single process parameters (PPs) to final product CQAs, especially in biopharmaceutical process development and production, where multiple unit operations are stacked together and interact with each other. Therefore, we want to present the application of Monte Carlo (MC) simulation using an integrated process model (IPM) that enables estimation of process capability even in early stages of process validation. Once the IPM is established, its capability in risk and criticality assessment is furthermore demonstrated. IPMs can be used to enable holistic production control strategies that take interactions of process parameters of multiple unit operations into account. Moreover, IPMs can be trained with development data, refined with qualification runs, and maintained with routine manufacturing data which underlines the lifecycle concept. These applications will be shown by means of a process characterization study recently conducted at a world-leading contract manufacturing organization (CMO). The new IPM methodology therefore allows anticipation of out of specification (OOS) events, identify critical process parameters, and take risk-based decisions on counteractions that increase process robustness and decrease the likelihood of OOS events.

An Assessment of Nondestructive Evaluation Capability for Complex Additive Manufacturing Aerospace Components

NASA Technical Reports Server (NTRS)

Walker, James; Beshears, Ron; Lambert, Dennis; Tilson, William

2016-01-01

The primary focus of this work is to investigate some of the fundamental relationships between processing, mechanical testing, materials characterization, and NDE for additively manufactured (AM) components using the powder bed fusion direct melt laser sintered process. The goal is to understand the criticality of defects unique to the AM process and then how conventional nondestructive evaluation methods as well as some of the more non-traditional methods such as computed tomography, are effected by the AM material. Specific defects including cracking, porosity and partially/unfused powder will be addressed. Besides line-of-site NDE, as appropriate these inspection capabilities will be put into the context of complex AM geometries where hidden features obscure, or inhibit traditional NDE methods.

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.

Microgravity Manufacturing: Extending Rapid Prototyping Past the Horizon

NASA Technical Reports Server (NTRS)

Cooper, Ken

2003-01-01

Over the last decade, rapid prototyping (RP) technologies have continued to advance in all aspects of operation and application. From continuously advanced materials and processes development to more hard-core manufacturing uses, the RP realm has stretched considerably past its original expectations as a prototyping capability. This paper discusses the unique applications for which NASA has chosen these manufacturing techniques to be utilized in outer space.

Design and Implementation of an Innovative Manufacturing Process for Aerial and Land Supply Needs

DTIC Science & Technology

2011-06-30

buildup of the pad , the incoming web should be held in place during cutting operation to eliminate any shifting / tilting , this has been achieved by...the required number of layers of the folded sheets is stacked to meet the desired size of the pad , the finished pad is ejected and the process...continues for making the remaining pads . Development of such innovative manufacturing process provides immediate capability for the Department of

Low-cost manufacturing of the point focus concentrating module and its key component, the Fresnel lens. Final subcontract report, 31 January 1991--6 May 1991

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

Saifee, T.; Konnerth, A. III

1991-11-01

Solar Kinetics, Inc. (SKI) has been developing point-focus concentrating PV modules since 1986. SKI is currently in position to manufacture between 200 to 600 kilowatts annually of the current design by a combination of manual and semi-automated methods. This report reviews the current status of module manufacture and specifies the required approach to achieve a high-volume manufacturing capability and low cost. The approach taken will include process development concurrent with module design for automated manufacturing. The current effort reviews the major manufacturing costs and identifies components and processes whose improvements would produce the greatest effect on manufacturability and cost reduction.more » The Fresnel lens is one such key component. Investigating specific alternative manufacturing methods and sources has substantially reduced the lens costs and has exceeded the DOE cost-reduction goals. 15 refs.« less

Application of advanced diffraction based optical metrology overlay capabilities for high-volume manufacturing

NASA Astrophysics Data System (ADS)

Chen, Kai-Hsiung; Huang, Guo-Tsai; Hsieh, Hung-Chih; Ni, Wei-Feng; Chuang, S. M.; Chuang, T. K.; Ke, Chih-Ming; Huang, Jacky; Rao, Shiuan-An; Cumurcu Gysen, Aysegul; d'Alfonso, Maxime; Yueh, Jenny; Izikson, Pavel; Soco, Aileen; Wu, Jon; Nooitgedagt, Tjitte; Ottens, Jeroen; Kim, Yong Ho; Ebert, Martin

2017-03-01

On-product overlay requirements are becoming more challenging with every next technology node due to the continued decrease of the device dimensions and process tolerances. Therefore, current and future technology nodes require demanding metrology capabilities such as target designs that are robust towards process variations and high overlay measurement density (e.g. for higher order process corrections) to enable advanced process control solutions. The impact of advanced control solutions based on YieldStar overlay data is being presented in this paper. Multi patterning techniques are applied for critical layers and leading to additional overlay measurement demands. The use of 1D process steps results in the need of overlay measurements relative to more than one layer. Dealing with the increased number of overlay measurements while keeping the high measurement density and metrology accuracy at the same time presents a challenge for high volume manufacturing (HVM). These challenges are addressed by the capability to measure multi-layer targets with the recently introduced YieldStar metrology tool, YS350. On-product overlay results of such multi-layers and standard targets are presented including measurement stability performance.

55th Annual Fuze Conference

DTIC Science & Technology

2011-05-26

concrete plate and compact soil Confirmation: Complete Success both tests The TDD functioned as programmed; traces show entry and exit from each...concrete target and difference in deceleration levels between concrete and soil configuration The final exit & fire signals were generated as planned...Technical Data Package • Determine Process Capability • FMEA Manufacturing • Determine process capability • Cp = ( USL -LSL)/(6*Sigma) • Cpl

Manufacturing Processes for Long-Life Gas Turbines

NASA Astrophysics Data System (ADS)

Hoppin, G. S.; Danesi, W. P.

1986-07-01

Dual-alloy turbine wheels produced by solid-state diffusion bonding of vacuum investment cast blade rings of one superalloy to preconsolidated powder metal hubs of a second superalloy have the long cyclic lives characteristic of wrought or powder superalloys combined with the high creep strength and net-shape blades characteristic of cast superalloys. A wide variety of superalloys and turbine configurations are compatible with this technology. Improved temperature capability turbine blades and vanes of the MAR-M 247 alloy made by directional solidification casting processes are now in volume production for Garrett gas turbines. Single-crystal alloys derivative to MAR-M 247 further extend the temperature capability of turbine blades and have been successfully engine tested. These blades are produced by a relatively simple modification of the processes used to manufacture directionally solidified blades.

The heat removal capability of actively cooled plasma-facing components for the ITER divertor

NASA Astrophysics Data System (ADS)

Missirlian, M.; Richou, M.; Riccardi, B.; Gavila, P.; Loarer, T.; Constans, S.

2011-12-01

Non-destructive examination followed by high-heat-flux testing was performed for different small- and medium-scale mock-ups; this included the most recent developments related to actively cooled tungsten (W) or carbon fibre composite (CFC) armoured plasma-facing components. In particular, the heat-removal capability of these mock-ups manufactured by European companies with all the main features of the ITER divertor design was investigated both after manufacturing and after thermal cycling up to 20 MW m-2. Compliance with ITER requirements was explored in terms of bonding quality, heat flux performances and operational compatibility. The main results show an overall good heat-removal capability after the manufacturing process independent of the armour-to-heat sink bonding technology and promising behaviour with respect to thermal fatigue lifetime under heat flux up to 20 MW m-2 for the CFC-armoured tiles and 15 MW m-2 for the W-armoured tiles, respectively.

Concurrent use of magnetic bearings for rotor support and force sensing for the nondestructive evaluation of manufacturing processes

NASA Astrophysics Data System (ADS)

Kasarda, Mary; Imlach, Joseph; Balaji, P. A.; Marshall, Jeremy T.

2000-06-01

Active magnetic bearings are a proven technology in turbomachinery applications and they offer considerable promise for improving the performance of manufacturing processes. The Active Magnetic Bearing (AMB) is a feedback mechanism that supports a spinning shaft by levitating it in a magnetic field. AMBs have significantly higher surface speed capability than rolling element bearings and they eliminate the potential for product contamination by eliminating the requirement for bearing lubrication. In addition, one of the most promising capabilities for manufacturing applications is the ability of the AMB to act concurrently as both a support bearing and non-invasive force sensor. The feedback nature of the AMB allows for its use as a load cell to continuously measure shaft forces necessary for levitation based on information about the magnetic flux density in the air gaps. This measurement capability may be exploited to improve the process control of such products as textile fibers and photographic films where changes in shaft loads may indicate changes in product quality. This paper discusses the operation of AMBs and their potential benefits in manufacturing equipment along with results from research addressing accurate AMB force sensing performance in field applications. Specifically, results from the development of enhanced AMB measurement algorithms to better account for magnetic fringing and leakage effects to improve the accuracy of this technique are presented. Results from the development of a new on-line calibration procedure for robust in-situ calibration of AMBs in a field application such as a manufacturing plant scenario are also presented including results of Magnetic Finite Element Analysis (MFEA) verification of the procedure.

EUV mask manufacturing readiness in the merchant mask industry

NASA Astrophysics Data System (ADS)

Green, Michael; Choi, Yohan; Ham, Young; Kamberian, Henry; Progler, Chris; Tseng, Shih-En; Chiou, Tsann-Bim; Miyazaki, Junji; Lammers, Ad; Chen, Alek

2017-10-01

As nodes progress into the 7nm and below regime, extreme ultraviolet lithography (EUVL) becomes critical for all industry participants interested in remaining at the leading edge. One key cost driver for EUV in the supply chain is the reflective EUV mask. As of today, the relatively few end users of EUV consist primarily of integrated device manufactures (IDMs) and foundries that have internal (captive) mask manufacturing capability. At the same time, strong and early participation in EUV by the merchant mask industry should bring value to these chip makers, aiding the wide-scale adoption of EUV in the future. For this, merchants need access to high quality, representative test vehicles to develop and validate their own processes. This business circumstance provides the motivation for merchants to form Joint Development Partnerships (JDPs) with IDMs, foundries, Original Equipment Manufacturers (OEMs) and other members of the EUV supplier ecosystem that leverage complementary strengths. In this paper, we will show how, through a collaborative supplier JDP model between a merchant and OEM, a novel, test chip driven strategy is applied to guide and validate mask level process development. We demonstrate how an EUV test vehicle (TV) is generated for mask process characterization in advance of receiving chip maker-specific designs. We utilize the TV to carry out mask process "stress testing" to define process boundary conditions which can be used to create Mask Rule Check (MRC) rules as well as serve as baseline conditions for future process improvement. We utilize Advanced Mask Characterization (AMC) techniques to understand process capability on designs of varying complexity that include EUV OPC models with and without sub-resolution assist features (SRAFs). Through these collaborations, we demonstrate ways to develop EUV processes and reduce implementation risks for eventual mass production. By reducing these risks, we hope to expand access to EUV mask capability for the broadest community possible as the technology is implemented first within and then beyond the initial early adopters.

Terrestrial solar cell module automated array assembly, task 4

NASA Technical Reports Server (NTRS)

1978-01-01

A cost effective design and manufacturing process which would produce solar cell modules capable of meeting qualification test criteria was developed. Emphasis was placed on the development of an aluminum paste back contact process.

Bayesian assurance and sample size determination in the process validation life-cycle.

PubMed

Faya, Paul; Seaman, John W; Stamey, James D

2017-01-01

Validation of pharmaceutical manufacturing processes is a regulatory requirement and plays a key role in the assurance of drug quality, safety, and efficacy. The FDA guidance on process validation recommends a life-cycle approach which involves process design, qualification, and verification. The European Medicines Agency makes similar recommendations. The main purpose of process validation is to establish scientific evidence that a process is capable of consistently delivering a quality product. A major challenge faced by manufacturers is the determination of the number of batches to be used for the qualification stage. In this article, we present a Bayesian assurance and sample size determination approach where prior process knowledge and data are used to determine the number of batches. An example is presented in which potency uniformity data is evaluated using a process capability metric. By using the posterior predictive distribution, we simulate qualification data and make a decision on the number of batches required for a desired level of assurance.

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.

Integrating Materials, Manufacturing, Design and Validation for Sustainability in Future Transport Systems

NASA Astrophysics Data System (ADS)

Price, M. A.; Murphy, A.; Butterfield, J.; McCool, R.; Fleck, R.

2011-05-01

The predictive methods currently used for material specification, component design and the development of manufacturing processes, need to evolve beyond the current `metal centric' state of the art, if advanced composites are to realise their potential in delivering sustainable transport solutions. There are however, significant technical challenges associated with this process. Deteriorating environmental, political, economic and social conditions across the globe have resulted in unprecedented pressures to improve the operational efficiency of the manufacturing sector generally and to change perceptions regarding the environmental credentials of transport systems in particular. There is a need to apply new technologies and develop new capabilities to ensure commercial sustainability in the face of twenty first century economic and climatic conditions as well as transport market demands. A major technology gap exists between design, analysis and manufacturing processes in both the OEMs, and the smaller companies that make up the SME based supply chain. As regulatory requirements align with environmental needs, manufacturers are increasingly responsible for the broader lifecycle aspects of vehicle performance. These include not only manufacture and supply but disposal and re-use or re-cycling. In order to make advances in the reduction of emissions coupled with improved economic efficiency through the provision of advanced lightweight vehicles, four key challenges are identified as follows: Material systems, Manufacturing systems, Integrated design methods using digital manufacturing tools and Validation systems. This paper presents a project which has been designed to address these four key issues, using at its core, a digital framework for the creation and management of key parameters related to the lifecycle performance of thermoplastic composite parts and structures. It aims to provide capability for the proposition, definition, evaluation and demonstration of advanced lightweight structures for new generation vehicles in the context of whole life performance parameters.

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

Semisolid forming of S48C steel grade

NASA Astrophysics Data System (ADS)

Plata, Gorka; Lozares, Jokin; Azpilgain, Zigor; Hurtado, Iñaki; Loizaga, Iñigo; Idoyaga, Zuriñe

2017-10-01

Steel production and component manufacturing industries have to face the challenge of globalization, trying to overcome the economic pressure to remain competitive. Moreover, the lightweighting trend of the latter years implies an even higher challenge to maintain the steel use. Therefore, advanced manufacturing processes will be the cornerstone. In this field, Semisolid forming (SSF) has demonstrated the capability of obtaining complex geometries and saving raw material and energy. Despite it is complicated the SSF of sound components, in Mondragon Unibertsitatea it has been successfully demonstrated the capability of producing strong enough automotive components with 42CrMo4 steel grade. In this work, we demonstrate the capability of SSF S48C steel grade with great mechanical properties.

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.

Design and implementation of a Windows NT network to support CNC activities

NASA Technical Reports Server (NTRS)

Shearrow, C. A.

1996-01-01

The Manufacturing, Materials, & Processes Technology Division is undergoing dramatic changes to bring it's manufacturing practices current with today's technological revolution. The Division is developing Computer Automated Design and Computer Automated Manufacturing (CAD/CAM) abilities. The development of resource tracking is underway in the form of an accounting software package called Infisy. These two efforts will bring the division into the 1980's in relationship to manufacturing processes. Computer Integrated Manufacturing (CIM) is the final phase of change to be implemented. This document is a qualitative study and application of a CIM application capable of finishing the changes necessary to bring the manufacturing practices into the 1990's. The documentation provided in this qualitative research effort includes discovery of the current status of manufacturing in the Manufacturing, Materials, & Processes Technology Division including the software, hardware, network and mode of operation. The proposed direction of research included a network design, computers to be used, software to be used, machine to computer connections, estimate a timeline for implementation, and a cost estimate. Recommendation for the division's improvement include action to be taken, software to utilize, and computer configurations.

Fabrication of multilayered conductive polymer structures via selective visible light photopolymerization

NASA Astrophysics Data System (ADS)

Cullen, Andrew T.; Price, Aaron D.

2017-04-01

Electropolymerization of pyrrole is commonly employed to fabricate intrinsically conductive polymer films that exhibit desirable electromechanical properties. Due to their monolithic nature, electroactive polypyrrole films produced via this process are typically limited to simple linear or bending actuation modes, which has hindered their application in complex actuation tasks. This initiative aims to develop the specialized fabrication methods and polymer formulations required to realize three-dimensional conductive polymer structures capable of more elaborate actuation modes. Our group has previously reported the application of the digital light processing additive manufacturing process for the fabrication of three-dimensional conductive polymer structures using ultraviolet radiation. In this investigation, we further expand upon this initial work and present an improved polymer formulation designed for digital light processing additive manufacturing using visible light. This technology enables the design of novel electroactive polymer sensors and actuators with enhanced capabilities and brings us one step closer to realizing more advanced electroactive polymer enabled devices.

Assembly-line Simulation Program

NASA Technical Reports Server (NTRS)

Chamberlain, Robert G.; Zendejas, Silvino; Malhotra, Shan

1987-01-01

Costs and profits estimated for models based on user inputs. Standard Assembly-line Manufacturing Industry Simulation (SAMIS) program generalized so useful for production-line manufacturing companies. Provides accurate and reliable means of comparing alternative manufacturing processes. Used to assess impact of changes in financial parameters as cost of resources and services, inflation rates, interest rates, tax policies, and required rate of return of equity. Most important capability is ability to estimate prices manufacturer would have to receive for its products to recover all of costs of production and make specified profit. Written in TURBO PASCAL.

Capability of Rolling Efficiency for 100M High-Speed Rails

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

Huang, Howard

2014-03-22

OG Technologies, Inc. (OGT), along with its academic and industrial partners, proposes this CORE project for the Capability of Rolling Efficiency for 100m high-speed rails. The goal is to establish the competitive advantage, and thus the sustainability of the US-based rail manufacturers by greatly enhanced efficiency through innovative in-line metrology technology, in-depth process knowledge, and advanced process control to overcome detrimental factors such as higher labor costs that are saddling the US manufacturing sector. This Phase I project was carried out by an industrial-academia team over 9 months. The R&D team successfully completed all technical tasks and accomplished the objectivesmore » for the Phase I. In addition to the technical efforts, the introductory information of this project as well as anticipated progress was disseminated to steel mills interested in the project. The Phase I project has established the technical and commercial basis for additional development. There are needs to further completing the in-line sensing capability, deepening the capability of metamodeling, and supporting the process monitoring and control. The R&D team plans to submit a Phase II proposal based on the findings.« less

Annual Fuze Conference and Munitions Technology Symposium VI (43rd)

DTIC Science & Technology

1999-04-07

part manufacture and assembly and identify the parameters that we must control through production. Analyzing the coefficients of variation and the...processing energetic materials. The extruder is equipped with four independent temperature control zones, segmented screws, a jacketed die block capable of...and has vacuum capability. Data monitoring capabilities include melt temperature and pressure, torque, screw speed, and temperatures in all of the

Integrated flexible manufacturing program for manufacturing automation and rapid prototyping

NASA Technical Reports Server (NTRS)

Brooks, S. L.; Brown, C. W.; King, M. S.; Simons, W. R.; Zimmerman, J. J.

1993-01-01

The Kansas City Division of Allied Signal Inc., as part of the Integrated Flexible Manufacturing Program (IFMP), is developing an integrated manufacturing environment. Several systems are being developed to produce standards and automation tools for specific activities within the manufacturing environment. The Advanced Manufacturing Development System (AMDS) is concentrating on information standards (STEP) and product data transfer; the Expert Cut Planner system (XCUT) is concentrating on machining operation process planning standards and automation capabilities; the Advanced Numerical Control system (ANC) is concentrating on NC data preparation standards and NC data generation tools; the Inspection Planning and Programming Expert system (IPPEX) is concentrating on inspection process planning, coordinate measuring machine (CMM) inspection standards and CMM part program generation tools; and the Intelligent Scheduling and Planning System (ISAPS) is concentrating on planning and scheduling tools for a flexible manufacturing system environment. All of these projects are working together to address information exchange, standardization, and information sharing to support rapid prototyping in a Flexible Manufacturing System (FMS) environment.

Readiness Assessment Towards Smart Manufacturing System for Tuna Processing Industry in Indonesia

NASA Astrophysics Data System (ADS)

Anggrahini, D.; Kurniati, N.; Karningsih, P. D.; Parenreng, S. M.; Syahroni, N.

2018-04-01

Marine product processing is one of the top priority clusters in the national development. Tuna, as a kind of deep ocean fishes, has the highest number of production that significantly increased throughout the years. Indonesia government encourages tuna processing industry, which are mostly dominated by small to medium enterprises, to grow continuously. Nowadays, manufacturers are facing substantial challenges in adopting modern system and technology that will lead a significant improvement through the internet of things (IoT). A smart factory transform integrated manufacturing process, in a high speed processing to respond customer needs. It has some positive impacts, such as increasing productivity, reducing set up time, shortening marketing and other support activities, hence the process is being more flexible and efficient. To implement smart manufacturing system, factories should know the readiness at any level of them, technology capability and strategy appropriateness. This exploratory study aims to identify the criterias, and develop an assessment tools to measure the level towards smart factory.

Automotive manufacturing assessment system. Volume IV: engine manufacturing analysis. Final report Jun 77-Aug 78

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

Taylor, T. Jr

Volume IV represents the results of one of four major study areas under the Automotive Manufacturing Assessment System (AMAS) sponsored by the DOT/Transportation Systems Center. AMAS was designed to assist in the evaluation of industry's capability to produce fuel efficient vehicles. An analysis of automotive engine manufacturing was conducted in order to determine the impact of regulatory changes on tooling costs and the production process. The 351W CID V-8 engine at Ford's Windsor No. 1 Plant was the subject of the analysis. A review of plant history and its product is presented along with an analysis of manufacturing operations, includingmore » material and production flow, plant layout, machining and assembly processes, tooling, supporting facilities, inspection, service and repair. Four levels of product change intensity showing the impact on manufacturing methods and cost is also presented.« less

Low cost composite manufacturing utilizing intelligent pultrusion and resin transfer molding (IPRTM)

NASA Astrophysics Data System (ADS)

Bradley, James E.; Wysocki, Tadeusz S., Jr.

1993-02-01

This article describes an innovative method for the economical manufacturing of large, intricately-shaped tubular composite parts. Proprietary intelligent process control techniques are combined with standard pultrusion and RTM methodologies to provide high part throughput, performance, and quality while substantially reducing scrap, rework costs, and labor requirements. On-line process monitoring and control is achieved through a smart tooling interface consisting of modular zone tiles installed on part-specific die assemblies. Real-time archiving of process run parameters provides enhanced SPC and SQC capabilities.

Metrology for the manufacturing of freeform optics

NASA Astrophysics Data System (ADS)

Blalock, Todd; Myer, Brian; Ferralli, Ian; Brunelle, Matt; Lynch, Tim

2017-10-01

Recently the use of freeform surfaces have become a realization for optical designers. These non-symmetrical optical surfaces have allowed unique solutions to optical design problems. The implementation of freeform optical surfaces has been limited by manufacturing capabilities and quality. However over the past several years freeform fabrication processes have improved in capability and precision. But as with any manufacturing, proper metrology is required to monitor and verify the process. Typical optics metrology such as interferometry has its challenges and limitations with the unique shapes of freeform optics. Two contact metrology methods for freeform metrology are presented; a Leitz coordinate measurement machine (CMM) with an uncertainty of +/- 0.5 μm and a high resolution profilometer (Panasonic UA3P) with a measurement uncertainty of +/- 0.05 μm. We are also developing a non-contact high resolution technique based on the fringe reflection technique known as deflectometry. This fast non-contact metrology has the potential to compete with accuracies of the contact methods but also can acquire data in seconds rather than minutes or hours.

Fine pitch thermosonic wire bonding: analysis of state-of-the-art manufacturing capability

NASA Astrophysics Data System (ADS)

Cavasin, Daniel

1995-09-01

A comprehensive process characterization was performed at the Motorola plastic package assembly site in Selangor, Malaysia, to document the current fine pitch wire bond process capability, using state-of-the-art equipment, in an actual manufacturing environment. Two machines, representing the latest technology from two separate manufacturers, were operated one shift per day for five days, bonding a 132 lead Plastic Quad Flat Pack. Using a test device specifically designed for fine pitch wire bonding, the bonding programs were alternated between 107 micrometers and 92 micrometers pad pitch, running each pitch for a total of 1600 units per machine. Wire, capillary type, and related materials were standardized and commercially available. A video metrology measurement system, with a demonstrated six sigma repeatability band width of 0.51 micrometers , was utilized to measure the bonded units for bond dimensions and placement. Standard Quality Assurance (QA) metrics were also performed. Results indicate that state-of-the-art thermosonic wire bonding can achieve acceptable assembly yields at these fine pad pitches.

Continuous flow technology vs. the batch-by-batch approach to produce pharmaceutical compounds.

PubMed

Cole, Kevin P; Johnson, Martin D

2018-01-01

For the manufacture of small molecule drugs, many pharmaceutical innovator companies have recently invested in continuous processing, which can offer significant technical and economic advantages over traditional batch methodology. This Expert Review will describe the reasons for this interest as well as many considerations and challenges that exist today concerning continuous manufacturing. Areas covered: Continuous processing is defined and many reasons for its adoption are described. The current state of continuous drug substance manufacturing within the pharmaceutical industry is summarized. Current key challenges to implementation of continuous manufacturing are highlighted, and an outlook provided regarding the prospects for continuous within the industry. Expert commentary: Continuous processing at Lilly has been a journey that started with the need for increased safety and capability. Over twelve years the original small, dedicated group has grown to more than 100 Lilly employees in discovery, development, quality, manufacturing, and regulatory designing in continuous drug substance processing. Recently we have focused on linked continuous unit operations for the purpose of all-at-once pharmaceutical manufacturing, but the technical and business drivers that existed in the very beginning for stand-alone continuous unit operations in hybrid processes have persisted, which merits investment in both approaches.

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

Foreword: Additive Manufacturing: Interrelationships of Fabrication, Constitutive Relationships Targeting Performance, and Feedback to Process Control

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

Carpenter, John S.; Beese, Allison M.; Bourell, David L.

Additive manufacturing (AM) offers distinct advantages over conventional manufacturing processes including the capability to both build and repair complex part shapes; to integrate and consolidate parts and thus overcome joining concerns; and to locally tailor material compositions as well as properties. Moreover, a variety of fields such as aerospace, military, automotive, and biomedical are employing this manufacturing technique as a way to decrease costs, increase manufacturing agility, and explore novel geometry/functionalities. In order to increase acceptance of AM as a viable processing method, pathways for qualifying both the material and the process need to be developed and, perhaps, standardized. Thismore » symposium was designed to serve as a venue for the international AM community—including government, academia, and industry—to define the fundamental interrelationships between feedstock, processing, microstructure, shape, mechanical behavior/materials properties, and function/performance. Eventually, insight into the connections between processing, microstructure, property, and performance will be achieved through experimental observations, theoretical advances, and computational modeling of physical processes. Finally, once this insight matures, AM will be able to move from the realm of making parts to making qualified materials that are certified for use with minimal need for post-fabrication characterization.« less

Increasing component functionality via multi-process additive manufacturing

NASA Astrophysics Data System (ADS)

Coronel, Jose L.; Fehr, Katherine H.; Kelly, Dominic D.; Espalin, David; Wicker, Ryan B.

2017-05-01

Additively manufactured components, although extensively customizable, are often limited in functionality. Multi-process additive manufacturing (AM) grants the ability to increase the functionality of components via subtractive manufacturing, wire embedding, foil embedding and pick and place. These processes are scalable to include several platforms ranging from desktop to large area printers. The Multi3D System is highlighted, possessing the capability to perform the above mentioned processes, all while transferring a fabricated component with a robotic arm. Work was conducted to fabricate a patent inspired, printed missile seeker. The seeker demonstrated the advantage of multi-process AM via introduction of the pick and place process. Wire embedding was also explored, with the successful interconnect of two layers of embedded wires in different planes. A final demonstration of a printed contour bracket, served to show the reduction of surface roughness on a printed part is 87.5% when subtractive manufacturing is implemented in tandem with AM. Functionality of the components on all the cases was improved. Results included optical components embedded within the printed housing, wires embedded with interconnection, and reduced surface roughness. These results highlight the improved functionality of components through multi-process AM, specifically through work conducted with the Multi3D System.

Foreword: Additive Manufacturing: Interrelationships of Fabrication, Constitutive Relationships Targeting Performance, and Feedback to Process Control

DOE PAGES

Carpenter, John S.; Beese, Allison M.; Bourell, David L.; ...

2015-06-26

Additive manufacturing (AM) offers distinct advantages over conventional manufacturing processes including the capability to both build and repair complex part shapes; to integrate and consolidate parts and thus overcome joining concerns; and to locally tailor material compositions as well as properties. Moreover, a variety of fields such as aerospace, military, automotive, and biomedical are employing this manufacturing technique as a way to decrease costs, increase manufacturing agility, and explore novel geometry/functionalities. In order to increase acceptance of AM as a viable processing method, pathways for qualifying both the material and the process need to be developed and, perhaps, standardized. Thismore » symposium was designed to serve as a venue for the international AM community—including government, academia, and industry—to define the fundamental interrelationships between feedstock, processing, microstructure, shape, mechanical behavior/materials properties, and function/performance. Eventually, insight into the connections between processing, microstructure, property, and performance will be achieved through experimental observations, theoretical advances, and computational modeling of physical processes. Finally, once this insight matures, AM will be able to move from the realm of making parts to making qualified materials that are certified for use with minimal need for post-fabrication characterization.« less

A framework for the computer-aided planning and optimisation of manufacturing processes for components with functional graded properties

NASA Astrophysics Data System (ADS)

Biermann, D.; Gausemeier, J.; Heim, H.-P.; Hess, S.; Petersen, M.; Ries, A.; Wagner, T.

2014-05-01

In this contribution a framework for the computer-aided planning and optimisation of functional graded components is presented. The framework is divided into three modules - the "Component Description", the "Expert System" for the synthetisation of several process chains and the "Modelling and Process Chain Optimisation". The Component Description module enhances a standard computer-aided design (CAD) model by a voxel-based representation of the graded properties. The Expert System synthesises process steps stored in the knowledge base to generate several alternative process chains. Each process chain is capable of producing components according to the enhanced CAD model and usually consists of a sequence of heating-, cooling-, and forming processes. The dependencies between the component and the applied manufacturing processes as well as between the processes themselves need to be considered. The Expert System utilises an ontology for that purpose. The ontology represents all dependencies in a structured way and connects the information of the knowledge base via relations. The third module performs the evaluation of the generated process chains. To accomplish this, the parameters of each process are optimised with respect to the component specification, whereby the result of the best parameterisation is used as representative value. Finally, the process chain which is capable of manufacturing a functionally graded component in an optimal way regarding to the property distributions of the component description is presented by means of a dedicated specification technique.

Freeform Optics: current challenges for future serial production

NASA Astrophysics Data System (ADS)

Schindler, C.; Köhler, T.; Roth, E.

2017-10-01

One of the major developments in optics industry recently is the commercial manufacturing of freeform surfaces for optical mid- and high performance systems. The loss of limitation on rotational symmetry enables completely new optical design solutions - but causes completely new challenges for the manufacturer too. Adapting the serial production from radial-symmetric to freeform optics cannot be done just by the extension of machine capabilities and software for every process step. New solutions for conventional optics productions or completely new process chains are necessary.

Electrical features of new DNC, CNC system viewed

NASA Astrophysics Data System (ADS)

Fritzsch, W.; Kochan, D.; Schaller, J.; Zander, H. J.

1985-03-01

Control structures capable of solving the problems of a flexible minial-labor manufacturing process are analyzed. The present state of development of equipment technology is described, and possible ways of modeling control processes are surveyed. Concepts which are frequently differently interpreted in various specialized disciplines are systematized, with a view toward creating the prerequisites for interdisciplinary cooperation. Problems and information flow during the preparatory and performance phases of manufacturing are examined with respect to coupling CAD/CAM functions. Mathematical modeling for direct numerical control is explored.

Manufacturing Technology Support (MATES II) Task Order 0005: Manufacturing Integration and Technology Evaluation to Enable Technology Transition. Subtask Phase 0 Study Task: Manufacturing Technology (ManTech) and Systems Engineering For Quick Reaction Systems

DTIC Science & Technology

2014-10-01

Porosity from gas entrapment & shrinkage 4 Continuous Fiber Ti Metal Matrix Composites (Aircraft panels and rotor components) [14...process models for casting, forging, and welding , and software capability to integrate various independent models with design, thermal, and structural...Applications, Ph.D. Thesis, Queen’s College, University of Oxford, (2007). 14. S.A. Singerman and J.J. Jackson, Titanium Metal Matrix Composites for

47 CFR 22.921 - 911 call processing procedures; 911-only calling mode.

Code of Federal Regulations, 2011 CFR

2011-10-01

... 47 Telecommunication 2 2011-10-01 2011-10-01 false 911 call processing procedures; 911-only... CARRIER SERVICES PUBLIC MOBILE SERVICES Cellular Radiotelephone Service § 22.921 911 call processing procedures; 911-only calling mode. Mobile telephones manufactured after February 13, 2000 that are capable of...

47 CFR 22.921 - 911 call processing procedures; 911-only calling mode.

Code of Federal Regulations, 2012 CFR

2012-10-01

... 47 Telecommunication 2 2012-10-01 2012-10-01 false 911 call processing procedures; 911-only... CARRIER SERVICES PUBLIC MOBILE SERVICES Cellular Radiotelephone Service § 22.921 911 call processing procedures; 911-only calling mode. Mobile telephones manufactured after February 13, 2000 that are capable of...

Architecture for distributed design and fabrication

NASA Astrophysics Data System (ADS)

McIlrath, Michael B.; Boning, Duane S.; Troxel, Donald E.

1997-01-01

We describe a flexible, distributed system architecture capable of supporting collaborative design and fabrication of semi-conductor devices and integrated circuits. Such capabilities are of particular importance in the development of new technologies, where both equipment and expertise are limited. Distributed fabrication enables direct, remote, physical experimentation in the development of leading edge technology, where the necessary manufacturing resources are new, expensive, and scarce. Computational resources, software, processing equipment, and people may all be widely distributed; their effective integration is essential in order to achieve the realization of new technologies for specific product requirements. Our architecture leverages is essential in order to achieve the realization of new technologies for specific product requirements. Our architecture leverages current vendor and consortia developments to define software interfaces and infrastructure based on existing and merging networking, CIM, and CAD standards. Process engineers and product designers access processing and simulation results through a common interface and collaborate across the distributed manufacturing environment.

Inspection planning development: An evolutionary approach using reliability engineering as a tool

NASA Technical Reports Server (NTRS)

Graf, David A.; Huang, Zhaofeng

1994-01-01

This paper proposes an evolutionary approach for inspection planning which introduces various reliability engineering tools into the process and assess system trade-offs among reliability, engineering requirement, manufacturing capability and inspection cost to establish an optimal inspection plan. The examples presented in the paper illustrate some advantages and benefits of the new approach. Through the analysis, reliability and engineering impacts due to manufacturing process capability and inspection uncertainty are clearly understood; the most cost effective and efficient inspection plan can be established and associated risks are well controlled; some inspection reductions and relaxations are well justified; and design feedbacks and changes may be initiated from the analysis conclusion to further enhance reliability and reduce cost. The approach is particularly promising as global competitions and customer quality improvement expectations are rapidly increasing.

A new technology for manufacturing scheduling derived from space system operations

NASA Technical Reports Server (NTRS)

Hornstein, R. S.; Willoughby, J. K.

1993-01-01

A new technology for producing finite capacity schedules has been developed in response to complex requirements for operating space systems such as the Space Shuttle, the Space Station, and the Deep Space Network for telecommunications. This technology has proven its effectiveness in manufacturing environments where popular scheduling techniques associated with Materials Resources Planning (MRPII) and with factory simulation are not adequate for shop-floor work planning and control. The technology has three components. The first is a set of data structures that accommodate an extremely general description of a factory's resources, its manufacturing activities, and the constraints imposed by the environment. The second component is a language and set of software utilities that enable a rapid synthesis of functional capabilities. The third component is an algorithmic architecture called the Five Ruleset Model which accommodates the unique needs of each factory. Using the new technology, systems can model activities that generate, consume, and/or obligate resources. This allows work-in-process (WIP) to be generated and used; it permits constraints to be imposed or intermediate as well as finished goods inventories. It is also possible to match as closely as possible both the current factory state and future conditions such as promise dates. Schedule revisions can be accommodated without impacting the entire production schedule. Applications have been successful in both discrete and process manufacturing environments. The availability of a high-quality finite capacity production planning capability enhances the data management capabilities of MRP II systems. These schedules can be integrated with shop-floor data collection systems and accounting systems. Using the new technology, semi-custom systems can be developed at costs that are comparable to products that do not have equivalent functional capabilities and/or extensibility.

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

Mask manufacturing of advanced technology designs using multi-beam lithography (part 2)

NASA Astrophysics Data System (ADS)

Green, Michael; Ham, Young; Dillon, Brian; Kasprowicz, Bryan; Hur, Ik Boum; Park, Joong Hee; Choi, Yohan; McMurran, Jeff; Kamberian, Henry; Chalom, Daniel; Klikovits, Jan; Jurkovic, Michal; Hudek, Peter

2016-09-01

As optical lithography is extended into 10nm and below nodes, advanced designs are becoming a key challenge for mask manufacturers. Techniques including advanced optical proximity correction (OPC) and Inverse Lithography Technology (ILT) result in structures that pose a range of issues across the mask manufacturing process. Among the new challenges are continued shrinking sub-resolution assist features (SRAFs), curvilinear SRAFs, and other complex mask geometries that are counter-intuitive relative to the desired wafer pattern. Considerable capability improvements over current mask making methods are necessary to meet the new requirements particularly regarding minimum feature resolution and pattern fidelity. Advanced processes using the IMS Multi-beam Mask Writer (MBMW) are feasible solutions to these coming challenges. In this paper, Part 2 of our study, we further characterize an MBMW process for 10nm and below logic node mask manufacturing including advanced pattern analysis and write time demonstration.

Considerations on the construction of a Powder Bed Fusion platform for Additive Manufacturing

NASA Astrophysics Data System (ADS)

Andersen, Sebastian Aagaard; Nielsen, Karl-Emil; Pedersen, David Bue; Nielsen, Jakob Skov

As the demand for moulds and other tools becomes increasingly specific and complex, an additive manufacturing approach to production is making its way to the industry through laser based consolidation of metal powder particles by a method known as powder bed fusion. This paper concerns a variety of design choices facilitating the development of an experimental powder bed fusion machine tool, capable of manufacturing metal parts with strength matching that of conventional manufactured parts and a complexity surpassing that of subtractive processes. To understand the different mechanisms acting within such an experimental machine tool, a fully open and customizable rig is constructed. Emphasizing modularity in the rig, allows alternation of lasers, scanner systems, optical elements, powder deposition, layer height, temperature, atmosphere, and powder type. Through a custom-made software platform, control of the process is achieved, which extends into a graphical user interface, easing adjustment of process parameters and the job file generation.

A Search Algorithm for Generating Alternative Process Plans in Flexible Manufacturing System

NASA Astrophysics Data System (ADS)

Tehrani, Hossein; Sugimura, Nobuhiro; Tanimizu, Yoshitaka; Iwamura, Koji

Capabilities and complexity of manufacturing systems are increasing and striving for an integrated manufacturing environment. Availability of alternative process plans is a key factor for integration of design, process planning and scheduling. This paper describes an algorithm for generation of alternative process plans by extending the existing framework of the process plan networks. A class diagram is introduced for generating process plans and process plan networks from the viewpoint of the integrated process planning and scheduling systems. An incomplete search algorithm is developed for generating and searching the process plan networks. The benefit of this algorithm is that the whole process plan network does not have to be generated before the search algorithm starts. This algorithm is applicable to large and enormous process plan networks and also to search wide areas of the network based on the user requirement. The algorithm can generate alternative process plans and to select a suitable one based on the objective functions.

Process Control and Development for Ultrasonic Additive Manufacturing with Embedded Fibers

NASA Astrophysics Data System (ADS)

Hehr, Adam J.

Ultrasonic additive manufacturing (UAM) is a recent additive manufacturing technology which combines ultrasonic metal welding, CNC machining, and mechanized foil layering to create large gapless near net-shape metallic parts. The process has been attracting much attention lately due to its low formation temperature, the capability to join dissimilar metals, and the ability to create complex design features not possible with traditional subtractive processes alone. These process attributes enable light-weighting of structures and components in an unprecedented way. However, UAM is currently limited to niche areas due to the lack of quality tracking and inadequate scientific understanding of the process. As a result, this thesis work is focused on improving both component quality tracking and process understanding through the use of average electrical power input to the welder. Additionally, the understanding and application space of embedding fibers into metals using UAM is investigated, with particular focus on NiTi shape memory alloy fibers.

Implementing Lean Six Sigma to achieve inventory control in supply chain management

NASA Astrophysics Data System (ADS)

Hong, Chen

2017-11-01

The inventory cost has important impact on the production cost. In order to get the maximum circulation of funds of enterprise with minimum inventory cost, the inventory control with Lean Six Sigma is presented in supply chain management. The inventory includes both the raw material and the semi-finished parts in manufacturing process. Though the inventory is often studied, the inventory control in manufacturing process is seldom mentioned. This paper reports the inventory control from the perspective of manufacturing process by using statistical techniques including DMAIC, Control Chart, and Statistical Process Control. The process stability is evaluated and the process capability is verified with Lean Six Sigma philosophy. The demonstration in power meter production shows the inventory is decreased from 25% to 0.4%, which indicates the inventory control can be achieved with Lean Six Sigma philosophy and the inventory cost in production can be saved for future sustainable development in supply chain management.

Additive Manufacturing of Fuel Injectors

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

Sadek Tadros, Dr. Alber Alphonse; Ritter, Dr. George W.; Drews, Charles Donald

Additive manufacturing (AM), also known as 3D-printing, has been shifting from a novelty prototyping paradigm to a legitimate manufacturing tool capable of creating components for highly complex engineered products. An emerging AM technology for producing metal parts is the laser powder bed fusion (L-PBF) process; however, industry manufacturing specifications and component design practices for L-PBF have not yet been established. Solar Turbines Incorporated (Solar), an industrial gas turbine manufacturer, has been evaluating AM technology for development and production applications with the desire to enable accelerated product development cycle times, overall turbine efficiency improvements, and supply chain flexibility relative to conventionalmore » manufacturing processes (casting, brazing, welding). Accordingly, Solar teamed with EWI on a joint two-and-a-half-year project with the goal of developing a production L-PBF AM process capable of consistently producing high-nickel alloy material suitable for high temperature gas turbine engine fuel injector components. The project plan tasks were designed to understand the interaction of the process variables and their combined impact on the resultant AM material quality. The composition of the high-nickel alloy powders selected for this program met the conventional cast Hastelloy X compositional limits and were commercially available in different particle size distributions (PSD) from two suppliers. Solar produced all the test articles and both EWI and Solar shared responsibility for analyzing them. The effects of powder metal input stock, laser parameters, heat treatments, and post-finishing methods were evaluated. This process knowledge was then used to generate tensile, fatigue, and creep material properties data curves suitable for component design activities. The key process controls for ensuring consistent material properties were documented in AM powder and process specifications. The basic components of the project were: • Powder metal input stock: Powder characterization, dimensional accuracy, metallurgical characterization, and mechanical properties evaluation. • Process parameters: Laser parameter effects, post-printing heat-treatment development, mechanical properties evaluation, and post-finishing technique. • Material design curves: Room and elevated temperature tensiles, low cycle fatigue, and creep rupture properties curves generated. • AM specifications: Key metal powder characteristics, laser parameters, and heat-treatment controls identified.« less

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

Eshraghi, Ray

In September 2008, the U.S. Department of Energy and Martin County Economic Development Corporation entered into an agreement to further the advancement of a microtubular PEM fuel cell developed by Microcell Corporation. The overall focus of this project was on research and development related to high volume manufacturing of fuel cells and cost reduction in the fuel cell manufacturing process. The extrusion process used for the microfiber fuel cells in this project is inherently a low cost, high volume, high speed manufacturing process. In order to take advantage of the capabilities that the extrusion process provides, all subsequent manufacturing processesmore » must be enhanced to meet the extrusion line’s speed and output. Significant research and development was completed on these subsequent processes to ensure that power output and performance were not negatively impacted by the higher speeds, design changes and process improvements developed in this project. All tasks were successfully completed resulting in cost reductions, performance improvements and process enhancements in the areas of speed and quality. These results support the Department of Energy’s goal of fuel cell commercialization.« less

The Development of Model for Measuring Railway Wheels Manufacturing Readiness Level

NASA Astrophysics Data System (ADS)

Inrawan Wiratmadja, Iwan; Mufid, Anas

2016-02-01

In an effort to grow the railway wheel industry in Indonesia and reduce the dependence on imports, Metal Industries Development Center (MIDC) makes the implementation of the railway wheel manufacturing technology in Indonesia. MIDC is an institution based on research and development having a task to research the production of railway wheels prototype and acts as a supervisor to the industry in Indonesia, for implementing the railway wheel manufacturing technology. The process of implementing manufacturing technology requires a lot of resources. Therefore it is necessary to measure the manufacturing readiness process. Measurement of railway wheels manufacturing readiness was in this study done using the manufacturing readiness level (MRL) model from the United States Department of Defense. MRL consists of 10 manufacturing readiness levels described by 90 criteria and 184 sub-criteria. To get a manufacturing readiness measurement instrument that is good and accurate, the development process involved experts through expert judgment method and validated with a content validity ratio (CVR). Measurement instrument developed in this study consist of 448 indicators. The measurement results show that MIDC's railway wheels manufacturing readiness is at the level 4. This shows that there is a gap between the current level of manufacturing readiness owned by MIDC and manufacturing readiness levels required to achieve the program objectives, which is level 5. To achieve the program objectives at level 5, a number of actions were required to be done by MIDC. Indicators that must be improved to be able to achieve level 5 are indicators related to the cost and financing, process capability and control, quality management, workers, and manufacturing management criteria.

Laser polishing of additive manufactured Ti alloys

NASA Astrophysics Data System (ADS)

Ma, C. P.; Guan, Y. C.; Zhou, W.

2017-06-01

Laser-based additive manufacturing has attracted much attention as a promising 3D printing method for metallic components in recent years. However, surface roughness of additive manufactured components has been considered as a challenge to achieve high performance. In this work, we demonstrate the capability of fiber laser in polishing rough surface of additive manufactured Ti-based alloys as Ti-6Al-4V and TC11. Both as-received surface and laser-polished surfaces as well as cross-section subsurfaces were analyzed carefully by White-Light Interference, Confocal Microscope, Focus Ion Beam, Scanning Electron Microscopy, Energy Dispersive Spectrometer, and X-ray Diffraction. Results revealed that as-received Ti-based alloys with surface roughness more than 5 μm could be reduce to less than 1 μm through laser polishing process. Moreover, microstructure, microhardness and wear resistance of laser-polished zone was investigated in order to examine the thermal effect of laser polishing processing on the substrate of additive manufactured Ti alloys. This proof-of-concept process has the potential to effectively improve the surface roughness of additive manufactured metallic alloy by local polishing method without damage to the substrate.

Framework for adaptive interoperability of manufacturing enterprises (FAIME): a case study

NASA Astrophysics Data System (ADS)

Sims, John E.; Chu, Bei Tseng B.; Long, Junshen; Matthews, Mike; Barnes, Johnny G.; Jones, Chris H.; Anderson, Rayne A.; Lambert, Russ; Drake, Doug C.; Hamilton, Mark A.; Connard, Mark

1997-01-01

In todays global economy, manufacturing industries require to connect disparate applications seamlessly. They require not only to exchange data and transactions, but present a single business process image to their employees in the office, headquarters, and on the plant floor. Also, it is imperative that small and medium size manufacturing companies deploy manufacturing execution systems applications in conjunction with modern enterprise resource programs for cycle time reduction and better quality. This paper presents the experiences and reflections on a project that created a tool set to assist the above be accomplished not only in a shorter cycle time, with a better predictable quality, and with an object oriented framework, but also a tool set that allows the manufacturer to still use legacy applications. This framework has the capability of plug-and- play so that future migrations and re-engineering of processes are more productive.

Updraft Fixed Bed Gasification Aspen Plus Model

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

2007-09-27

The updraft fixed bed gasification model provides predictive modeling capabilities for updraft fixed bed gasifiers, when devolatilization data is available. The fixed bed model is constructed using Aspen Plus, process modeling software, coupled with a FORTRAN user kinetic subroutine. Current updraft gasification models created in Aspen Plus have limited predictive capabilities and must be "tuned" to reflect a generalized gas composition as specified in literature or by the gasifier manufacturer. This limits the applicability of the process model.

Process monitoring and control with CHEMIN, a miniaturized CCD-based instrument for simultaneous XRD/XRF analysis

NASA Astrophysics Data System (ADS)

Vaniman, David T.; Bish, D.; Guthrie, G.; Chipera, S.; Blake, David E.; Collins, S. Andy; Elliott, S. T.; Sarrazin, P.

1999-10-01

There is a large variety of mining and manufacturing operations where process monitoring and control can benefit from on-site analysis of both chemical and mineralogic constituents. CHEMIN is a CCD-based instrument capable of both X-ray fluorescence (XRF; chemical) and X-ray diffraction (XRD; mineralogic) analysis. Monitoring and control with an instrument like CHEMIN can be applied to feedstocks, intermediate materials, and final products to optimize production. Examples include control of cement feedstock, of ore for smelting, and of minerals that pose inhalation hazards in the workplace. The combined XRD/XRF capability of CHEMIN can be used wherever a desired commodity is associated with unwanted constituents that may be similar in chemistry or structure but not both (e.g., Ca in both gypsum and feldspar, where only the gypsum is desired to make wallboard). In the mining industry, CHEMIN can determine mineral abundances on the spot and enable more economical mining by providing the means to assay when is being mined, quickly and frequently, at minimal cost. In manufacturing, CHEMIN could be used to spot-check the chemical composition and crystalline makeup of a product at any stage of production. Analysis by CHEMIN can be used as feedback in manufacturing processes where rates of heating, process temperature, mixture of feedstocks, and other variables must be adjusted in real time to correct structure and/or chemistry of the product (e.g., prevention of periclase and alkali sulfate coproduction in cement manufacture).

DOD Manufacturing Arsenals: Actions Needed to Identify and Sustain Critical Capabilities

DTIC Science & Technology

2015-11-01

to each develop their own unique method. A senior OSD official described the resulting process as unsound . Each manufacturing arsenal declared what...Public reporting burden for the collection of information is estimated to average 1 hour per response, including the time for reviewing instructions...searching existing data sources, gathering and maintaining the data needed, and completing and reviewing the collection of information. Send comments

Summary Report on Phase I and Phase II Results From the 3D Printing in Zero-G Technology Demonstration Mission. Volume II

NASA Technical Reports Server (NTRS)

Prater, T. J.; Werkheiser, N. J.; Ledbetter, F. E., III

2018-01-01

In-space manufacturing seeks to develop the processes, skill sets, and certification architecture needed to provide a rapid response manufacturing capability on long-duration exploration missions. The first 3D printer on the Space Station was developed by Made in Space, Inc. and completed two rounds of operation on orbit as part of the 3D Printing in Zero-G Technology Demonstration Mission. This Technical Publication provides a comprehensive overview of the technical objections of the mission, the two phases of hardware operation conducted on orbit, and the subsequent detailed analysis of specimens produced. No engineering significant evidence of microgravity effects on material outcomes was noted. This technology demonstration mission represents the first step in developing a suite of manufacturing capabilities to meet future mission needs.

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.

Advanced materials for aircraft engine applications.

PubMed

Backman, D G; Williams, J C

1992-02-28

A review of advances for aircraft engine structural materials and processes is presented. Improved materials, such as superalloys, and the processes for making turbine disks and blades have had a major impact on the capability of modern gas turbine engines. New structural materials, notably composites and intermetallic materials, are emerging that will eventually further enhance engine performance, reduce engine weight, and thereby enable new aircraft systems. In the future, successful aerospace manufacturers will combine product design and materials excellence with improved manufacturing methods to increase production efficiency, enhance product quality, and decrease the engine development cycle time.

Exploring Flow Procedures for Diazonium Formation.

PubMed

Hu, Te; Baxendale, Ian R; Baumann, Marcus

2016-07-14

The synthesis of diazonium salts is historically an important transformation extensively utilized in dye manufacture. However the highly reactive nature of the diazonium functionality has additionally led to the development of many new reactions including several carbon-carbon bond forming processes. It is therefore highly desirable to determine optimum conditions for the formation of diazonium compounds utilizing the latest processing tools such as flow chemistry to take advantage of the increased safety and continuous manufacturing capabilities. Herein we report a series of flow-based procedures to prepare diazonium salts for subsequent in-situ consumption.

Using Additive Manufacturing to Print a CubeSat Propulsion System

NASA Technical Reports Server (NTRS)

Marshall, William M.

2015-01-01

CubeSats are increasingly being utilized for missions traditionally ascribed to larger satellites CubeSat unit (1U) defined as 10 cm x 10 cm x 11 cm. Have been built up to 6U sizes. CubeSats are typically built up from commercially available off-the-shelf components, but have limited capabilities. By using additive manufacturing, mission specific capabilities (such as propulsion), can be built into a system. This effort is part of STMD Small Satellite program Printing the Complete CubeSat. Interest in propulsion concepts for CubeSats is rapidly gaining interest-Numerous concepts exist for CubeSat scale propulsion concepts. The focus of this effort is how to incorporate into structure using additive manufacturing. End-use of propulsion system dictates which type of system to develop-Pulse-mode RCS would require different system than a delta-V orbital maneuvering system. Team chose an RCS system based on available propulsion systems and feasibility of printing using a materials extrusion process. Initially investigated a cold-gas propulsion system for RCS applications-Materials extrusion process did not permit adequate sealing of part to make this a functional approach.

Wafer-shape metrics based foundry lithography

NASA Astrophysics Data System (ADS)

Kim, Sungtae; Liang, Frida; Mileham, Jeffrey; Tsai, Damon; Bouche, Eric; Lee, Sean; Huang, Albert; Hua, C. F.; Wei, Ming Sheng

2017-03-01

As device shrink, there are many difficulties with process integration and device yield. Lithography process control is expected to be a major challenge due to tighter overlay and focus control requirement. The understanding and control of stresses accumulated during device fabrication has becoming more critical at advanced technology nodes. Within-wafer stress variations cause local wafer distortions which in turn present challenges for managing overlay and depth of focus during lithography. A novel technique for measuring distortion is Coherent Gradient Sensing (CGS) interferometry, which is capable of generating a high-density distortion data set of the full wafer within a time frame suitable for a high volume manufacturing (HVM) environment. In this paper, we describe the adoption of CGS (Coherent Gradient Sensing) interferometry into high volume foundry manufacturing to overcome these challenges. Leveraging this high density 3D metrology, we characterized its In-plane distortion as well as its topography capabilities applied to the full flow of an advanced foundry manufacturing. Case studies are presented that summarize the use of CGS data to reveal correlations between in-plane distortion and overlay variation as well as between topography and device yield.

A Program Office Guide to Technology Transfer

DTIC Science & Technology

1988-11-01

Requirements 2-4 2.4.1 Equipment Complexity 2-5 2.4.2 Industrial Capabilities 2-5 2.4.3 Logistics Requirements/Configuration Control 2-5 2.4.4 Schedule...accomplishment of these milestones re- with the leverage of the FSD and production pro- sults in second source full production capability , grams. For more...MANUFACTURING PROCESSES BUILD UP COMPETITIVE PRODUCTION RATE CAPABILITY DURING LOT III Table 1.2-1 AMRAAM Technology Transfer The leader-follower approach is

Waveguide device and method for making same

DOEpatents

Forman, Michael A [San Francisco, CA

2007-08-14

A monolithic micromachined waveguide device or devices with low-loss, high-power handling, and near-optical frequency ranges is set forth. The waveguide and integrated devices are capable of transmitting near-optical frequencies due to optical-quality sidewall roughness. The device or devices are fabricated in parallel, may be mass produced using a LIGA manufacturing process, and may include a passive component such as a diplexer and/or an active capping layer capable of particularized signal processing of the waveforms propagated by the waveguide.

Laser speckle velocimetry for robot manufacturing

NASA Astrophysics Data System (ADS)

Charrett, Thomas O. H.; Bandari, Yashwanth K.; Michel, Florent; Ding, Jialuo; Williams, Stewart W.; Tatam, Ralph P.

2017-06-01

A non-contact speckle correlation sensor for the measurement of robotic tool speed is presented for use in robotic manufacturing and is capable of measuring the in-plane relative velocities between a robot end-effector and the workpiece or other surface. The sensor performance was assessed in the laboratory with the sensor accuracies found to be better than 0:01 mm/s over a 70 mm/s velocity range. Finally an example of the sensors application to robotic manufacturing is presented where the sensor was applied to tool speed measurement for path planning in the wire and arc additive manufacturing process using a KUKA KR150 L110/2 industrial robot.

Electronic Design Automation: Integrating the Design and Manufacturing Functions

NASA Technical Reports Server (NTRS)

Bachnak, Rafic; Salkowski, Charles

1997-01-01

As the complexity of electronic systems grows, the traditional design practice, a sequential process, is replaced by concurrent design methodologies. A major advantage of concurrent design is that the feedback from software and manufacturing engineers can be easily incorporated into the design. The implementation of concurrent engineering methodologies is greatly facilitated by employing the latest Electronic Design Automation (EDA) tools. These tools offer integrated simulation of the electrical, mechanical, and manufacturing functions and support virtual prototyping, rapid prototyping, and hardware-software co-design. This report presents recommendations for enhancing the electronic design and manufacturing capabilities and procedures at JSC based on a concurrent design methodology that employs EDA tools.

Calibrating IR Cameras for In-Situ Temperature Measurement During the Electron Beam Melting Process using Inconel 718 and Ti-Al6-V4

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

Dinwiddie, Ralph Barton; Lloyd, Peter D; Dehoff, Ryan R

2016-01-01

The Department of Energy s (DOE) Manufacturing Demonstration Facility (MDF) at Oak Ridge National Laboratory (ORNL) provides world-leading capabilities in advanced manufacturing (AM) facilities which leverage previous, on-going government investments in materials science research and characterization. MDF contains systems for fabricating components with complex geometries using AM techniques (i.e. 3D-Printing). Various metal alloy printers, for example, use electron beam melting (EBM) systems for creating these components which are otherwise extremely difficult- if not impossible- to machine. ORNL has partnered with manufacturers on improving the final part quality of components and developing new materials for further advancing these devices. One methodmore » being used to study (AM) processes in more depth relies on the advanced imaging capabilities at ORNL. High performance mid-wave infrared (IR) cameras are used for in-situ process monitoring and temperature measurements. However, standard factory calibrations are insufficient due to very low transmissions of the leaded glass window required for X-ray absorption. Two techniques for temperature calibrations will be presented and compared. In-situ measurement of emittance will also be discussed. Ample information can be learned from in-situ IR process monitoring of the EBM process. Ultimately, these imaging systems have the potential for routine use for online quality assurance and feedback control.« less

Additive Manufacturing Design Considerations for Liquid Engine Components

NASA Technical Reports Server (NTRS)

Whitten, Dave; Hissam, Andy; Baker, Kevin; Rice, Darron

2014-01-01

The Marshall Space Flight Center's Propulsion Systems Department has gained significant experience in the last year designing, building, and testing liquid engine components using additive manufacturing. The department has developed valve, duct, turbo-machinery, and combustion device components using this technology. Many valuable lessons were learned during this process. These lessons will be the focus of this presentation. We will present criteria for selecting part candidates for additive manufacturing. Some part characteristics are 'tailor made' for this process. Selecting the right parts for the process is the first step to maximizing productivity gains. We will also present specific lessons we learned about feature geometry that can and cannot be produced using additive manufacturing machines. Most liquid engine components were made using a two-step process. The base part was made using additive manufacturing and then traditional machining processes were used to produce the final part. The presentation will describe design accommodations needed to make the base part and lessons we learned about which features could be built directly and which require the final machine process. Tolerance capabilities, surface finish, and material thickness allowances will also be covered. Additive Manufacturing can produce internal passages that cannot be made using traditional approaches. It can also eliminate a significant amount of manpower by reducing part count and leveraging model-based design and analysis techniques. Information will be shared about performance enhancements and design efficiencies we experienced for certain categories of engine parts.

Manufacturing Diamond Under Very High Pressure

NASA Technical Reports Server (NTRS)

Voronov, Oleg

2007-01-01

A process for manufacturing bulk diamond has been made practical by the invention of the High Pressure and Temperature Apparatus capable of applying the combination of very high temperature and high pressure needed to melt carbon in a sufficiently large volume. The apparatus includes a reaction cell wherein a controlled static pressure as high as 20 GPa and a controlled temperature as high as 5,000 C can be maintained.

3D Printing In Zero-G ISS Technology Demonstration

NASA Technical Reports Server (NTRS)

Werkheiser, Niki; Cooper, Kenneth; Edmunson, Jennifer; Dunn, Jason; Snyder, Michael

2014-01-01

The National Aeronautics and Space Administration (NASA) has a long term strategy to fabricate components and equipment on-demand for manned missions to the Moon, Mars, and beyond. To support this strategy, NASA and Made in Space, Inc. are developing the 3D Printing In Zero-G payload as a Technology Demonstration for the International Space Station (ISS). The 3D Printing In Zero-G experiment ('3D Print') will be the first machine to perform 3D printing in space. The greater the distance from Earth and the longer the mission duration, the more difficult resupply becomes; this requires a change from the current spares, maintenance, repair, and hardware design model that has been used on the International Space Station (ISS) up until now. Given the extension of the ISS Program, which will inevitably result in replacement parts being required, the ISS is an ideal platform to begin changing the current model for resupply and repair to one that is more suitable for all exploration missions. 3D Printing, more formally known as Additive Manufacturing, is the method of building parts/objects/tools layer-by-layer. The 3D Print experiment will use extrusion-based additive manufacturing, which involves building an object out of plastic deposited by a wire-feed via an extruder head. Parts can be printed from data files loaded on the device at launch, as well as additional files uplinked to the device while on-orbit. The plastic extrusion additive manufacturing process is a low-energy, low-mass solution to many common needs on board the ISS. The 3D Print payload will serve as the ideal first step to proving that process in space. It is unreasonable to expect NASA to launch large blocks of material from which parts or tools can be traditionally machined, and even more unreasonable to fly up multiple drill bits that would be required to machine parts from aerospace-grade materials such as titanium 6-4 alloy and Inconel. The technology to produce parts on demand, in space, offers unique design options that are not possible through traditional manufacturing methods while offering cost-effective, high-precision, low-unit on-demand manufacturing. Thus, Additive Manufacturing capabilities are the foundation of an advanced manufacturing in space roadmap. The 3D Printing In Zero-G experiment will demonstrate the capability of utilizing Additive Manufacturing technology in space. This will serve as the enabling first step to realizing an additive manufacturing, print-on-demand "machine shop" for long-duration missions and sustaining human exploration of other planets, where there is extremely limited ability and availability of Earth-based logistics support. Simply put, Additive Manufacturing in space is a critical enabling technology for NASA. It will provide the capability to produce hardware on-demand, directly lowering cost and decreasing risk by having the exact part or tool needed in the time it takes to print. This capability will also provide the much-needed solution to the cost, volume, and up-mass constraints that prohibit launching everything needed for long-duration or long-distance missions from Earth, including spare parts and replacement systems. A successful mission for the 3D Printing In Zero-G payload is the first step to demonstrate the capability of printing on orbit. The data gathered and lessons learned from this demonstration will be applied to the next generation of additive manufacturing technology on orbit. It is expected that Additive Manufacturing technology will quickly become a critical part of any mission's infrastructure.

In-line ATR-UV and Raman Spectroscopy for Monitoring API Dissolution Process During Liquid-Filled Soft-Gelatin Capsule Manufacturing.

PubMed

Wan, Boyong; Zordan, Christopher A; Lu, Xujin; McGeorge, Gary

2016-10-01

Complete dissolution of the active pharmaceutical ingredient (API) is critical in the manufacturing of liquid-filled soft-gelatin capsules (SGC). Attenuated total reflectance UV spectroscopy (ATR-UV) and Raman spectroscopy have been investigated for in-line monitoring of API dissolution during manufacturing of an SGC product. Calibration models have been developed with both techniques for in-line determination of API potency. Performance of both techniques was evaluated and compared. The ATR-UV methodology was found to be able to monitor the dissolution process and determine the endpoint, but was sensitive to temperature variations. The Raman technique was also capable of effectively monitoring the process and was more robust to the temperature variation and process perturbations by using an excipient peak for internal correction. Different data preprocessing methodologies were explored in an attempt to improve method performance.

Three-Axis Distributed Fiber Optic Strain Measurement in 3D Woven Composite Structures

NASA Technical Reports Server (NTRS)

Castellucci, Matt; Klute, Sandra; Lally, Evan M.; Froggatt, Mark E.; Lowry, David

2013-01-01

Recent advancements in composite materials technologies have broken further from traditional designs and require advanced instrumentation and analysis capabilities. Success or failure is highly dependent on design analysis and manufacturing processes. By monitoring smart structures throughout manufacturing and service life, residual and operational stresses can be assessed and structural integrity maintained. Composite smart structures can be manufactured by integrating fiber optic sensors into existing composite materials processes such as ply layup, filament winding and three-dimensional weaving. In this work optical fiber was integrated into 3D woven composite parts at a commercial woven products manufacturing facility. The fiber was then used to monitor the structures during a VARTM manufacturing process, and subsequent static and dynamic testing. Low cost telecommunications-grade optical fiber acts as the sensor using a high resolution commercial Optical Frequency Domain Reflectometer (OFDR) system providing distributed strain measurement at spatial resolutions as low as 2mm. Strain measurements using the optical fiber sensors are correlated to resistive strain gage measurements during static structural loading. Keywords: fiber optic, distributed strain sensing, Rayleigh scatter, optical frequency domain reflectometry

Product pricing in the Solar Array Manufacturing Industry - An executive summary of SAMICS

NASA Technical Reports Server (NTRS)

Chamberlain, R. G.

1978-01-01

Capabilities, methodology, and a description of input data to the Solar Array Manufacturing Industry Costing Standards (SAMICS) are presented. SAMICS were developed to provide a standardized procedure and data base for comparing manufacturing processes of Low-cost Solar Array (LSA) subcontractors, guide the setting of research priorities, and assess the progress of LSA toward its hundred-fold cost reduction goal. SAMICS can be used to estimate the manufacturing costs and product prices and determine the impact of inflation, taxes, and interest rates, but it is limited by its ignoring the effects of the market supply and demand and an assumption that all factories operate in a production line mode. The SAMICS methodology defines the industry structure, hypothetical supplier companies, and manufacturing processes and maintains a body of standardized data which is used to compute the final product price. The input data includes the product description, the process characteristics, the equipment cost factors, and production data for the preparation of detailed cost estimates. Activities validating that SAMICS produced realistic price estimates and cost breakdowns are described.

In-Space Manufacturing: Pioneering a Sustainable Path to Mars

NASA Technical Reports Server (NTRS)

Werkheiser, Niki

2015-01-01

ISM is responsible for developing the on-demand manufacturing capabilities that will be required for affordable, sustainable operations during Exploration Missions (in-transit and on-surface) to destinations such as Mars. This includes advancing the needed technologies, as well as establishing the skills & processes (such as certification and characterization) that will enable the technologies to go from novel to institutionalized. These technologies are evolving rapidly due to terrestrial markets. ISM is leveraging this commercial development to develop these capabilities within a realistic timeframe and budget. ISM utilizes the International Space Station (ISS) as a test-bed to adapt these technologies for microgravity operations and evolve the current operations mindset from earth-reliant to earth-independent.

Modeling of Powder Bed Manufacturing Defects

NASA Astrophysics Data System (ADS)

Mindt, H.-W.; Desmaison, O.; Megahed, M.; Peralta, A.; Neumann, J.

2018-01-01

Powder bed additive manufacturing offers unmatched capabilities. The deposition resolution achieved is extremely high enabling the production of innovative functional products and materials. Achieving the desired final quality is, however, hampered by many potential defects that have to be managed in due course of the manufacturing process. Defects observed in products manufactured via powder bed fusion have been studied experimentally. In this effort we have relied on experiments reported in the literature and—when experimental data were not sufficient—we have performed additional experiments providing an extended foundation for defect analysis. There is large interest in reducing the effort and cost of additive manufacturing process qualification and certification using integrated computational material engineering. A prerequisite is, however, that numerical methods can indeed capture defects. A multiscale multiphysics platform is developed and applied to predict and explain the origin of several defects that have been observed experimentally during laser-based powder bed fusion processes. The models utilized are briefly introduced. The ability of the models to capture the observed defects is verified. The root cause of the defects is explained by analyzing the numerical results thus confirming the ability of numerical methods to provide a foundation for rapid process qualification.

Vision Systems Illuminate Industrial Processes

NASA Technical Reports Server (NTRS)

2013-01-01

When NASA designs a spacecraft to undertake a new mission, innovation does not stop after the design phase. In many cases, these spacecraft are firsts of their kind, requiring not only remarkable imagination and expertise in their conception but new technologies and methods for their manufacture. In the realm of manufacturing, NASA has from necessity worked on the cutting-edge, seeking new techniques and materials for creating unprecedented structures, as well as capabilities for reducing the cost and increasing the efficiency of existing manufacturing technologies. From friction stir welding enhancements (Spinoff 2009) to thermoset composites (Spinoff 2011), NASA s innovations in manufacturing have often transferred to the public in ways that enable the expansion of the Nation s industrial productivity. NASA has long pursued ways of improving upon and ensuring quality results from manufacturing processes ranging from arc welding to thermal coating applications. But many of these processes generate blinding light (hence the need for special eyewear during welding) that obscures the process while it is happening, making it difficult to monitor and evaluate. In the 1980s, NASA partnered with a company to develop technology to address this issue. Today, that collaboration has spawned multiple commercial products that not only support effective manufacturing for private industry but also may support NASA in the use of an exciting, rapidly growing field of manufacturing ideal for long-duration space missions.

Battery resource assessment. Subtask 2.5: Battery manufacturing capability recycling of battery materials

NASA Astrophysics Data System (ADS)

Pemsler, P.

1981-02-01

Studies were conducted on the recycling of advanced battery system components for six different battery systems. These include: nickel/zinc, nickel/iron, zinc/chlorine, zinc/bromine, sodium/sulfur, and lithium-aluminum/iron sulfide. For each battery system, one or more processes were developed which would permit recycling of the major or active materials. Each recycle process was designed to produce a product material which can be used directly as a raw material by the battery manufacturer. Metal recoverabilities are in the range of 93 to 95% for all processes. In each case, capital and operating costs were developed for a recycling plant which processes 100,000 electric vehicle batteries per year.

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.

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.

Manufacturing process and material selection in concurrent collaborative design of MEMS devices

NASA Astrophysics Data System (ADS)

Zha, Xuan F.; Du, H.

2003-09-01

In this paper we present knowledge of an intensive approach and system for selecting suitable manufacturing processes and materials for microelectromechanical systems (MEMS) devices in concurrent collaborative design environment. In the paper, fundamental issues on MEMS manufacturing process and material selection such as concurrent design framework, manufacturing process and material hierarchies, and selection strategy are first addressed. Then, a fuzzy decision support scheme for a multi-criteria decision-making problem is proposed for estimating, ranking and selecting possible manufacturing processes, materials and their combinations. A Web-based prototype advisory system for the MEMS manufacturing process and material selection, WebMEMS-MASS, is developed based on the client-knowledge server architecture and framework to help the designer find good processes and materials for MEMS devices. The system, as one of the important parts of an advanced simulation and modeling tool for MEMS design, is a concept level process and material selection tool, which can be used as a standalone application or a Java applet via the Web. The running sessions of the system are inter-linked with webpages of tutorials and reference pages to explain the facets, fabrication processes and material choices, and calculations and reasoning in selection are performed using process capability and material property data from a remote Web-based database and interactive knowledge base that can be maintained and updated via the Internet. The use of the developed system including operation scenario, use support, and integration with an MEMS collaborative design system is presented. Finally, an illustration example is provided.

Process and product development in the manufacturing of molecular therapeutics.

PubMed

Atkinson, E M; Christensen, J R

1999-08-01

In the development of molecular therapies, a great deal of attention has focused on tissue targets, gene delivery vectors, and expression cassettes. In order to become an approved therapy, however, a molecular therapeutic has to pass down the same product registration pathway as any other biological product. Moving from research into industrial production requires careful attention to regulatory, manufacturing and quality concerns. Early work on developing and characterizing robust and scaleable manufacturing processes will ultimately be rewarded by ease of implementation as the product is successful in clinical trials. Regulatory agencies require solid process and product characterization studies to demonstrate control and understanding of the molecular therapeutic. As the gene therapy industry matures, standards will continue to rise, creating an industry that is capable of producing safe, high-quality and effective therapies for many of the world's most difficult disease targets.

Grain Structure Control of Additively Manufactured Metallic Materials

PubMed Central

Faierson, Eric J.

2017-01-01

Grain structure control is challenging for metal additive manufacturing (AM). Grain structure optimization requires the control of grain morphology with grain size refinement, which can improve the mechanical properties of additive manufactured components. This work summarizes methods to promote fine equiaxed grains in both the additive manufacturing process and subsequent heat treatment. Influences of temperature gradient, solidification velocity and alloy composition on grain morphology are discussed. Equiaxed solidification is greatly promoted by introducing a high density of heterogeneous nucleation sites via powder rate control in the direct energy deposition (DED) technique or powder surface treatment for powder-bed techniques. Grain growth/coarsening during post-processing heat treatment can be restricted by presence of nano-scale oxide particles formed in-situ during AM. Grain refinement of martensitic steels can also be achieved by cyclic austenitizing in post-processing heat treatment. Evidently, new alloy powder design is another sustainable method enhancing the capability of AM for high-performance components with desirable microstructures.

Deep anisotropic ICP plasma etching designed for high-volume MEMS manufacturing

NASA Astrophysics Data System (ADS)

Yu, Keven; Feldbaum, Michael; Pandhumsoporn, Tam; Gadgil, Prashant

1999-08-01

ICP plasma etching is gaining widespread acceptance as an enabling micromachining technology for advanced MEMS fabrication. Whereas this technology has shown a capability of delivering multiple novel applications for R and D, its acceptance by industry for high volume production has been limited. This acceptance into production will only occur when the plasma etching equipment with this technology offers the device performance, throughput, reliability, and uptime criteria required by a production facility. The design of the plasma etcher using this technology and the process capability it consequently delivers, has significant implications in making this a reality. Alcatel has been supplying such a technology to this MEMS industry for over 5 years and in the interim has evolved its product and process to make this technology production worthy. Alcatel's next generation etcher, the Alcatel 601E, offers multiple advantages to MEMS manufacturers in realizing their production goals.

U-10Mo Baseline Fuel Fabrication Process Description

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

Hubbard, Lance R.; Arendt, Christina L.; Dye, Daniel F.

This document provides a description of the U.S. High Power Research Reactor (USHPRR) low-enriched uranium (LEU) fuel fabrication process. This document is intended to be used in conjunction with the baseline process flow diagram (PFD) presented in Appendix A. The baseline PFD is used to document the fabrication process, communicate gaps in technology or manufacturing capabilities, convey alternatives under consideration, and as the basis for a dynamic simulation model of the fabrication process. The simulation model allows for the assessment of production rates, costs, and manufacturing requirements (manpower, fabrication space, numbers and types of equipment, etc.) throughout the lifecycle ofmore » the USHPRR program. This document, along with the accompanying PFD, is updated regularly« less

A new application for food customization with additive manufacturing technologies

NASA Astrophysics Data System (ADS)

Serenó, L.; Vallicrosa, G.; Delgado, J.; Ciurana, J.

2012-04-01

Additive Manufacturing (AM) technologies have emerged as a freeform approach capable of producing almost any complete three dimensional (3D) objects from computer-aided design (CAD) data by successively adding material layer by layer. Despite the broad range of possibilities, commercial AM technologies remain complex and expensive, making them suitable only for niche applications. The developments of the Fab@Home system as an open AM technology discovered a new range of possibilities of processing different materials such as edible products. The main objective of this work is to analyze and optimize the manufacturing capacity of this system when producing 3D edible objects. A new heated syringe deposition tool was developed and several process parameters were optimized to adapt this technology to consumers' needs. The results revealed in this study show the potential of this system to produce customized edible objects without qualified personnel knowledge, therefore saving manufacturing costs compared to traditional technologies.

Process Approach to Determining Quality Inspection Deployment

DTIC Science & Technology

2015-06-08

27 B.1 The Deming Rule...k1/k2? [5] At this stage it is assumed that the manufacturing process is capable and that inspection is effective. The Deming rule is explained in...justify reducing inspectors. (See Appendix B for Deming rule discussion.) Three quantities must be determined: p, the probability of a nonconformity

47 CFR 22.921 - 911 call processing procedures; 911-only calling mode.

Code of Federal Regulations, 2010 CFR

2010-10-01

... programming in the mobile unit that determines the handling of a non-911 call and permit the call to be... CARRIER SERVICES PUBLIC MOBILE SERVICES Cellular Radiotelephone Service § 22.921 911 call processing procedures; 911-only calling mode. Mobile telephones manufactured after February 13, 2000 that are capable of...

Improving mixing efficiency of a polymer micromixer by use of a plastic shim divider

NASA Astrophysics Data System (ADS)

Li, Lei; Lee, L. James; Castro, Jose M.; Yi, Allen Y.

2010-03-01

In this paper, a critical modification to a polymer based affordable split-and-recombination static micromixer is described. To evaluate the improvement, both the original and the modified design were carefully investigated using an experimental setup and numerical modeling approach. The structure of the micromixer was designed to take advantage of the process capabilities of both ultraprecision micromachining and microinjection molding process. Specifically, the original and the modified design were numerically simulated using commercial finite element method software ANSYS CFX to assist the re-designing of the micromixers. The simulation results have shown that both designs are capable of performing mixing while the modified design has a much improved performance. Mixing experiments with two different fluids were carried out using the original and the modified mixers again showed a significantly improved mixing uniformity by the latter. The measured mixing coefficient for the original design was 0.11, and for the improved design it was 0.065. The developed manufacturing process based on ultraprecision machining and microinjection molding processes for device fabrication has the advantage of high-dimensional precision, low cost and manufacturing flexibility.

Microgravity Manufacturing

NASA Technical Reports Server (NTRS)

Cooper, Ken; Munafo, Paul M. (Technical Monitor)

2002-01-01

Manufacturing capability in outer space remains one of the critical milestones to surpass to allow humans to conduct long-duration manned space exploration. The high cost-to-orbit for leaving the Earth's gravitational field continues to be the limiting factor in carrying sufficient hardware to maintain extended life support in microgravity or on other planets. Additive manufacturing techniques, or 'chipless' fabrication, like RP are being considered as the most promising technologies for achieving in situ or remote processing of hardware components, as well as for the repair of existing hardware. At least three RP technologies are currently being explored for use in microgravity and extraterrestrial fabrication.

Magnesium in North America: A Changing Landscape

NASA Astrophysics Data System (ADS)

Slade, Susan

The changing landscape of North American manufacturing in the context of global competition is impacting the market of all raw materials, including magnesium. Current automotive fuel economy legislation and pending legislation on the emissions of greenhouse gases are impacting magnesium's largest consuming industries, such as aluminum, automotive components, steel and transition metals. These industries are all considering innovative ways to efficiently incorporate the needed raw materials into their processes. The North American magnesium market differs from other regions based on maturity, supply streams, changing manufacturing capabilities and trade cases, combined with the transformation of North American manufacturing.

40 CFR Appendix F to Subpart B of... - Standard for Recover-Only Equipment That Extracts a Single, Specific Refrigerant Other Than CFC...

Code of Federal Regulations, 2013 CFR

2013-07-01

... refrigerant, which are either (1) to be returned to a refrigerant reclamation facility that will process the... capability is required which shall process contaminated refrigerant samples at specific temperatures. 6.2The... the recovery process to ±2% of the original manufacturer's formulation submitted to, and accepted by...

40 CFR Appendix F to Subpart B of... - Standard for Recover-Only Equipment That Extracts a Single, Specific Refrigerant Other Than CFC...

Code of Federal Regulations, 2010 CFR

2010-07-01

... refrigerant, which are either (1) to be returned to a refrigerant reclamation facility that will process the... capability is required which shall process contaminated refrigerant samples at specific temperatures. 6.2The... the recovery process to ±2% of the original manufacturer's formulation submitted to, and accepted by...

40 CFR Appendix F to Subpart B of... - Standard for Recover-Only Equipment That Extracts a Single, Specific Refrigerant Other Than CFC...

Code of Federal Regulations, 2011 CFR

2011-07-01

... refrigerant, which are either (1) to be returned to a refrigerant reclamation facility that will process the... capability is required which shall process contaminated refrigerant samples at specific temperatures. 6.2The... the recovery process to ±2% of the original manufacturer's formulation submitted to, and accepted by...

40 CFR Appendix F to Subpart B of... - Standard for Recover-Only Equipment That Extracts a Single, Specific Refrigerant Other Than CFC...

Code of Federal Regulations, 2012 CFR

2012-07-01

... refrigerant, which are either (1) to be returned to a refrigerant reclamation facility that will process the... capability is required which shall process contaminated refrigerant samples at specific temperatures. 6.2The... the recovery process to ±2% of the original manufacturer's formulation submitted to, and accepted by...

40 CFR Appendix F to Subpart B of... - Standard for Recover-Only Equipment That Extracts a Single, Specific Refrigerant Other Than CFC...

Code of Federal Regulations, 2014 CFR

2014-07-01

... refrigerant, which are either (1) to be returned to a refrigerant reclamation facility that will process the... capability is required which shall process contaminated refrigerant samples at specific temperatures. 6.2The... the recovery process to ±2% of the original manufacturer's formulation submitted to, and accepted by...

Material Processing Laser Systems In Production

NASA Astrophysics Data System (ADS)

Taeusch, David R.

1988-11-01

The laser processing system is now a respected, productive machine tool in the manufacturing industries. Systems in use today are proving their cost effectiveness and capabilities of processing quality parts. Several types of industrial lasers are described and their applications are discussed, with emphasis being placed on the production environment and methods of protection required for optical equipment against this normally hostile environment.

Application of Rapid Prototyping and Wire Arc Spray to the Fabrication of Injection Mold Tools (MSFC Center Director's Discretionary Fund)

NASA Technical Reports Server (NTRS)

Cooper, K. G.

2000-01-01

Rapid prototyping (RP) is a layer-by-layer-based additive manufacturing process for constructing three-dimensional representations of a computer design from a wax, plastic, or similar material. Wire arc spray (WAS) is a metal spray forming technique, which deposits thin layers of metal onto a substrate or pattern. Marshall Space Flight Center currently has both capabilities in-house, and this project proposed merging the two processes into an innovative manufacturing technique, in which intermediate injection molding tool halves were to be fabricated with RP and WAS metal forming.

Defect recognition in CFRP components using various NDT methods within a smart manufacturing process

NASA Astrophysics Data System (ADS)

Schumacher, David; Meyendorf, Norbert; Hakim, Issa; Ewert, Uwe

2018-04-01

The manufacturing process of carbon fiber reinforced polymer (CFRP) components is gaining a more and more significant role when looking at the increasing amount of CFRPs used in industries today. The monitoring of the manufacturing process and hence the reliability of the manufactured products, is one of the major challenges we need to face in the near future. Common defects which arise during manufacturing process are e.g. porosity and voids which may lead to delaminations during operation and under load. To find irregularities and classify them as possible defects in an early stage of the manufacturing process is of high importance for the safety and reliability of the finished products, as well as of significant impact from an economical point of view. In this study we compare various NDT methods which were applied to similar CFRP laminate samples in order to detect and characterize regions of defective volume. Besides ultrasound, thermography and eddy current, different X-ray methods like radiography, laminography and computed tomography are used to investigate the samples. These methods are compared with the intention to evaluate their capability to reliably detect and characterize defective volume. Beyond the detection and evaluation of defects, we also investigate possibilities to combine various NDT methods within a smart manufacturing process in which the decision which method shall be applied is inherent within the process. Is it possible to design an in-line or at-line testing process which can recognize defects reliably and reduce testing time and costs? This study aims to show up opportunities of designing a smart NDT process synchronized to the production based on the concepts of smart production (Industry 4.0). A set of defective CFRP laminate samples and different NDT methods were used to demonstrate how effective defects are recognized and how communication between interconnected NDT sensors and the manufacturing process could be organized.

Process industries - graphic arts, paint, plastics, and textiles: all cousins under the skin

NASA Astrophysics Data System (ADS)

Simon, Frederick T.

2002-06-01

The origin and selection of colors in the process industries is different depending upon how the creative process is applied and what are the capabilities of the manufacturing process. The fashion industry (clothing) with its supplier of textiles is the leader of color innovation. Color may be introduced into textile products at several stages in the manufacturing process from fiber through yarn and finally into fabric. The paint industry is divided into two major applications: automotive and trades sales. Automotive colors are selected by stylists who are in the employ of the automobile manufacturers. Trade sales paint on the other hand can be decided by paint manufactureres or by invididuals who patronize custom mixing facilities. Plastics colors are for the most part decided by the industrial designers who include color as part of the design. Graphic Arts (painting) is a burgeoning industry that uses color in image reproduction and package design. Except for text, printed material in color today has become the norm rather than an exception.

Survey of the US materials processing and manufacturing in space program

NASA Technical Reports Server (NTRS)

Mckannan, E. C.

1981-01-01

To promote potential commercial applications of low-g technology, the materials processing and manufacturing in space program is structured to: (1) analyze the scientific principles of gravitational effects on processes used in producing materials; (2) apply the research toward the technology used to control production process (on Earth or in space, as appropriate); and (3) establish the legal and managerial framework for commercial ventures. Presently federally funded NASA research is described as well as agreements for privately funded commercial activity, and a proposed academic participation process. The future scope of the program and related capabilities using ground based facilities, aircraft, sounding rockets, and space shuttles are discussed. Areas of interest described include crystal growth; solidification of metals and alloys; containerless processing; fluids and chemical processes (including biological separation processes); and processing extraterrestrial materials.

JOWOG 22/2 - Actinide Chemical Technology (July 9-13, 2012)

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

Jackson, Jay M.; Lopez, Jacquelyn C.; Wayne, David M.

2012-07-05

The Plutonium Science and Manufacturing Directorate provides world-class, safe, secure, and reliable special nuclear material research, process development, technology demonstration, and manufacturing capabilities that support the nation's defense, energy, and environmental needs. We safely and efficiently process plutonium, uranium, and other actinide materials to meet national program requirements, while expanding the scientific and engineering basis of nuclear weapons-based manufacturing, and while producing the next generation of nuclear engineers and scientists. Actinide Process Chemistry (NCO-2) safely and efficiently processes plutonium and other actinide compounds to meet the nation's nuclear defense program needs. All of our processing activities are done in amore » world class and highly regulated nuclear facility. NCO-2's plutonium processing activities consist of direct oxide reduction, metal chlorination, americium extraction, and electrorefining. In addition, NCO-2 uses hydrochloric and nitric acid dissolutions for both plutonium processing and reduction of hazardous components in the waste streams. Finally, NCO-2 is a key team member in the processing of plutonium oxide from disassembled pits and the subsequent stabilization of plutonium oxide for safe and stable long-term storage.« less

Novel folding device for manufacturing aerospace composite structures

NASA Astrophysics Data System (ADS)

Tewfic, Tarik; Sarhadi, M.

2000-10-01

A new manufacturing methodology, termed shape-inclusive lay-up has been applied that allows the generation of three-dimensional preforms for the resin transfer molding (RTM) process. A flexible novel folding device for forming dry fabrics including non-crimp fabric (NCF) preform is designed and integrated with a Material Delivery System (MDS) into a robotic cell for manufacturing dry fiber composite aerospace components. The paper describes detailed design, implementation and operational performance of a prototype device. The proposed folding device has been implemented and tested by manufacturing a range of reinforcement structure preforms (C,T,J and I reinforcement preforms), normally used in aerostructure applications. A key advantage of the proposed device is its flexibility. The system is capable of manufacturing a wide range of components of various sizes without the need for reconfiguration.

U.S.-Coalition Forces and Host Nations: DOTmLPF-P for Contingency Procurements. Part 2. Conclusion

DTIC Science & Technology

2014-08-01

doesn’t have to be stood up. Examples include textile/cloth- ing/ footwear , construction, and furniture, industries that usu- ally exist in some...meet its needs but be within the HNVs’ capability to manufacture. Finally, materials used by HNVs to manufacture products under U.S. or HNG...procurement efforts should come from reliable sources with processes and physical features in place to prevent substandard or fake material from entering the

Methods and Research for Multi-Component Cutting Force Sensing Devices and Approaches in Machining

PubMed Central

Liang, Qiaokang; Zhang, Dan; Wu, Wanneng; Zou, Kunlin

2016-01-01

Multi-component cutting force sensing systems in manufacturing processes applied to cutting tools are gradually becoming the most significant monitoring indicator. Their signals have been extensively applied to evaluate the machinability of workpiece materials, predict cutter breakage, estimate cutting tool wear, control machine tool chatter, determine stable machining parameters, and improve surface finish. Robust and effective sensing systems with capability of monitoring the cutting force in machine operations in real time are crucial for realizing the full potential of cutting capabilities of computer numerically controlled (CNC) tools. The main objective of this paper is to present a brief review of the existing achievements in the field of multi-component cutting force sensing systems in modern manufacturing. PMID:27854322

Methods and Research for Multi-Component Cutting Force Sensing Devices and Approaches in Machining.

PubMed

Liang, Qiaokang; Zhang, Dan; Wu, Wanneng; Zou, Kunlin

2016-11-16

Multi-component cutting force sensing systems in manufacturing processes applied to cutting tools are gradually becoming the most significant monitoring indicator. Their signals have been extensively applied to evaluate the machinability of workpiece materials, predict cutter breakage, estimate cutting tool wear, control machine tool chatter, determine stable machining parameters, and improve surface finish. Robust and effective sensing systems with capability of monitoring the cutting force in machine operations in real time are crucial for realizing the full potential of cutting capabilities of computer numerically controlled (CNC) tools. The main objective of this paper is to present a brief review of the existing achievements in the field of multi-component cutting force sensing systems in modern manufacturing.

Composites Manufacturing Education and Technology Facility Expedites Manufacturing Innovation

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

The Composites Manufacturing Education and Technology facility (CoMET) at the National Wind Technology Center at the National Renewable Energy Laboratory (NREL) paves the way for innovative wind turbine components and accelerated manufacturing. Available for use by industry partners and university researchers, the 10,000-square-foot facility expands NREL's composite manufacturing research capabilities by enabling researchers to design, prototype, and test composite wind turbine blades and other components -- and then manufacture them onsite. Designed to work in conjunction with NREL's design, analysis, and structural testing capabilities, the CoMET facility expedites manufacturing innovation.

Investigation of dimensional variation in parts manufactured by fused deposition modeling using Gauge Repeatability and Reproducibility

NASA Astrophysics Data System (ADS)

Mohamed, Omar Ahmed; Hasan Masood, Syed; Lal Bhowmik, Jahar

2018-02-01

In the additive manufacturing (AM) market, the question is raised by industry and AM users on how reproducible and repeatable the fused deposition modeling (FDM) process is in providing good dimensional accuracy. This paper aims to investigate and evaluate the repeatability and reproducibility of the FDM process through a systematic approach to answer this frequently asked question. A case study based on the statistical gage repeatability and reproducibility (gage R&R) technique is proposed to investigate the dimensional variations in the printed parts of the FDM process. After running the simulation and analysis of the data, the FDM process capability is evaluated, which would help the industry for better understanding the performance of FDM technology.

Forming Mandrels for X-Ray Mirror Substrates

NASA Technical Reports Server (NTRS)

Blake, Peter N.; Saha. To,p; Zhang, Will; O'Dell, Stephen; Kester, Thomas; Jones, William

2011-01-01

Precision forming mandrels are one element in X-ray mirror development at NASA. Current mandrel fabrication process is capable of meeting the allocated precision requirements for a 5 arcsec telescope. A manufacturing plan is outlined for a large IXO-scale program.

Space processing applications payload equipment study. Volume 2C: Data acquisition and process control

NASA Technical Reports Server (NTRS)

Kayton, M.; Smith, A. G.

1974-01-01

The services provided by the Spacelab Information Management System are discussed. The majority of the services are provided by the common-support subsystems in the Support Module furnished by the Spacelab manufacturer. The information processing requirements for the space processing applications (SPA) are identified. The requirements and capabilities for electric power, display and control panels, recording and telemetry, intercom, and closed circuit television are analyzed.

Bidding-based autonomous process planning and scheduling

NASA Astrophysics Data System (ADS)

Gu, Peihua; Balasubramanian, Sivaram; Norrie, Douglas H.

1995-08-01

Improving productivity through computer integrated manufacturing systems (CIMS) and concurrent engineering requires that the islands of automation in an enterprise be completely integrated. The first step in this direction is to integrate design, process planning, and scheduling. This can be achieved through a bidding-based process planning approach. The product is represented in a STEP model with detailed design and administrative information including design specifications, batch size, and due dates. Upon arrival at the manufacturing facility, the product registered in the shop floor manager which is essentially a coordinating agent. The shop floor manager broadcasts the product's requirements to the machines. The shop contains autonomous machines that have knowledge about their functionality, capabilities, tooling, and schedule. Each machine has its own process planner and responds to the product's request in a different way that is consistent with its capabilities and capacities. When more than one machine offers certain process(es) for the same requirements, they enter into negotiation. Based on processing time, due date, and cost, one of the machines wins the contract. The successful machine updates its schedule and advises the product to request raw material for processing. The concept was implemented using a multi-agent system with the task decomposition and planning achieved through contract nets. The examples are included to illustrate the approach.

Traceability of On-Machine Tool Measurement: A Review.

PubMed

Mutilba, Unai; Gomez-Acedo, Eneko; Kortaberria, Gorka; Olarra, Aitor; Yagüe-Fabra, Jose A

2017-07-11

Nowadays, errors during the manufacturing process of high value components are not acceptable in driving industries such as energy and transportation. Sectors such as aerospace, automotive, shipbuilding, nuclear power, large science facilities or wind power need complex and accurate components that demand close measurements and fast feedback into their manufacturing processes. New measuring technologies are already available in machine tools, including integrated touch probes and fast interface capabilities. They provide the possibility to measure the workpiece in-machine during or after its manufacture, maintaining the original setup of the workpiece and avoiding the manufacturing process from being interrupted to transport the workpiece to a measuring position. However, the traceability of the measurement process on a machine tool is not ensured yet and measurement data is still not fully reliable enough for process control or product validation. The scientific objective is to determine the uncertainty on a machine tool measurement and, therefore, convert it into a machine integrated traceable measuring process. For that purpose, an error budget should consider error sources such as the machine tools, components under measurement and the interactions between both of them. This paper reviews all those uncertainty sources, being mainly focused on those related to the machine tool, either on the process of geometric error assessment of the machine or on the technology employed to probe the measurand.

Repurposing mainstream CNC machine tools for laser-based additive manufacturing

NASA Astrophysics Data System (ADS)

Jones, Jason B.

2016-04-01

The advent of laser technology has been a key enabler for industrial 3D printing, known as Additive Manufacturing (AM). Despite its commercial success and unique technical capabilities, laser-based AM systems are not yet able to produce parts with the same accuracy and surface finish as CNC machining. To enable the geometry and material freedoms afforded by AM, yet achieve the precision and productivity of CNC machining, hybrid combinations of these two processes have started to gain traction. To achieve the benefits of combined processing, laser technology has been integrated into mainstream CNC machines - effectively repurposing them as hybrid manufacturing platforms. This paper reviews how this engineering challenge has prompted beam delivery innovations to allow automated changeover between laser processing and machining, using standard CNC tool changers. Handling laser-processing heads using the tool changer also enables automated change over between different types of laser processing heads, further expanding the breadth of laser processing flexibility in a hybrid CNC. This paper highlights the development, challenges and future impact of hybrid CNCs on laser processing.

Collaborative Manufacturing for Small-Medium Enterprises

NASA Astrophysics Data System (ADS)

Irianto, D.

2016-02-01

Manufacturing systems involve decisions concerning production processes, capacity, planning, and control. In a MTO manufacturing systems, strategic decisions concerning fulfilment of customer requirement, manufacturing cost, and due date of delivery are the most important. In order to accelerate the decision making process, research on decision making structure when receiving order and sequencing activities under limited capacity is required. An effective decision making process is typically required by small-medium components and tools maker as supporting industries to large industries. On one side, metal small-medium enterprises are expected to produce parts, components or tools (i.e. jigs, fixture, mold, and dies) with high precision, low cost, and exact delivery time. On the other side, a metal small- medium enterprise may have weak bargaining position due to aspects such as low production capacity, limited budget for material procurement, and limited high precision machine and equipment. Instead of receiving order exclusively, a small-medium enterprise can collaborate with other small-medium enterprise in order to fulfill requirements high quality, low manufacturing cost, and just in time delivery. Small-medium enterprises can share their best capabilities to form effective supporting industries. Independent body such as community service at university can take a role as a collaboration manager. The Laboratory of Production Systems at Bandung Institute of Technology has implemented shared manufacturing systems for small-medium enterprise collaboration.

Save money by understanding variance and tolerancing.

PubMed

Stuart, K

2007-01-01

Manufacturing processes are inherently variable, which results in component and assembly variance. Unless process capability, variance and tolerancing are fully understood, incorrect design tolerances may be applied, which will lead to more expensive tooling, inflated production costs, high reject rates, product recalls and excessive warranty costs. A methodology is described for correctly allocating tolerances and performing appropriate analyses.

Furnace and support equipment for space processing. [space manufacturing - Czochralski method

NASA Technical Reports Server (NTRS)

Mazelsky, R.; Duncan, C. S.; Seidensticker, R. G.; Johnson, R. A.; Hopkins, R. H.; Roland, G. W.

1975-01-01

A core facility capable of performing a majority of materials processing experiments is discussed. Experiment classes are described, the needs peculiar to each experiment type are outlined, and projected facility requirements to perform the experiments are treated. Control equipment (automatic control) and variations of the Czochralski method for use in space are discussed.

High Throughput Manufacturing of Thin-Film CdTe Photovoltaic Materials; Final Subcontract Report, 16 November 1993-31 December 1998

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

Sandwisch, D. W.

1999-09-02

This report describes work performed by Solar Cells, Inc. (SCI), during this Photovoltaic Manufacturing Technology (PVMaT) subcontract. Cadmium telluride (CdTe) is recognized as one of the leading materials for low-cost photovoltaic modules. SCI has developed this technology and is preparing to scale its pilot production capabilities to a multi-megawatt level. This four-phase PVMaT subcontract supports these efforts. The work was related to product definition, process definition, equipment engineering, and support programs development. In the area of product definition and demonstration, two products were specified and demonstrated-a grid-connected, frameless, high-voltage product that incorporates a pigtail potting design and a remote low-voltagemore » product that may be framed and may incorporate a junction box. SCI produced a 60.3-W thin-film CdTe module with total-area efficiency of 8.4%; SCI also improved module pass rate on the interim qualification test protocol from less than 20% to 100% as a result of work related to the subcontract. In the manufacturing process definition area, the multi-megawatt manufacturing process was defined, several of the key processes were demonstrated, and the process was refined and proven on a 100-kW pilot line that now operates as a 250-kW line. In the area of multi-megawatt manufacturing-line conceptual design review, SCI completed a conceptual layout of the multi-megawatt lines. The layout models the manufacturing line and predicts manufacturing costs. SCI projected an optimized capacity, two-shift/day operation of greater than 25 MW at a manufacturing cost of below $1.00/W.« less

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.

Facility for orbital material processing

NASA Astrophysics Data System (ADS)

Starodubov, D.; McCormick, K.; Dellosa, M.; Erdelyi, E.; Volfson, L.

2018-05-01

The sustainable orbital manufacturing with commercially viable and profitable operation has tremendous potential for driving the space exploration industry and human expansion into outer space. This highly challenging task has never been accomplished before. The current relatively high delivery cost of materials represents the business challenge of value proposition for making products in space. FOMS Inc. team identified an opportunity of fluoride optical fiber manufacturing in space that can lead to the first commercial production on orbit. To address continued cost effective International Space Station (ISS) operations FOMS Inc. has developed and demonstrated for the first time a fully operational space facility for orbital remote manufacturing with up to 50 km fiber fabrication capability and strong commercial potential for manufacturing operations on board the ISS.

Outgassing of Out-of-Autoclave Composite Primary Structures for Small Satellites

NASA Astrophysics Data System (ADS)

Komus, Alastair

Out-of-autoclave vacuum-bagged-only (VBO) processing is capable of producing lower cost composite primary structures for small satellites than autoclave processing. However, the outgassing performance of VBO structures in a vacuum environment has not been examined. Panels were manufactured from CYCOM 5320-1 and TC275-1 carbon fiber/epoxy prepreg using VBO processing. The humidity level, pre-cure dwell time, and cure cycle parameters were varied during manufacturing. The degree of cure and glass transition temperature were shown to increase with increasing oven temperature. Processing humidity levels and the length of pre-cure dwell times had no discernable effect on the total mass loss (TML) and collected volatile condensable material (CVCM) that were outgassed under vacuum. Instead the TML was controlled by moisture saturation after manufacturing. Fourier transform infrared spectroscopy showed that epoxy oligomers were the primary CVCM. The study showed the VBO laminates had outgassing values that were comparable to the autoclave-cured laminates.

Space Spurred Computer Graphics

NASA Technical Reports Server (NTRS)

1983-01-01

Dicomed Corporation was asked by NASA in the early 1970s to develop processing capabilities for recording images sent from Mars by Viking spacecraft. The company produced a film recorder which increased the intensity levels and the capability for color recording. This development led to a strong technology base resulting in sophisticated computer graphics equipment. Dicomed systems are used to record CAD (computer aided design) and CAM (computer aided manufacturing) equipment, to update maps and produce computer generated animation.

[Quality by design approaches for pharmaceutical development and manufacturing of Chinese medicine].

PubMed

Xu, Bing; Shi, Xin-Yuan; Wu, Zhi-Sheng; Zhang, Yan-Ling; Wang, Yun; Qiao, Yan-Jiang

2017-03-01

The pharmaceutical quality was built by design, formed in the manufacturing process and improved during the product's lifecycle. Based on the comprehensive literature review of pharmaceutical quality by design (QbD), the essential ideas and implementation strategies of pharmaceutical QbD were interpreted. Considering the complex nature of Chinese medicine, the "4H" model was innovated and proposed for implementing QbD in pharmaceutical development and industrial manufacture of Chinese medicine product. "4H" corresponds to the acronym of holistic design, holistic information analysis, holistic quality control, and holistic process optimization, which is consistent with the holistic concept of Chinese medicine theory. The holistic design aims at constructing both the quality problem space from the patient requirement and the quality solution space from multidisciplinary knowledge. Holistic information analysis emphasizes understanding the quality pattern of Chinese medicine by integrating and mining multisource data and information at a relatively high level. The batch-to-batch quality consistence and manufacturing system reliability can be realized by comprehensive application of inspective quality control, statistical quality control, predictive quality control and intelligent quality control strategies. Holistic process optimization is to improve the product quality and process capability during the product lifecycle management. The implementation of QbD is useful to eliminate the ecosystem contradictions lying in the pharmaceutical development and manufacturing process of Chinese medicine product, and helps guarantee the cost effectiveness. Copyright© by the Chinese Pharmaceutical Association.

Process science development at the Center for Optics Manufacturing

NASA Astrophysics Data System (ADS)

Pollicove, Harvey M.; Moore, Duncan T.; Golini, Donald

1992-01-01

The Center for Optics Manufacturing (COM) has organized a volunteer Process Science Committee that will cooperate in advancing the optical manufacturing sciences. The objective is to develop technical information and processes that improve manufacturing capability, especially in grinding and polishing technology. Chaired by Donald Golini of Litton Itek Optical Systems, the committee members are volunteers from several American Precision Optics Manufacturers Association (APOMA) companies and institutions. Many of the companies are also funding project elements. The committee will accelerate industry progress by integrating the research and development activities of cooperating APOMA companies and institutions involved in both COM and independent programs. In the short term, the effort concentrates on grinding and polishing process innovation. In later phases, the effort will aid in the design future generations of machines and processes. While the developments are directly adaptable to COM's OPTICAM program, the results will influence a wide range of innovation and application in all methods of optical fabrication. Several leaders in the field are participating in the research and development effort--Boston University, Eastman Kodak Company, Hughes Leitz Optical Technologies, Lawrence Livermore National Laboratory, Litton Itek Optical Systems, Melles Griot, Optical Components Inc., Precision Optical, Rank Pneumo, Schott Glass Technologies, Solution Technology, Texas Instruments, Tropel, and the universities of Arizona and Rochester. Other APOMA member companies will participate as resource needs grow. The collaboration is unique in the industry's history.

Status of Fuel Development and Manufacturing for Space Nuclear Reactors at BWX Technologies

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

Carmack, W.J.; Husser, D.L.; Mohr, T.C.

2004-02-04

New advanced nuclear space propulsion systems will soon seek a high temperature, stable fuel form. BWX Technologies Inc (BWXT) has a long history of fuel manufacturing. UO2, UCO, and UCx have been fabricated at BWXT for various US and international programs. Recent efforts at BWXT have focused on establishing the manufacturing techniques and analysis capabilities needed to provide a high quality, high power, compact nuclear reactor for use in space nuclear powered missions. To support the production of a space nuclear reactor, uranium nitride has recently been manufactured by BWXT. In addition, analytical chemistry and analysis techniques have been developedmore » to provide verification and qualification of the uranium nitride production process. The fabrication of a space nuclear reactor will require the ability to place an unclad fuel form into a clad structure for assembly into a reactor core configuration. To this end, BWX Technologies has reestablished its capability for machining, GTA welding, and EB welding of refractory metals. Specifically, BWX Technologies has demonstrated GTA welding of niobium flat plate and EB welding of niobium and Nb-1Zr tubing. In performing these demonstration activities, BWX Technologies has established the necessary infrastructure to manufacture UO2, UCx, or UNx fuel, components, and complete reactor assemblies in support of space nuclear programs.« less

Optical surface analysis: a new technique for the inspection and metrology of optoelectronic films and wafers

NASA Astrophysics Data System (ADS)

Bechtler, Laurie; Velidandla, Vamsi

2003-04-01

In response to demand for higher volumes and greater product capability, integrated optoelectronic device processing is rapidly increasing in complexity, benefiting from techniques developed for conventional silicon integrated circuit processing. The needs for high product yield and low manufacturing cost are also similar to the silicon wafer processing industry. This paper discusses the design and use of an automated inspection instrument called the Optical Surface Analyzer (OSA) to evaluate two critical production issues in optoelectronic device manufacturing: (1) film thickness uniformity, and (2) defectivity at various process steps. The OSA measurement instrument is better suited to photonics process development than most equipment developed for conventional silicon wafer processing in two important ways: it can handle both transparent and opaque substrates (unlike most inspection and metrology tools), and it is a full-wafer inspection method that captures defects and film variations over the entire substrate surface (unlike most film thickness measurement tools). Measurement examples will be provided in the paper for a variety of films and substrates used for optoelectronics manufacturing.

Lightweight Metal Matrix Composite Segmented for Manufacturing High-Precision Mirrors

NASA Technical Reports Server (NTRS)

Vudler, Vladimir

2012-01-01

High-precision mirrors for space applications are traditionally manufactured from one piece of material, such as lightweight glass sandwich or beryllium. The purpose of this project was to develop and test the feasibility of a manufacturing process capable of producing mirrors out of welded segments of AlBeMet(Registered Trademark) (AM162H). AlBeMet(Registered Trademark) is a HIP'd (hot isostatic pressed) material containing approximately 62% beryllium and 38% aluminum. As a result, AlBeMet shares many of the benefits of both of those materials for use in high performance mirrors, while minimizing many of their weaknesses.

Application of surface-enhanced Raman spectroscopy (SERS) for cleaning verification in pharmaceutical manufacture.

PubMed

Corrigan, Damion K; Cauchi, Michael; Piletsky, Sergey; Mccrossen, Sean

2009-01-01

Cleaning verification is the process by which pharmaceutical manufacturing equipment is determined as sufficiently clean to allow manufacture to continue. Surface-enhanced Raman spectroscopy (SERS) is a very sensitive spectroscopic technique capable of detection at levels appropriate for cleaning verification. In this paper, commercially available Klarite SERS substrates were employed in order to obtain the necessary enhancement of signal for the identification of chemical species at concentrations of 1 to 10 ng/cm2, which are relevant to cleaning verification. The SERS approach was combined with principal component analysis in the identification of drug compounds recovered from a contaminated steel surface.

3D printed fluidics with embedded analytic functionality for automated reaction optimisation

PubMed Central

Capel, Andrew J; Wright, Andrew; Harding, Matthew J; Weaver, George W; Li, Yuqi; Harris, Russell A; Edmondson, Steve; Goodridge, Ruth D

2017-01-01

Additive manufacturing or ‘3D printing’ is being developed as a novel manufacturing process for the production of bespoke micro- and milliscale fluidic devices. When coupled with online monitoring and optimisation software, this offers an advanced, customised method for performing automated chemical synthesis. This paper reports the use of two additive manufacturing processes, stereolithography and selective laser melting, to create multifunctional fluidic devices with embedded reaction monitoring capability. The selectively laser melted parts are the first published examples of multifunctional 3D printed metal fluidic devices. These devices allow high temperature and pressure chemistry to be performed in solvent systems destructive to the majority of devices manufactured via stereolithography, polymer jetting and fused deposition modelling processes previously utilised for this application. These devices were integrated with commercially available flow chemistry, chromatographic and spectroscopic analysis equipment, allowing automated online and inline optimisation of the reaction medium. This set-up allowed the optimisation of two reactions, a ketone functional group interconversion and a fused polycyclic heterocycle formation, via spectroscopic and chromatographic analysis. PMID:28228852

Using a simulation assistant in modeling manufacturing systems

NASA Technical Reports Server (NTRS)

Schroer, Bernard J.; Tseng, Fan T.; Zhang, S. X.; Wolfsberger, John W.

1988-01-01

Numerous simulation languages exist for modeling discrete event processes, and are now ported to microcomputers. Graphic and animation capabilities were added to many of these languages to assist the users build models and evaluate the simulation results. With all these languages and added features, the user is still plagued with learning the simulation language. Futhermore, the time to construct and then to validate the simulation model is always greater than originally anticipated. One approach to minimize the time requirement is to use pre-defined macros that describe various common processes or operations in a system. The development of a simulation assistant for modeling discrete event manufacturing processes is presented. A simulation assistant is defined as an interactive intelligent software tool that assists the modeler in writing a simulation program by translating the modeler's symbolic description of the problem and then automatically generating the corresponding simulation code. The simulation assistant is discussed with emphasis on an overview of the simulation assistant, the elements of the assistant, and the five manufacturing simulation generators. A typical manufacturing system will be modeled using the simulation assistant and the advantages and disadvantages discussed.

Study for identification of Beneficial Uses of Space (BUS), phase 2. Volume 2: Technical report. Book 2: Section 5, appendices A through D

NASA Technical Reports Server (NTRS)

1973-01-01

An investigation of the technology and programmatics involved in the development of four of the products selected as capable of benefitting from space manufacturing was conducted. The four activities selected are as follows: (1) levitation heating and melting of tungsten, (2) free suspension processing of oxides to form amorphous oxide materials, (3) crystals for surface wave acoustic substrates, and (4) space manufacturing of surface acoustic wave devices.

Ensuring Biologics Advanced Development and Manufacturing Capability for the United States Government: A Summary of Key Findings and Conclusions

DTIC Science & Technology

2009-10-06

Government: A Summary of Key Findings and Conclusions. This report has passed the Department of Defense’s security review process and is approved for...manufacturing and combine advance development and production of biologics in a multi-product facility focused on satisfying USG needs. Finally, the study...MCM needs of both DoD and HHS, an extensive survey was conducted. This included a review of all published requirements, the biodefense R&D portfolio

A preliminary investigation of the Environmental Control and Life Support Subsystem (EC/LSS) for the space construction base manufacturing modules

NASA Technical Reports Server (NTRS)

Wells, H. B.

1977-01-01

The preliminary data of the environmental control and life support subsystem for a space construction base manufacturing module was reported. A space processing module, which is capable of performing production biological experiments, was chosen as a baseline configuration. The primary assemblies and components considered for use were humidity and temperature control, ventilation fan, cabin fan, water separator, condensate storage, overboard dumping, distribution system, contaminant monitoring, cabin sensors, and fire and smoke detection.

Development of an advanced uncooled 10-Gb DFB laser for volume manufacture

NASA Astrophysics Data System (ADS)

Burns, Gordon; Charles, Paul M.

2003-03-01

Optical communication systems operating at 10Gbit/s such as 10Gigabit Ethernet are becoming more and more important in Local Area Networks (LAN) and Metropolitan Area Networks (MAN). This market requires optical transceivers of low cost, size and power consumption. This drives a need for uncooled DFB lasers directly modulated at 10Gbit/s. This paper describes the development of a state of the art uncooled high speed DFB laser which is capable of being manufactured in high volume at the low cost demanded by the GbE market. A DFB laser was designed by developing technological building blocks within the 'conventional" InGaAsP materials system, using existing well proven manufacturing processes modules wherever possible, limiting the design risk to a few key areas where innovation was required. The temperature and speed performance of the InGaAsP SMQW active layer system was carefully optimized and then coupled with a low parasitic lateral confinement system. Using concurrent engineering, new processes were demonstrated to have acceptable process capability within a manufacturing fabrication environment, proving their ability to support high volume manufacturing requirements. The DFB laser fabricated was shown to operate at 100C chip temperature with an open eye at 10Gbit/s operation (with an extinction ratio >5dB). Up to 90C operation this DFB shows threshold current as low as 29mA, optical power as high as 13mW and it meets the 10Gb scaled Ethernet mask with extinction ratio >6dB. It was found that the high temperature dynamic behavior of these lasers could not be fully predicted from static test data. A production test strategy was therefore followed where equipment was designed to fully test devices/subassemblies at 100C and up to 20Gbit/s at key points in the product build. This facilitated the rapid optimisation of product yields upon manufacturing ramp up and minimization of product costs. This state of the art laser is now transferred into volume manufacture.

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.

A Framework for Preliminary Design of Aircraft Structures Based on Process Information. Part 1

NASA Technical Reports Server (NTRS)

Rais-Rohani, Masoud

1998-01-01

This report discusses the general framework and development of a computational tool for preliminary design of aircraft structures based on process information. The described methodology is suitable for multidisciplinary design optimization (MDO) activities associated with integrated product and process development (IPPD). The framework consists of three parts: (1) product and process definitions; (2) engineering synthesis, and (3) optimization. The product and process definitions are part of input information provided by the design team. The backbone of the system is its ability to analyze a given structural design for performance as well as manufacturability and cost assessment. The system uses a database on material systems and manufacturing processes. Based on the identified set of design variables and an objective function, the system is capable of performing optimization subject to manufacturability, cost, and performance constraints. The accuracy of the manufacturability measures and cost models discussed here depend largely on the available data on specific methods of manufacture and assembly and associated labor requirements. As such, our focus in this research has been on the methodology itself and not so much on its accurate implementation in an industrial setting. A three-tier approach is presented for an IPPD-MDO based design of aircraft structures. The variable-complexity cost estimation methodology and an approach for integrating manufacturing cost assessment into design process are also discussed. This report is presented in two parts. In the first part, the design methodology is presented, and the computational design tool is described. In the second part, a prototype model of the preliminary design Tool for Aircraft Structures based on Process Information (TASPI) is described. Part two also contains an example problem that applies the methodology described here for evaluation of six different design concepts for a wing spar.

Process Capability of High Speed Micro End-Milling of Inconel 718 with Minimum Quantity Lubrication

NASA Astrophysics Data System (ADS)

Rahman, Mohamed Abd; Yeakub Ali, Mohammad; Rahman Shah Rosli, Abdul; Banu, Asfana

2017-03-01

The demand for micro-parts is expected to grow and micro-machining has been shown to be a viable manufacturing process to produce these products. These micro-products may be produced from hard-to-machine materials such as superalloys under little or no metal cutting fluids to reduce machining cost or drawbacks associated with health and environment. This project aims to investigate the capability of micro end-milling process of Inconel 718 with minimum quantity lubrication (MQL). Microtools DT-110 multi-process micro machine was used to machine 10 micro-channels with MQL and 10 more under dry condition while maintaining the same machining parameters. The width of the micro-channels was measured using digital microscope and used to determine the process capability indices, Cp and Cpk. QI Macros SPC for Excel was used to analyze the resultant machining data. The results indicated that micro end-milling process of Inconel 718 was not capable under both MQL and dry cutting conditions as indicated by the Cp values of less than 1.0. However, the use of MQL helped the process to be more stable and capable. Results obtained showed that the process variation was greatly reduced by using MQL in micro end-milling of Inconel 718.

Microgravity Manufacturing Via Fused Deposition

NASA Technical Reports Server (NTRS)

Cooper, K. G.; Griffin, M. R.

2003-01-01

Manufacturing polymer hardware during space flight is currently outside the state of the art. A process called fused deposition modeling (FDM) can make this approach a reality by producing net-shaped components of polymer materials directly from a CAE model. FDM is a rapid prototyping process developed by Stratasys, Inc.. which deposits a fine line of semi-molten polymer onto a substrate while moving via computer control to form the cross-sectional shape of the part it is building. The build platen is then lowered and the process is repeated, building a component directly layer by layer. This method enables direct net-shaped production of polymer components directly from a computer file. The layered manufacturing process allows for the manufacture of complex shapes and internal cavities otherwise impossible to machine. This task demonstrated the benefits of the FDM technique to quickly and inexpensively produce replacement components or repair broken hardware in a Space Shuttle or Space Station environment. The intent of the task was to develop and fabricate an FDM system that was lightweight, compact, and required minimum power consumption to fabricate ABS plastic hardware in microgravity. The final product of the shortened task turned out to be a ground-based breadboard device, demonstrating miniaturization capability of the system.

Space Shuttle Orbiter oxygen partial pressure sensing and control system improvements

NASA Technical Reports Server (NTRS)

Frampton, Robert F.; Hoy, Dennis M.; Kelly, Kevin J.; Walleshauser, James J.

1992-01-01

A program aimed at developing a new PPO2 oxygen sensor and a replacement amplifier for the Space Shuttle Orbiter is described. Experimental design methodologies used in the test and modeling process made it possible to enhance the effectiveness of the program and to reduce its cost. Significant cost savings are due to the increased lifetime of the basic sensor cell, the maximization of useful sensor life through an increased amplifier gain adjustment capability, the use of streamlined production processes for the manufacture of the assemblies, and the refurbishment capability of the replacement sensor.

Composites Materials and Manufacturing Technologies for Space Applications

NASA Technical Reports Server (NTRS)

Vickers, J. H.; Tate, L. C.; Gaddis, S. W.; Neal, R. E.

2016-01-01

Composite materials offer significant advantages in space applications. Weight reduction is imperative for deep space systems. However, the pathway to deployment of composites alternatives is problematic. Improvements in the materials and processes are needed, and extensive testing is required to validate the performance, qualify the materials and processes, and certify components. Addressing these challenges could lead to the confident adoption of composites in space applications and provide spin-off technical capabilities for the aerospace and other industries. To address the issues associated with composites applications in space systems, NASA sponsored a Technical Interchange Meeting (TIM) entitled, "Composites Materials and Manufacturing Technologies for Space Applications," the proceedings of which are summarized in this Conference Publication. The NASA Space Technology Mission Directorate and the Game Changing Program chartered the meeting. The meeting was hosted by the National Center for Advanced Manufacturing (NCAM)-a public/private partnership between NASA, the State of Louisiana, Louisiana State University, industry, and academia, in association with the American Composites Manufacturers Association. The Louisiana Center for Manufacturing Sciences served as the coordinator for the TIM.

Toward Higher QA: From Parametric Release of Sterile Parenteral Products to PAT for Other Pharmaceutical Dosage Forms.

PubMed

Hock, Sia Chong; Constance, Neo Xue Rui; Wah, Chan Lai

2012-01-01

Pharmaceutical products are generally subjected to end-product batch testing as a means of quality control. Due to the inherent limitations of conventional batch testing, this is not the most ideal approach for determining the pharmaceutical quality of the finished dosage form. In the case of terminally sterilized parenteral products, the limitations of conventional batch testing have been successfully addressed with the application of parametric release (the release of a product based on control of process parameters instead of batch sterility testing at the end of the manufacturing process). Consequently, there has been an increasing interest in applying parametric release to other pharmaceutical dosage forms, beyond terminally sterilized parenteral products. For parametric release to be possible, manufacturers must be capable of designing quality into the product, monitoring the manufacturing processes, and controlling the quality of intermediates and finished products in real-time. Process analytical technology (PAT) has been thought to be capable of contributing to these prerequisites. It is believed that the appropriate use of PAT tools can eventually lead to the possibility of real-time release of other pharmaceutical dosage forms, by-passing the need for end-product batch testing. Hence, this literature review attempts to present the basic principles of PAT, introduce the various PAT tools that are currently available, present their recent applications to pharmaceutical processing, and explain the potential benefits that PAT can bring to conventional ways of processing and quality assurance of pharmaceutical products. Last but not least, current regulations governing the use of PAT and the manufacturing challenges associated with PAT implementation are also discussed. Pharmaceutical products are generally subjected to end-product batch testing as a means of quality control. Due to the inherent limitations of conventional batch testing, this is not the most ideal approach. In the case of terminally sterilized parenteral products, these limitations have been successfully addressed with the application of parametric release (the release of a product based on control of process parameters instead of batch sterility testing at the end of the manufacturing process). Consequently, there has been an increasing interest in applying parametric release to other pharmaceutical dosage forms. With the advancement of process analytical technology (PAT), it is possible to monitor the manufacturing processes closely. This will eventually enable quality control of the intermediates and finished products, and thus their release in real-time. Hence, this literature review attempts to present the basic principles of PAT, introduce the various PAT tools that are currently available, present their recent applications to pharmaceutical processing, and explain the potential benefits that PAT can bring to conventional ways of processing and quality assurance of pharmaceutical products. It will also discuss the current regulations governing the use of PAT and the manufacturing challenges associated with the implementation of PAT.

Low Cost Process for Manufacture of Oxide Dispersion Strengthened (ODS) Turbine Nozzle Components.

DTIC Science & Technology

1979-12-01

SWTTPROCESS FORJIANUFACTURE OF9OXIDE)ISPERSIONSTRENGTHENED (ODS) O0 TURBINE !IJOZZLE COMPONENTS, -- , General Electric Company Aircraft Engine Group...machining processes for low pressure turbine (LPT) vanes , high pressure turbine (HPT) vanes , and HPT band segments for the F101 engine . The primary intent...for aircraft turbine nozzle components. These processes were shown capable of maintaining required microstructures and properties for the vane and

All-Printed Flexible and Stretchable Electronics.

PubMed

Mohammed, Mohammed G; Kramer, Rebecca

2017-05-01

A fully automated additive manufacturing process that produces all-printed flexible and stretchable electronics is demonstrated. The printing process combines soft silicone elastomer printing and liquid metal processing on a single high-precision 3D stage. The platform is capable of fabricating extremely complex conductive circuits, strain and pressure sensors, stretchable wires, and wearable circuits with high yield and repeatability. © 2017 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim.

ODIN-object-oriented development interface for NMR.

PubMed

Jochimsen, Thies H; von Mengershausen, Michael

2004-09-01

A cross-platform development environment for nuclear magnetic resonance (NMR) experiments is presented. It allows rapid prototyping of new pulse sequences and provides a common programming interface for different system types. With this object-oriented interface implemented in C++, the programmer is capable of writing applications to control an experiment that can be executed on different measurement devices, even from different manufacturers, without the need to modify the source code. Due to the clear design of the software, new pulse sequences can be created, tested, and executed within a short time. To post-process the acquired data, an interface to well-known numerical libraries is part of the framework. This allows a transparent integration of the data processing instructions into the measurement module. The software focuses mainly on NMR imaging, but can also be used with limitations for spectroscopic experiments. To demonstrate the capabilities of the framework, results of the same experiment, carried out on two NMR imaging systems from different manufacturers are shown and compared with the results of a simulation.

Advances in deep-UV processing using cluster tools

NASA Astrophysics Data System (ADS)

Escher, Gary C.; Tepolt, Gary; Mohondro, Robert D.

1993-09-01

Deep-UV laser lithography has shown the capability of supporting the manufacture of multiple generations of integrated circuits (ICs) due to its wide process latitude and depth of focus (DOF) for 0.2 micrometers to 0.5 micrometers feature sizes. This capability has been attained through improvements in deep-UV wide field lens technology, excimer lasers, steppers and chemically amplified, positive deep-UV resists. Chemically amplified deep-UV resists are required for 248 nm lithography due to the poor absorption and sensitivity of conventional novolac resists. The acid catalyzation processes of the new resists requires control of the thermal history and environmental conditions of the lithographic process. Work is currently underway at several resist vendors to reduce the need for these controls, but practical manufacturing solutions exist today. One of these solutions is the integration of steppers and resist tracks into a `cluster tool' or `Lithocell' to insure a consistent thermal profile for the resist process and reduce the time the resist is exposed to atmospheric contamination. The work here reports processing and system integration results with a Machine Technology, Inc (MTI) post-exposure bake (PEB) track interfaced with an advanced GCA XLS 7800 deep-UV stepper [31 mm diameter, variable NA (0.35 - 0.53) and variable sigma (0.3 - 0.74)].

Assessment of Intelligent Processing Equipment in the National Aeronautics and Space Administration, 1991

NASA Technical Reports Server (NTRS)

Jones, C. S.

1992-01-01

Summarized here is an assessment of intelligent processing equipment (IPE) within NASA. An attempt is made to determine the state of IPE development and research in specific areas where NASA might contribute to the national capability. Mechanisms to transfer NASA technology to the U.S. private sector in this critical area are discussed. It was concluded that intelligent processing equipment is finding extensive use in the manufacture of space hardware, especially in the propulsion components of the shuttle. The major benefits are found in improved process consistency, which lowers cost as it reduces rework. Advanced feedback controls are under development and being implemented gradually into shuttle manufacturing. Implementation is much more extensive in new programs, such as in the advanced solid rocket motor and the Space Station Freedom.

Virtual aluminum castings: An industrial application of ICME

NASA Astrophysics Data System (ADS)

Allison, John; Li, Mei; Wolverton, C.; Su, Xuming

2006-11-01

The automotive product design and manufacturing community is continually besieged by Hercule an engineering, timing, and cost challenges. Nowhere is this more evident than in the development of designs and manufacturing processes for cast aluminum engine blocks and cylinder heads. Increasing engine performance requirements coupled with stringent weight and packaging constraints are pushing aluminum alloys to the limits of their capabilities. To provide high-quality blocks and heads at the lowest possible cost, manufacturing process engineers are required to find increasingly innovative ways to cast and heat treat components. Additionally, to remain competitive, products and manufacturing methods must be developed and implemented in record time. To bridge the gaps between program needs and engineering reality, the use of robust computational models in up-front analysis will take on an increasingly important role. This article describes just such a computational approach, the Virtual Aluminum Castings methodology, which was developed and implemented at Ford Motor Company and demonstrates the feasibility and benefits of integrated computational materials engineering.

New high-precision deep concave optical surface manufacturing capability

NASA Astrophysics Data System (ADS)

Piché, François; Maloney, Chris; VanKerkhove, Steve; Supranowicz, Chris; Dumas, Paul; Donohue, Keith

2017-10-01

This paper describes the manufacturing steps necessary to manufacture hemispherical concave aspheric mirrors for high- NA systems. The process chain is considered from generation to final figuring and includes metrology testing during the various manufacturing steps. Corning Incorporated has developed this process by taking advantage of recent advances in commercially available Satisloh and QED Technologies equipment. Results are presented on a 100 mm concave radius nearly hemispherical (NA = 0.94) fused silica sphere with a better than 5 nm RMS figure. Part interferometric metrology was obtained on a QED stitching interferometer. Final figure was made possible by the implementation of a high-NA rotational MRF mode recently developed by QED Technologies which is used at Corning Incorporated for production. We also present results from a 75 mm concave radius (NA = 0.88) Corning ULE sphere that was produced using sub-aperture tools from generation to final figuring. This part demonstrates the production chain from blank to finished optics for high-NA concave asphere.

Biocompatibility of Advanced Manufactured Titanium Implants-A Review.

PubMed

Sidambe, Alfred T

2014-12-19

Titanium (Ti) and its alloys may be processed via advanced powder manufacturing routes such as additive layer manufacturing (or 3D printing) or metal injection moulding. This field is receiving increased attention from various manufacturing sectors including the medical devices sector. It is possible that advanced manufacturing techniques could replace the machining or casting of metal alloys in the manufacture of devices because of associated advantages that include design flexibility, reduced processing costs, reduced waste, and the opportunity to more easily manufacture complex or custom-shaped implants. The emerging advanced manufacturing approaches of metal injection moulding and additive layer manufacturing are receiving particular attention from the implant fabrication industry because they could overcome some of the difficulties associated with traditional implant fabrication techniques such as titanium casting. Using advanced manufacturing, it is also possible to produce more complex porous structures with improved mechanical performance, potentially matching the modulus of elasticity of local bone. While the economic and engineering potential of advanced manufacturing for the manufacture of musculo-skeletal implants is therefore clear, the impact on the biocompatibility of the materials has been less investigated. In this review, the capabilities of advanced powder manufacturing routes in producing components that are suitable for biomedical implant applications are assessed with emphasis placed on surface finishes and porous structures. Given that biocompatibility and host bone response are critical determinants of clinical performance, published studies of in vitro and in vivo research have been considered carefully. The review concludes with a future outlook on advanced Ti production for biomedical implants using powder metallurgy.

Biocompatibility of Advanced Manufactured Titanium Implants—A Review

PubMed Central

Sidambe, Alfred T.

2014-01-01

Titanium (Ti) and its alloys may be processed via advanced powder manufacturing routes such as additive layer manufacturing (or 3D printing) or metal injection moulding. This field is receiving increased attention from various manufacturing sectors including the medical devices sector. It is possible that advanced manufacturing techniques could replace the machining or casting of metal alloys in the manufacture of devices because of associated advantages that include design flexibility, reduced processing costs, reduced waste, and the opportunity to more easily manufacture complex or custom-shaped implants. The emerging advanced manufacturing approaches of metal injection moulding and additive layer manufacturing are receiving particular attention from the implant fabrication industry because they could overcome some of the difficulties associated with traditional implant fabrication techniques such as titanium casting. Using advanced manufacturing, it is also possible to produce more complex porous structures with improved mechanical performance, potentially matching the modulus of elasticity of local bone. While the economic and engineering potential of advanced manufacturing for the manufacture of musculo-skeletal implants is therefore clear, the impact on the biocompatibility of the materials has been less investigated. In this review, the capabilities of advanced powder manufacturing routes in producing components that are suitable for biomedical implant applications are assessed with emphasis placed on surface finishes and porous structures. Given that biocompatibility and host bone response are critical determinants of clinical performance, published studies of in vitro and in vivo research have been considered carefully. The review concludes with a future outlook on advanced Ti production for biomedical implants using powder metallurgy. PMID:28788296

Six-sigma application in tire-manufacturing company: a case study

NASA Astrophysics Data System (ADS)

Gupta, Vikash; Jain, Rahul; Meena, M. L.; Dangayach, G. S.

2017-09-01

Globalization, advancement of technologies, and increment in the demand of the customer change the way of doing business in the companies. To overcome these barriers, the six-sigma define-measure-analyze-improve-control (DMAIC) method is most popular and useful. This method helps to trim down the wastes and generating the potential ways of improvement in the process as well as service industries. In the current research, the DMAIC method was used for decreasing the process variations of bead splice causing wastage of material. This six-sigma DMAIC research was initiated by problem identification through voice of customer in the define step. The subsequent step constitutes of gathering the specification data of existing tire bead. This step was followed by the analysis and improvement steps, where the six-sigma quality tools such as cause-effect diagram, statistical process control, and substantial analysis of existing system were implemented for root cause identification and reduction in process variation. The process control charts were used for systematic observation and control the process. Utilizing DMAIC methodology, the standard deviation was decreased from 2.17 to 1.69. The process capability index (C p) value was enhanced from 1.65 to 2.95 and the process performance capability index (C pk) value was enhanced from 0.94 to 2.66. A DMAIC methodology was established that can play a key role for reducing defects in the tire-manufacturing process in India.

Recent developments in turbomachinery component materials and manufacturing challenges for aero engine applications

NASA Astrophysics Data System (ADS)

Srinivas, G.; Raghunandana, K.; Satish Shenoy, B.

2018-02-01

In the recent years the development of turbomachinery materials performance enhancement plays a vital role especially in aircraft air breathing engines like turbojet engine, turboprop engine, turboshaft engine and turbofan engines. Especially the transonic flow engines required highly sophisticated materials where it can sustain the entire thrust which can create by the engine. The main objective of this paper is to give an overview of the present cost-effective and technological capabilities process for turbomachinery component materials. Especially the main focus is given to study the Electro physical, Photonic additive removal process and Electro chemical process for turbomachinery parts manufacture. The aeronautical propulsion based technologies are reviewed thoroughly where in surface reliability, geometrical precession, and material removal and highly strengthened composite material deposition rates usually difficult to cut dedicated steels, Titanium and Nickel based alloys. In this paper the past aeronautical and propulsion mechanical based manufacturing technologies, current sophisticated technologies and also future challenging material processing techniques are covered. The paper also focuses on the brief description of turbomachinery components of shaping process and coating in aeromechanical applications.

High Power Laser Processing Of Materials

NASA Astrophysics Data System (ADS)

Martyr, D. R.; Holt, T.

1987-09-01

The first practical demonstration of a laser device was in 1960 and in the following years, the high power carbon dioxide laser has matured as an industrial machine tool. Modern carbon dioxide gas lasers can be used for cutting, welding, heat treatment, drilling, scribing and marking. Since their invention over 25 years ago they are now becoming recognised as highly reliable devices capable of achieving huge savings in production costs in many situations. This paper introduces the basic laser processing techniques of cutting, welding and heat treatment as they apply to the most common engineering materials. Typical processing speeds achieved with a wide range of laser powers are reported. Accuracies achievable and fit-up tolerances required are presented. Methods of integrating lasers with machine tools are described and their suitability in a wide range of manufacturing industries is described by reference to recent installations. Examples from small batch manufacturing, high volume production using dedicated laser welding equipment, and high volume manufacturing using 'flexible' automated laser welding equipment are described Future applications of laser processing are suggested by reference to current process developments.

Lightweighting Automotive Materials for Increased Fuel Efficiency and Delivering Advanced Modeling and Simulation Capabilities to U.S. Manufacturers

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

Hale, Steve

Abstract The National Center for Manufacturing Sciences (NCMS) worked with the U.S. Department of Energy (DOE), National Energy Technology Laboratory (NETL), to bring together research and development (R&D) collaborations to develop and accelerate the knowledgebase and infrastructure for lightweighting materials and manufacturing processes for their use in structural and applications in the automotive sector. The purpose/importance of this DOE program: • 2016 CAFÉ standards. • Automotive industry technology that shall adopt the insertion of lightweighting material concepts towards manufacturing of production vehicles. • Development and manufacture of advanced research tools for modeling and simulation (M&S) applications to reduce manufacturing andmore » material costs. • U.S. competitiveness that will help drive the development and manufacture of the next generation of materials. NCMS established a focused portfolio of applied R&D projects utilizing lightweighting materials for manufacture into automotive structures and components. Areas that were targeted in this program: • Functionality of new lightweighting materials to meet present safety requirements. • Manufacturability using new lightweighting materials. • Cost reduction for the development and use of new lightweighting materials. The automotive industry’s future continuously evolves through innovation, and lightweight materials are key in achieving a new era of lighter, more efficient vehicles. Lightweight materials are among the technical advances needed to achieve fuel/energy efficiency and reduce carbon dioxide (CO2) emissions: • Establish design criteria methodology to identify the best materials for lightweighting. • Employ state-of-the-art design tools for optimum material development for their specific applications. • Match new manufacturing technology to production volume. • Address new process variability with new production-ready processes.« less

RTD-based Material Tracking in a Fully-Continuous Dry Granulation Tableting Line.

PubMed

Martinetz, M C; Karttunen, A-P; Sacher, S; Wahl, P; Ketolainen, J; Khinast, J G; Korhonen, O

2018-06-06

Continuous manufacturing (CM) offers quality and cost-effectiveness benefits over currently dominating batch processing. One challenge that needs to be addressed when implementing CM is traceability of materials through the process, which is needed for the batch/lot definition and control strategy. In this work the residence time distributions (RTD) of single unit operations (blender, roller compactor and tablet press) of a continuous dry granulation tableting line were captured with NIR based methods at selected mass flow rates to create training data. RTD models for continuous operated unit operations and the entire line were developed based on transfer functions. For semi-continuously operated bucket conveyor and pneumatic transport an assumption based the operation frequency was used. For validation of the parametrized process model, a pre-defined API step change and its propagation through the manufacturing line was computed and compared to multi-scale experimental runs conducted with the fully assembled continuous operated manufacturing line. This novel approach showed a very good prediction power at the selected mass flow rates for a complete continuous dry granulation line. Furthermore, it shows and proves the capabilities of process simulation as a tool to support development and control of pharmaceutical manufacturing processes. Copyright © 2018. Published by Elsevier B.V.

Selective Laser Sintering of Porous Silica Enabled by Carbon Additive.

PubMed

Chang, Shuai; Li, Liqun; Lu, Li; Fuh, Jerry Ying Hsi

2017-11-16

The aim of this study is to investigate the possibility of a freeform fabrication of porous ceramic parts through selective laser sintering (SLS). SLS was proposed to manufacture ceramic green parts because this additive manufacturing technique can be used to fabricate three-dimensional objects directly without a mold, and the technique has the capability of generating porous ceramics with controlled porosity. However, ceramic printing has not yet fully achieved its 3D fabrication capabilities without using polymer binder. Except for the limitations of high melting point, brittleness, and low thermal shock resistance from ceramic material properties, the key obstacle lies in the very poor absorptivity of oxide ceramics to fiber laser, which is widely installed in commercial SLS equipment. An alternative solution to overcome the poor laser absorptivity via improving material compositions is presented in this study. The positive effect of carbon additive on the absorptivity of silica powder to fiber laser is discussed. To investigate the capabilities of the SLS process, 3D porous silica structures were successfully prepared and characterized.

The evaluation of a new technology for gunshot residue (GSR) analysis in the field

NASA Astrophysics Data System (ADS)

Hondrogiannis, Ellen; Andersen, Danielle; Miziolek, Andrzej W.

2013-05-01

There continues to be a need for improved technology to be used in theater to quickly and accurately identify the person who shot any weapon during a terrorist attack as well as to link a suspect to the actual weapon fired during a crime. Beyond this, in areas of conflict it would be desirable to have the capability to establish the source country for weaponry and ammunition. Gunshot residue (GSR) analysis is a reasonably well-studied technology area. Recent scientific publications have reported that the residues have a rich composition of both organic and inorganic compounds. For the purposes of identifying the manufacturer or country of origin for the ammunition, the inorganic components of GSR appear to be especially promising since their presence in the propellant and primer formulations are either specific to a given chemical formula, or they represent impurities in the manufacturing process that can be unique to a manufacturer or the source country for the chemicals used for propellants and primers. The Laser Induced Breakdown Spectroscopy (LIBS) technology has already demonstrated considerable capability for elemental fingerprinting, especially for inorganic/metallic components. A number of reports have demonstrated LIBS capability in forensics for matching materials such as inks, fabrics, paper, glass, and paint. This work describes the encouraging results of an initial study to assess a new commercial field-portable (battery operated) LIBS system for GSR analysis with gunshot residues having been collected from inside cartridge casings from 3 different ammunition manufacturers.

Environmental Cracking and Irradiation Resistant Stainless Steels by Additive Manufacturing

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

Rebak, Raul B.; Lou, Xiaoyuan

Metal additive manufacturing (AM), or metal 3D printing is an emergent advanced manufacturing method that can create near net shape geometries directly from computer models. This technology can provide the capability to rapidly fabricate complex parts that may be required to enhance the integrity of reactor internals components. Such opportunities may be observed during a plant refueling outage and AM parts can be rapidly custom designed, manufactured and deployed within the outage interval. Additive manufacturing of stainless steel (SS) components can add business benefits on fast delivery on repair hardware, installation tooling, new design prototypes tests, etc. For the nuclearmore » industry, the supply chain is always an issue for reactor service. AM can provide through-life supply chain (40-60 years) for high-value low-volume components. In the meantime, the capability of generating complex geometries and functional gradient materials will improve the performance, reduce the overall component cost, plant asset management cost and increase the plant reliability by the improvement in materials performance in nuclear environments. While extensive work has been conducted regarding additively manufacturing of austenitic SS parts, most efforts focused only on basic attributes such as porosity, residual stress, basic tensile properties, along with components yield and process monitoring. Little work has been done to define and evaluate the material requirements for nuclear applications. Technical gaps exist, which limit this technology adoption in the nuclear industry, which includes high manufacturing cost, unknown risks, limited nuclear related data, lack of specification and qualification methods, and no prior business experience. The main objective of this program was to generate research data to address all these technical gaps and establish a commercial practice to use AM technology in the nuclear power industry. The detailed objectives are listed as follows: (1) Evaluate nuclear related properties of AM 316L SS, including microstructure, tensile properties, impact toughness, stress corrosion cracking (SCC), corrosion fatigue (CF), irradiation effects, and irradiation assisted stress corrosion cracking (IASCC). (2) Understand the correlations among laser processing, heat treatment, microstructure and SCC/irradiation properties; (3) Optimize and improve the manufacturing process to achieve enhanced nuclear application properties; (4) Fabricate, evaluate, qualify and test a prototype reactor component to demonstrate the commercial viability and cost benefit; (5) Create regulatory approval path and commercialization plans for the production of a commercial reactor component.« less

Large Composite Structures Processing Technologies for Reusable Launch Vehicles

NASA Technical Reports Server (NTRS)

Clinton, R. G., Jr.; Vickers, J. H.; McMahon, W. M.; Hulcher, A. B.; Johnston, N. J.; Cano, R. J.; Belvin, H. L.; McIver, K.; Franklin, W.; Sidwell, D.

2001-01-01

Significant efforts have been devoted to establishing the technology foundation to enable the progression to large scale composite structures fabrication. We are not capable today of fabricating many of the composite structures envisioned for the second generation reusable launch vehicle (RLV). Conventional 'aerospace' manufacturing and processing methodologies (fiber placement, autoclave, tooling) will require substantial investment and lead time to scale-up. Out-of-autoclave process techniques will require aggressive efforts to mature the selected technologies and to scale up. Focused composite processing technology development and demonstration programs utilizing the building block approach are required to enable envisioned second generation RLV large composite structures applications. Government/industry partnerships have demonstrated success in this area and represent best combination of skills and capabilities to achieve this goal.

Research on networked manufacturing system for reciprocating pump industry

NASA Astrophysics Data System (ADS)

Wu, Yangdong; Qi, Guoning; Xie, Qingsheng; Lu, Yujun

2005-12-01

Networked manufacturing is a trend of reciprocating pump industry. According to the enterprises' requirement, the architecture of networked manufacturing system for reciprocating pump industry was proposed, which composed of infrastructure layer, system management layer, application service layer and user layer. Its main functions included product data management, ASP service, business management, and customer relationship management, its physics framework was a multi-tier internet-based model; the concept of ASP service integration was put forward and its process model was also established. As a result, a networked manufacturing system aimed at the characteristics of reciprocating pump industry was built. By implementing this system, reciprocating pump industry can obtain a new way to fully utilize their own resources and enhance the capabilities to respond to the global market quickly.

Assessment of an approach to printed polymer lenses

NASA Astrophysics Data System (ADS)

Marasco, Peter L.; Foote, Bob

2017-05-01

Additive manufacturing is proving its relevancy across a wide spectrum of development, prototyping and manufacturing in the US. However, there is a desire to move the capability beyond modeling and structural components. The use of additive manufacturing techniques to fabricate low-cost optics and optical systems is highly desirable in a number of markets. But processes and techniques for successfully printing an optic are currently very new. This paper discusses early advances in printing optics suitable for commercial and military applications. Data from and analysis of early prototype lenses fabricated using one possible technique will be included and discussed. The potential for additive manufacturing of optics to open the design space for complex optics and reduce development time, lowering cost and speeding up time to market, will also be discussed.

Manufacturing process used to produce long-acting recombinant factor VIII Fc fusion protein.

PubMed

McCue, Justin; Kshirsagar, Rashmi; Selvitelli, Keith; Lu, Qi; Zhang, Mingxuan; Mei, Baisong; Peters, Robert; Pierce, Glenn F; Dumont, Jennifer; Raso, Stephen; Reichert, Heidi

2015-07-01

Recombinant factor VIII Fc fusion protein (rFVIIIFc) is a long-acting coagulation factor approved for the treatment of hemophilia A. Here, the rFVIIIFc manufacturing process and results of studies evaluating product quality and the capacity of the process to remove potential impurities and viruses are described. This manufacturing process utilized readily transferable and scalable unit operations and employed multi-step purification and viral clearance processing, including a novel affinity chromatography adsorbent and a 15 nm pore size virus removal nanofilter. A cell line derived from human embryonic kidney (HEK) 293H cells was used to produce rFVIIIFc. Validation studies evaluated identity, purity, activity, and safety. Process-related impurity clearance and viral clearance spiking studies demonstrate robust and reproducible removal of impurities and viruses, with total viral clearance >8-15 log10 for four model viruses (xenotropic murine leukemia virus, mice minute virus, reovirus type 3, and suid herpes virus 1). Terminal galactose-α-1,3-galactose and N-glycolylneuraminic acid, two non-human glycans, were undetectable in rFVIIIFc. Biochemical and in vitro biological analyses confirmed the purity, activity, and consistency of rFVIIIFc. In conclusion, this manufacturing process produces a highly pure product free of viruses, impurities, and non-human glycan structures, with scale capabilities to ensure a consistent and adequate supply of rFVIIIFc. Copyright © 2015 Biogen. Published by Elsevier Ltd.. All rights reserved.

Traceability of On-Machine Tool Measurement: A Review

PubMed Central

Gomez-Acedo, Eneko; Kortaberria, Gorka; Olarra, Aitor

2017-01-01

Nowadays, errors during the manufacturing process of high value components are not acceptable in driving industries such as energy and transportation. Sectors such as aerospace, automotive, shipbuilding, nuclear power, large science facilities or wind power need complex and accurate components that demand close measurements and fast feedback into their manufacturing processes. New measuring technologies are already available in machine tools, including integrated touch probes and fast interface capabilities. They provide the possibility to measure the workpiece in-machine during or after its manufacture, maintaining the original setup of the workpiece and avoiding the manufacturing process from being interrupted to transport the workpiece to a measuring position. However, the traceability of the measurement process on a machine tool is not ensured yet and measurement data is still not fully reliable enough for process control or product validation. The scientific objective is to determine the uncertainty on a machine tool measurement and, therefore, convert it into a machine integrated traceable measuring process. For that purpose, an error budget should consider error sources such as the machine tools, components under measurement and the interactions between both of them. This paper reviews all those uncertainty sources, being mainly focused on those related to the machine tool, either on the process of geometric error assessment of the machine or on the technology employed to probe the measurand. PMID:28696358

MODIFICATIONS TO REDUCE DRAG OUT AT A PRINTED CIRCUIT BOARD MANUFACTURER

EPA Science Inventory

This MnTAP/EPA Waste Reduction Innovative Technology Evaluation project at Micom, Inc., demonstrated the waste reducing capability of two simple rinsing modifications on an etchant and an electroless copper process. he simple, tow (or no) cost, low technology changes that were ma...

Computer Applications in the Design Process.

ERIC Educational Resources Information Center

Winchip, Susan

Computer Assisted Design (CAD) and Computer Assisted Manufacturing (CAM) are emerging technologies now being used in home economics and interior design applications. A microcomputer in a computer network system is capable of executing computer graphic functions such as three-dimensional modeling, as well as utilizing office automation packages to…

1366 Project Automate: Enabling Automation for <$0.10/W High-Efficiency Kerfless Wafers Manufactured in the US

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

Lorenz, Adam

For photovoltaic (PV) manufacturing to thrive in the U.S., there must be an innovative core to the technology. Project Automate builds on 1366’s proprietary Direct Wafer® kerfless wafer technology and aims to unlock the cost and efficiency advantages of thin kerfless wafers. Direct Wafer is an innovative, U.S.-friendly (efficient, low-labor content) manufacturing process that addresses the main cost barrier limiting silicon PV cost-reductions – the 35-year-old grand challenge of manufacturing quality wafers (40% of the cost of modules) without the cost and waste of sawing. This simple, scalable process will allow 1366 to manufacture “drop-in” replacement wafers for the $10more » billion silicon PV wafer market at 50% of the cost, 60% of the capital, and 30% of the electricity of conventional casting and sawing manufacturing processes. This SolarMat project developed the Direct Wafer processes’ unique capability to tailor the shape of wafers to simultaneously make thinner AND stronger wafers (with lower silicon usage) that enable high-efficiency cell architectures. By producing wafers with a unique target geometry including a thick border (which determines handling characteristics) and thin interior regions (which control light capture and electron transport and therefore determine efficiency), 1366 can simultaneously improve quality and lower cost (using less silicon).« less

Simulation Based Optimization of Complex Monolithic Composite Structures Using Cellular Core Technology

NASA Astrophysics Data System (ADS)

Hickmott, Curtis W.

Cellular core tooling is a new technology which has the capability to manufacture complex integrated monolithic composite structures. This novel tooling method utilizes thermoplastic cellular cores as inner tooling. The semi-rigid nature of the cellular cores makes them convenient for lay-up, and under autoclave temperature and pressure they soften and expand providing uniform compaction on all surfaces including internal features such as ribs and spar tubes. This process has the capability of developing fully optimized aerospace structures by reducing or eliminating assembly using fasteners or bonded joints. The technology is studied in the context of evaluating its capabilities, advantages, and limitations in developing high quality structures. The complex nature of these parts has led to development of a model using the Finite Element Analysis (FEA) software Abaqus and the plug-in COMPRO Common Component Architecture (CCA) provided by Convergent Manufacturing Technologies. This model utilizes a "virtual autoclave" technique to simulate temperature profiles, resin flow paths, and ultimately deformation from residual stress. A model has been developed simulating the temperature profile during curing of composite parts made with the cellular core technology. While modeling of composites has been performed in the past, this project will look to take this existing knowledge and apply it to this new manufacturing method capable of building more complex parts and develop a model designed specifically for building large, complex components with a high degree of accuracy. The model development has been carried out in conjunction with experimental validation. A double box beam structure was chosen for analysis to determine the effects of the technology on internal ribs and joints. Double box beams were manufactured and sectioned into T-joints for characterization. Mechanical behavior of T-joints was performed using the T-joint pull-off test and compared to traditional tooling methods. Components made with the cellular core tooling method showed an improved strength at the joints. It is expected that this knowledge will help optimize the processing of complex, integrated structures and benefit applications in aerospace where lighter, structurally efficient components would be advantageous.

Modelling of human-machine interaction in equipment design of manufacturing cells

NASA Astrophysics Data System (ADS)

Cochran, David S.; Arinez, Jorge F.; Collins, Micah T.; Bi, Zhuming

2017-08-01

This paper proposes a systematic approach to model human-machine interactions (HMIs) in supervisory control of machining operations; it characterises the coexistence of machines and humans for an enterprise to balance the goals of automation/productivity and flexibility/agility. In the proposed HMI model, an operator is associated with a set of behavioural roles as a supervisor for multiple, semi-automated manufacturing processes. The model is innovative in the sense that (1) it represents an HMI based on its functions for process control but provides the flexibility for ongoing improvements in the execution of manufacturing processes; (2) it provides a computational tool to define functional requirements for an operator in HMIs. The proposed model can be used to design production systems at different levels of an enterprise architecture, particularly at the machine level in a production system where operators interact with semi-automation to accomplish the goal of 'autonomation' - automation that augments the capabilities of human beings.

SPS Energy Conversion Power Management Workshop

NASA Technical Reports Server (NTRS)

1980-01-01

Energy technology concerning photovoltaic conversion, solar thermal conversion systems, and electrical power distribution processing is discussed. The manufacturing processes involving solar cells and solar array production are summarized. Resource issues concerning gallium arsenides and silicon alternatives are reported. Collector structures for solar construction are described and estimates in their service life, failure rates, and capabilities are presented. Theories of advanced thermal power cycles are summarized. Power distribution system configurations and processing components are presented.

RFI and SCRIMP Model Development and Verification

NASA Technical Reports Server (NTRS)

Loos, Alfred C.; Sayre, Jay

2000-01-01

Vacuum-Assisted Resin Transfer Molding (VARTM) processes are becoming promising technologies in the manufacturing of primary composite structures in the aircraft industry as well as infrastructure. A great deal of work still needs to be done on efforts to reduce the costly trial-and-error methods of VARTM processing that are currently in practice today. A computer simulation model of the VARTM process would provide a cost-effective tool in the manufacturing of composites utilizing this technique. Therefore, the objective of this research was to modify an existing three-dimensional, Resin Film Infusion (RFI)/Resin Transfer Molding (RTM) model to include VARTM simulation capabilities and to verify this model with the fabrication of aircraft structural composites. An additional objective was to use the VARTM model as a process analysis tool, where this tool would enable the user to configure the best process for manufacturing quality composites. Experimental verification of the model was performed by processing several flat composite panels. The parameters verified included flow front patterns and infiltration times. The flow front patterns were determined to be qualitatively accurate, while the simulated infiltration times over predicted experimental times by 8 to 10%. Capillary and gravitational forces were incorporated into the existing RFI/RTM model in order to simulate VARTM processing physics more accurately. The theoretical capillary pressure showed the capability to reduce the simulated infiltration times by as great as 6%. The gravity, on the other hand, was found to be negligible for all cases. Finally, the VARTM model was used as a process analysis tool. This enabled the user to determine such important process constraints as the location and type of injection ports and the permeability and location of the high-permeable media. A process for a three-stiffener composite panel was proposed. This configuration evolved from the variation of the process constraints in the modeling of several different composite panels. The configuration was proposed by considering such factors as: infiltration time, the number of vacuum ports, and possible areas of void entrapment.

Reference earth orbital research and applications investigations (blue book). Volume 6: Materials sciences and manufacturing

NASA Technical Reports Server (NTRS)

1971-01-01

The development of commercial manufacturing and research activities in space is discussed. The capability is to be installed in space stations in order to exploit the extended free fall which makes many novel manipulations of materials possible and alters the behavior of certain chemical and physical processes. The broad objectives are: (1) to develop technical basis required for commercial use of manned space facilities, (2) to provide indirect economic benefits by exploiting advantages of space laboratory facilities to solve critical experimental problems, and (3) to initiate manufacturing operations in space by private enterprise for commercial purposes and by agencies of the Government for public purposes.

Extending the performance of single-degree-of-freedom rate integrating gyros in strapdown applications

NASA Astrophysics Data System (ADS)

Baker, G. N.

This paper examines the constraints upon a typical manufacturer of gyros and strapdown systems. It describes that while being responsive to exchange and keeping abreast of 'state of the art' technology, there are many reasons why the manufacturer must satisfy the market using existing technology and production equipment. The Single-Degree-of-Freedom Rate Integrating Gyro is a well established product, yet is capable of achieving far higher performances than originally envisaged due to modelling and characterization within digital strapdown systems. The parameters involved are discussed, and a description given of the calibration process undertaken on a strapdown system being manufactured in a production environment in batch quantities.

Propulsion Design With Freeform Fabrication (PDFF)

NASA Technical Reports Server (NTRS)

Barnes, Daudi; McKinnon, James; Priem, Richard

2010-01-01

The nation is challenged to decrease the cost and schedule to develop new space transportation propulsion systems for commercial, scientific, and military purposes. Better design criteria and manufacturing techniques for small thrusters are needed to meet current applications in missile defense, space, and satellite propulsion. The requirements of these systems present size, performance, and environmental demands on these thrusters that have posed significant challenges to the current designers and manufacturers. Designers are limited by manufacturing processes, which are complex, costly, and time consuming, and ultimately limited in their capabilities. The PDFF innovation vastly extends the design opportunities of rocket engine components and systems by making use of the unique manufacturing freedom of solid freeform rapid prototype manufacturing technology combined with the benefits of ceramic materials. The unique features of PDFF are developing and implementing a design methodology that uses solid freeform fabrication (SFF) techniques to make propulsion components with significantly improved performance, thermal management, power density, and stability, while reducing development and production costs. PDFF extends the design process envelope beyond conventional constraints by leveraging the key feature of the SFF technique with the capability to form objects with nearly any geometric complexity without the need for elaborate machine setup. The marriage of SFF technology to propulsion components allows an evolution of design practice to harmonize material properties with functional design efficiency. Reduced density of materials when coupled with the capability to honeycomb structure used in the injector will have significant impact on overall mass reduction. Typical thrusters in use for attitude control have 60 90 percent of its mass in the valve and injector, which is typically made from titanium. The combination of material and structure envisioned for use in an SFF thruster design could reduce thruster weight by a factor of two or more. The thrust-to-weight ratios for such designs can achieve 1,000:1 or more, depending on chamber pressure. The potential exists for continued development in materials, size, speed, accuracy of SFF techniques, which can lead to speculative developments of PDFF processes such as fabrication of custom human interface devices like masks, chairs, and clothing, and advanced biomedical application to human organ reconstruction. Other potential applications are: higher fidelity lower cost test fixtures for probes and inspection, disposable thrusters, and ISRU (in situ resource utilization) for component production in space or on Lunar and Martian missions, and application for embedding MEMS (microelectromechanical systems) during construction process of form changing aerostructure/dynamic structures.

LDRD Final Report 15-ERD-037 Matthews

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

Matthews, Manyalibo J.

2017-10-26

The physics and materials science involved in laser materials processing of metals was studied experimentally using custom-built test beds and in situ diagnostics. Special attention was given to laser-based powder bed fusion additive manufacturing processes, a technology critically important to the stockpile stewardship program in NNSA. New light has been shed on several phenomena such as laser-driven spatter, material displacement and morphology changes. The results presented here and in publications generated by this work have proven impactful and useful to both internal and external communities. New directions in additive manufacturing research at LLNL have been enabled, along with new scientificmore » capabilities that can serve future program needs.« less

An Examination of the Navy’s Future Naval Capability Technology Transition Process

DTIC Science & Technology

2004-12-01

managing innovation , innovation is a lot of art and a little science. b. Innovation Skills The President of the small manufacturing company...34 managing innovation ", the breakthroughs do not come from managed, tightly structured programs. The development of those breakthroughs into truly useful

Enhancing Surface Finish of Additively Manufactured Titanium and Cobalt Chrome Elements Using Laser Based Finishing

NASA Astrophysics Data System (ADS)

Gora, Wojciech S.; Tian, Yingtao; Cabo, Aldara Pan; Ardron, Marcus; Maier, Robert R. J.; Prangnell, Philip; Weston, Nicholas J.; Hand, Duncan P.

Additive manufacturing (AM) offers the possibility of creating a complex free form object as a single element, which is not possible using traditional mechanical machining. Unfortunately the typically rough surface finish of additively manufactured parts is unsuitable for many applications. As a result AM parts must be post-processed; typically mechanically machined and/or and polished using either chemical or mechanical techniques (both of which have their limitations). Laser based polishing is based on remelting of a very thin surface layer and it offers potential as a highly repeatable, higher speed process capable of selective area polishing, and without any waste problems (no abrasives or liquids). In this paper an in-depth investigation of CW laser polishing of titanium and cobalt chrome AM elements is presented. The impact of different scanning strategies, laser parameters and initial surface condition on the achieved surface finish is evaluated.

Low work function materials for microminiature energy conversion and recovery applications

DOEpatents

Zavadil, Kevin R.; Ruffner, Judith A.; King, Donald B.

2003-05-13

Low work function materials are disclosed together with methods for their manufacture and integration with electrodes used in thermionic conversion applications (specifically microminiature thermionic conversion applications). The materials include a mixed oxide system and metal in a compositionally modulated structure comprised of localized discontinuous structures of material that are deposited using techniques suited to IC manufacture, such as rf sputtering or CVD. The structures, which can include layers are then heated to coalescence yielding a thin film that is both durable and capable of electron emission under thermionic conversion conditions used for microminiature thermionic converters. Using the principles of the invention, thin film electrodes (emitters and collectors) required for microconverter technology are manufactured using a single process deposition so as to allow for full fabrication integration consistent with batch processing, and tailoring of emission/collection properties. In the preferred embodiment, the individual layers include mixed BaSrCaO, scandium oxide and tungsten.

US Department of Energy's Efforts in Intelligent Processing Equipment

NASA Technical Reports Server (NTRS)

Peavy, Richard D.; Mcfarland, Janet C.

1992-01-01

The Department of Energy (DOE) uses intelligent processing equipment (IPE) technologies to conduct research and development and manufacturing for energy and nuclear weapons programs. This paper highlights several significant IPE efforts underway in DOE. IPE technologies are essential to the accomplishment of DOE's missions, because of the need for small lot production, precision, and accuracy in manufacturing, hazardous waste management, and protection of the environment and the safety and health of the workforce and public. Applications of IPE technologies include environmental remediation and waste handling, advanced manufacturing, and automation of tasks carried out in hazardous areas. DOE laboratories have several key programs that integrate robotics, sensor, and control technologies. These programs embody a considerable technical capability that also may be used to enhance U.S. industrial competitiveness. DOE encourages closer cooperation with U.S. industrial partners based on mutual benefits. This paper briefly describes technology transfer mechanisms available for industrial involvement.

Design requirements for SRB production control system. Volume 3: Package evaluation, modification and hardware

NASA Technical Reports Server (NTRS)

1981-01-01

The software package evaluation was designed to analyze commercially available, field-proven, production control or manufacturing resource planning management technology and software package. The analysis was conducted by comparing SRB production control software requirements and conceptual system design to software package capabilities. The methodology of evaluation and the findings at each stage of evaluation are described. Topics covered include: vendor listing; request for information (RFI) document; RFI response rate and quality; RFI evaluation process; and capabilities versus requirements.

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.

Energy absorption capabilities of complex thin walled structures

NASA Astrophysics Data System (ADS)

Tarlochan, F.; AlKhatib, Sami

2017-10-01

Thin walled structures have been used in the area of energy absorption during an event of a crash. A lot of work has been done on tubular structures. Due to limitation of manufacturing process, complex geometries were dismissed as potential solutions. With the advancement in metal additive manufacturing, complex geometries can be realized. As a motivation, the objective of this study is to investigate computationally the crash performance of complex tubular structures. Five designs were considered. In was found that complex geometries have better crashworthiness performance than standard tubular structures used currently.

The impact of preventive maintenance practices on manufacturing performance: A proposed model for SMEs in Malaysia

NASA Astrophysics Data System (ADS)

Lazim, Halim Mad; Taib, Che Azlan; Lamsali, Hendrik; Saleh, Mohamed Najib; Subramaniam, Chandrakantan

2016-08-01

Preventive maintenance (PM) plays important role to avoid or mitigate potential stoppages and disruptions of equipment or machinery from occurring in daily operations. PM emphasized total employee involvement and it is important for companies as well as Small and Medium Sized Enterprises (SMEs). SME sectors contribution to the Malaysian economy makes up 95% of the total manufacturers, however PM remain relatively lacking. The ability, reliability and effective maintenance management is highly important in order to achieve desired manufacturing performance. Therefore, organizational capability in planning, controlling, implementing and monitoring PM activities is important. Furthermore, empirical evidence on the potential impact of PM practices towards manufacturing performance with organizational capability as a moderating effect is still limited and indecisive. Henceforth, this paper aims to explore and investigate potential relationships between PM practices and manufacturing performance moderated by organizational capability in the contact of Malaysian SMEs in the manufacturing sector. Correspondently, the study intends to propose a new research framework and hypotheses to examine the abovementioned relationships. The proposed framework includes PM team, PM strategy and planned maintenance as the determinants, while organizational capability serves as the moderating variable. Manufacturing performance will be viewed in terms of innovation and financial factors. Proposed research direction and conclusion are discussed at the end of the study.

A study on Aerosol jet printing technology in LED module manufacturing

NASA Astrophysics Data System (ADS)

Rudorfer, Andreas; Tscherner, Martin; Palfinger, Christian; Reil, Frank; Hartmann, Paul; Seferis, Ioannis E.; Zych, Eugeniusz; Wenzl, Franz P.

2016-09-01

State of the art fabrication of LED modules based on chip-on-board (COB) technology comprises some shortcomings both with respect to the manufacturing process itself but also with regard to potential sources of failures and manufacturing impreciseness. One promising alternative is additive manufacturing, a technology which has gained a lot of attention during the last years due to its materials and cost saving capabilities. Especially direct-write technologies like Aerosol jet printing have demonstrated advantages compared to other technological approaches when printing high precision layers or high precision electronic circuits on substrates which, as an additional advantage, also can be flexible and 3D shaped. Based on test samples and test structures manufactured by Aerosol jet printing technology, in this context we discuss the potentials of additive manufacturing in various aspects of LED module fabrication, ranging from the deposition of the die-attach material, wire bond replacement by printed electrical connects as well as aspects of high-precision phosphor layer deposition for color conversion and white light generation.

The use of a very high temperature nuclear reactor in the manufacture of synthetic fuels

NASA Technical Reports Server (NTRS)

Farbman, G. H.; Brecher, L. E.

1976-01-01

The three parts of a program directed toward creating a cost-effective nuclear hydrogen production system are described. The discussion covers the development of a very high temperature nuclear reactor (VHTR) as a nuclear heat and power source capable of producing the high temperature needed for hydrogen production and other processes; the development of a hydrogen generation process based on water decomposition, which can utilize the outputs of the VHTR and be integrated with many different ultimate hydrogen consuming processes; and the evaluation of the process applications of the nuclear hydrogen systems to assess the merits and potential payoffs. It is shown that the use of VHTR for the manufacture of synthetic fuels appears to have a very high probability of making a positive contribution to meeting the nation's energy needs in the future.

Laser beam welding quality monitoring system based in high-speed (10 kHz) uncooled MWIR imaging sensors

NASA Astrophysics Data System (ADS)

Linares, Rodrigo; Vergara, German; Gutiérrez, Raúl; Fernández, Carlos; Villamayor, Víctor; Gómez, Luis; González-Camino, Maria; Baldasano, Arturo; Castro, G.; Arias, R.; Lapido, Y.; Rodríguez, J.; Romero, Pablo

2015-05-01

The combination of flexibility, productivity, precision and zero-defect manufacturing in future laser-based equipment are a major challenge that faces this enabling technology. New sensors for online monitoring and real-time control of laserbased processes are necessary for improving products quality and increasing manufacture yields. New approaches to fully automate processes towards zero-defect manufacturing demand smarter heads where lasers, optics, actuators, sensors and electronics will be integrated in a unique compact and affordable device. Many defects arising in laser-based manufacturing processes come from instabilities in the dynamics of the laser process. Temperature and heat dynamics are key parameters to be monitored. Low cost infrared imagers with high-speed of response will constitute the next generation of sensors to be implemented in future monitoring and control systems for laser-based processes, capable to provide simultaneous information about heat dynamics and spatial distribution. This work describes the result of using an innovative low-cost high-speed infrared imager based on the first quantum infrared imager monolithically integrated with Si-CMOS ROIC of the market. The sensor is able to provide low resolution images at frame rates up to 10 KHz in uncooled operation at the same cost as traditional infrared spot detectors. In order to demonstrate the capabilities of the new sensor technology, a low-cost camera was assembled on a standard production laser welding head, allowing to register melting pool images at frame rates of 10 kHz. In addition, a specific software was developed for defect detection and classification. Multiple laser welding processes were recorded with the aim to study the performance of the system and its application to the real-time monitoring of laser welding processes. During the experiments, different types of defects were produced and monitored. The classifier was fed with the experimental images obtained. Self-learning strategies were implemented with very promising results, demonstrating the feasibility of using low-cost high-speed infrared imagers in advancing towards a real-time / in-line zero-defect production systems.

Microeconomics of yield learning and process control in semiconductor manufacturing

NASA Astrophysics Data System (ADS)

Monahan, Kevin M.

2003-06-01

Simple microeconomic models that directly link yield learning to profitability in semiconductor manufacturing have been rare or non-existent. In this work, we review such a model and provide links to inspection capability and cost. Using a small number of input parameters, we explain current yield management practices in 200mm factories. The model is then used to extrapolate requirements for 300mm factories, including the impact of technology transitions to 130nm design rules and below. We show that the dramatic increase in value per wafer at the 300mm transition becomes a driver for increasing metrology and inspection capability and sampling. These analyses correlate well wtih actual factory data and often identify millions of dollars in potential cost savings. We demonstrate this using the example of grating-based overlay metrology for the 65nm node.

Digitalization in roll forming manufacturing

NASA Astrophysics Data System (ADS)

Sedlmaier, A.; Dietl, T.; Ferreira, P.

2017-09-01

Roll formed profiles are used in automotive chassis production as building blocks for the body-in-white. The ability to produce profiles with discontinuous cross sections, both in width and in depth, allows weight savings in the final automotive chassis through the use of load optimized cross sections. This has been the target of the 3D Roll Forming process. A machine concept is presented where a new forming concept for roll formed parts in combination with advanced robotics allowing freely positioned roll forming tooling in 3D space enables the production of complex shapes by roll forming. This is a step forward into the digitalization of roll forming manufacturing by making the process flexible and capable of rapid prototyping and production of small series of parts. Moreover, data collection in a large scale through the control system and integrated sensors lead to an increased understanding of the process and provide the basis to develop self-optimizing roll forming machines, increasing the productivity, quality and predictability of the roll-forming process. The first parts successfully manufactured with this new forming concept are presented.

Microstructure and Magnetic Properties of Magnetic Material Fabricated by Selective Laser Melting

NASA Astrophysics Data System (ADS)

Jhong, Kai Jyun; Huang, Wei-Chin; Lee, Wen Hsi

Selective Laser Melting (SLM) is a powder-based additive manufacturing which is capable of producing parts layer-by-layer from a 3D CAD model. The aim of this study is to adopt the selective laser melting technique to magnetic material fabrication. [1]For the SLM process to be practical in industrial use, highly specific mechanical properties of the final product must be achieved. The integrity of the manufactured components depend strongly on each single laser-melted track and every single layer, as well as the strength of the connections between them. In this study, effects of the processing parameters, such as the space distance of surface morphology is analyzed. Our hypothesis is that when a magnetic product is made by the selective laser melting techniques instead of traditional techniques, the finished component will have more precise and effective properties. This study analyzed the magnitudes of magnetic properties in comparison with different parameters in the SLM process and compiled a completed product to investigate the efficiency in contrast with products made with existing manufacturing processes.

A cost-effective intelligent robotic system with dual-arm dexterous coordination and real-time vision

NASA Technical Reports Server (NTRS)

Marzwell, Neville I.; Chen, Alexander Y. K.

1991-01-01

Dexterous coordination of manipulators based on the use of redundant degrees of freedom, multiple sensors, and built-in robot intelligence represents a critical breakthrough in development of advanced manufacturing technology. A cost-effective approach for achieving this new generation of robotics has been made possible by the unprecedented growth of the latest microcomputer and network systems. The resulting flexible automation offers the opportunity to improve the product quality, increase the reliability of the manufacturing process, and augment the production procedures for optimizing the utilization of the robotic system. Moreover, the Advanced Robotic System (ARS) is modular in design and can be upgraded by closely following technological advancements as they occur in various fields. This approach to manufacturing automation enhances the financial justification and ensures the long-term profitability and most efficient implementation of robotic technology. The new system also addresses a broad spectrum of manufacturing demand and has the potential to address both complex jobs as well as highly labor-intensive tasks. The ARS prototype employs the decomposed optimization technique in spatial planning. This technique is implemented to the framework of the sensor-actuator network to establish the general-purpose geometric reasoning system. The development computer system is a multiple microcomputer network system, which provides the architecture for executing the modular network computing algorithms. The knowledge-based approach used in both the robot vision subsystem and the manipulation control subsystems results in the real-time image processing vision-based capability. The vision-based task environment analysis capability and the responsive motion capability are under the command of the local intelligence centers. An array of ultrasonic, proximity, and optoelectronic sensors is used for path planning. The ARS currently has 18 degrees of freedom made up by two articulated arms, one movable robot head, and two charged coupled device (CCD) cameras for producing the stereoscopic views, and articulated cylindrical-type lower body, and an optional mobile base. A functional prototype is demonstrated.

Qualification of the Second Batch Production 9-Cell Cavities Manufactured by AES and Validation of the First US Industrial Cavity Vendor for ILC

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

Geng, R. L.; Golden, B. A.; Kushnick, P.

2011-07-01

One of the major goals of ILC SRF cavity R&D is to develop industrial capabilities of cavity manufacture and processing in all three regions. In the past several years, Jefferson Lab, in collaboration with Fermi National Accelerator Laboratory, has processed and tested all the 9-cell cavities of the first batch (4 cavities) and second batch (6 cavities) production cavities manufactured by Advanced Energy Systems Inc. (AES). Over the course, close information feedback was maintained, resulting in changes in fabrication and processing procedures. A light buffered chemical polishing was introduced, removing the weld splatters that could not be effectively removed bymore » heavy EP alone. An 800 Celsius 2 hour vacuum furnace heat treatment procedure replaced the original 600 Celsius 10 hour procedure. Four out of the six 9-cell cavities of the second production bath achieved a gradient of 36-41 MV/m at a Q0 of more than 8E9 at 35 MV/m. This result validated AES as the first ''ILC certified'' industrial vendor in the US for ILC cavity manufacture.« less

Liner-less Tanks for Space Application - Design and Manufacturing Considerations

NASA Technical Reports Server (NTRS)

Jones, Brian H.; Li, Min-Chung

2003-01-01

Composite pressure vessels, used extensively for gas and fuel containment in space vehicles, are generally constructed with a metallic liner, while the fiber reinforcement carries the major portion of the pressure-induced load. The design is dominated by the liner s low strain at yield since the reinforcing fibers cannot operate at their potential load-bearing capability without resorting to pre-stressing (or autofrettaging). An ultra high-efficiency pressure vessel, which operates at the optimum strain capability of the fibers, can be potentially achieved with a liner-less construction. This paper discusses the design and manufacturing challenges to be overcome in the development of such a pressure vessel. These include: (1) gas/liquid containment and permeation, (2) design and structural analysis, and (3) manufacturing process development. The paper also presents the development and validation tests on a liner-less pressure vessel developed by Kaiser Compositek Inc. (KCI). It should be noted that KCI s liner-less tank exhibits a highly controlled leak-before-burst mode. This feature results in a structure having the highest level of safety.

Simulating the Composite Propellant Manufacturing Process

NASA Technical Reports Server (NTRS)

Williamson, Suzanne; Love, Gregory

2000-01-01

There is a strategic interest in understanding how the propellant manufacturing process contributes to military capabilities outside the United States. The paper will discuss how system dynamics (SD) has been applied to rapidly assess the capabilities and vulnerabilities of a specific composite propellant production complex. These facilities produce a commonly used solid propellant with military applications. The authors will explain how an SD model can be configured to match a specific production facility followed by a series of scenarios designed to analyze operational vulnerabilities. By using the simulation model to rapidly analyze operational risks, the analyst gains a better understanding of production complexities. There are several benefits of developing SD models to simulate chemical production. SD is an effective tool for characterizing complex problems, especially the production process where the cascading effect of outages quickly taxes common understanding. By programming expert knowledge into an SD application, these tools are transformed into a knowledge management resource that facilitates rapid learning without requiring years of experience in production operations. It also permits the analyst to rapidly respond to crisis situations and other time-sensitive missions. Most importantly, the quantitative understanding gained from applying the SD model lends itself to strategic analysis and planning.

Gaussian Process Regression (GPR) Representation in Predictive Model Markup Language (PMML)

PubMed Central

Lechevalier, D.; Ak, R.; Ferguson, M.; Law, K. H.; Lee, Y.-T. T.; Rachuri, S.

2017-01-01

This paper describes Gaussian process regression (GPR) models presented in predictive model markup language (PMML). PMML is an extensible-markup-language (XML) -based standard language used to represent data-mining and predictive analytic models, as well as pre- and post-processed data. The previous PMML version, PMML 4.2, did not provide capabilities for representing probabilistic (stochastic) machine-learning algorithms that are widely used for constructing predictive models taking the associated uncertainties into consideration. The newly released PMML version 4.3, which includes the GPR model, provides new features: confidence bounds and distribution for the predictive estimations. Both features are needed to establish the foundation for uncertainty quantification analysis. Among various probabilistic machine-learning algorithms, GPR has been widely used for approximating a target function because of its capability of representing complex input and output relationships without predefining a set of basis functions, and predicting a target output with uncertainty quantification. GPR is being employed to various manufacturing data-analytics applications, which necessitates representing this model in a standardized form for easy and rapid employment. In this paper, we present a GPR model and its representation in PMML. Furthermore, we demonstrate a prototype using a real data set in the manufacturing domain. PMID:29202125

Gaussian Process Regression (GPR) Representation in Predictive Model Markup Language (PMML).

PubMed

Park, J; Lechevalier, D; Ak, R; Ferguson, M; Law, K H; Lee, Y-T T; Rachuri, S

2017-01-01

This paper describes Gaussian process regression (GPR) models presented in predictive model markup language (PMML). PMML is an extensible-markup-language (XML) -based standard language used to represent data-mining and predictive analytic models, as well as pre- and post-processed data. The previous PMML version, PMML 4.2, did not provide capabilities for representing probabilistic (stochastic) machine-learning algorithms that are widely used for constructing predictive models taking the associated uncertainties into consideration. The newly released PMML version 4.3, which includes the GPR model, provides new features: confidence bounds and distribution for the predictive estimations. Both features are needed to establish the foundation for uncertainty quantification analysis. Among various probabilistic machine-learning algorithms, GPR has been widely used for approximating a target function because of its capability of representing complex input and output relationships without predefining a set of basis functions, and predicting a target output with uncertainty quantification. GPR is being employed to various manufacturing data-analytics applications, which necessitates representing this model in a standardized form for easy and rapid employment. In this paper, we present a GPR model and its representation in PMML. Furthermore, we demonstrate a prototype using a real data set in the manufacturing domain.

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.

Intelligent manufacturing: the challenge for manufacturing strategy in China in the 21st century--what we will do

NASA Astrophysics Data System (ADS)

Yang, Shuzi; Lei, Ming; Guan, Zai-Lin; Xiong, Youlun

1995-08-01

This paper first introduces the project of intelligent manufacturing in China and the research state of the IIMRC (Intelligent and Integrated Manufacturing Research Centre) of HUST (Huazhong University of Science and Technology), then reviews the recent advances in object- oriented and distributed artificial intelligence and puts forth the view that these advances open up the prospect of systems that will enable the true integration of enterprises. In an attempt to identify domain requirements and match them with research achievements, the paper examines the current literature and distinguishes 14 features that are common. It argues that effective enterprise-wide support could be greatly facilitated by the existence of intelligent software entities with autonomous processing capabilities, that possess coordination and negotiation facilities and are organized in distributed hierarchical states.

In Situ Enhancement of Anaerobic Microbial Dechlorination of Polychlorinated Dibenzo-p-dioxins and Dibenzofurans in Marine and Estuarine Sediments

DTIC Science & Technology

2006-12-18

Defense. Reference herein to any specific commercial product, process , or service by trade name, trademark, manufacturer, or otherwise, does not...result of a combination of both respiratory and cometabolic processes . For in situ bioremediation, it would be most desirable to stimulate...conditions we examined. While the process has much potential, a key aspect of the technology – the nature and capability of the intrinsic microbial

Development of a plan for automating integrated circuit processing

NASA Technical Reports Server (NTRS)

1971-01-01

The operations analysis and equipment evaluations pertinent to the design of an automated production facility capable of manufacturing beam-lead CMOS integrated circuits are reported. The overall plan shows approximate cost of major equipment, production rate and performance capability, flexibility, and special maintenance requirements. Direct computer control is compared with supervisory-mode operations. The plan is limited to wafer processing operations from the starting wafer to the finished beam-lead die after separation etching. The work already accomplished in implementing various automation schemes, and the type of equipment which can be found for instant automation are described. The plan is general, so that small shops or large production units can perhaps benefit. Examples of major types of automated processing machines are shown to illustrate the general concepts of automated wafer processing.

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.

Manufacturing information system

NASA Astrophysics Data System (ADS)

Allen, D. K.; Smith, P. R.; Smart, M. J.

1983-12-01

The size and cost of manufacturing equipment has made it extremely difficult to perform realistic modeling and simulation of the manufacturing process in university research laboratories. Likewise the size and cost factors, coupled with many uncontrolled variables of the production situation has even made it difficult to perform adequate manufacturing research in the industrial setting. Only the largest companies can afford manufacturing research laboratories; research results are often held proprietary and seldom find their way into the university classroom to aid in education and training of new manufacturing engineers. It is the purpose for this research to continue the development of miniature prototype equipment suitable for use in an integrated CAD/CAM Laboratory. The equipment being developed is capable of actually performing production operations (e.g. drilling, milling, turning, punching, etc.) on metallic and non-metallic workpieces. The integrated CAD/CAM Mini-Lab is integrating high resolution, computer graphics, parametric design, parametric N/C parts programmings, CNC machine control, automated storage and retrieval, with robotics materials handling. The availability of miniature CAD/CAM laboratory equipment will provide the basis for intensive laboratory research on manufacturing information systems.

OAO battery data analysis

NASA Technical Reports Server (NTRS)

Gaston, S.; Wertheim, M.; Orourke, J. A.

1973-01-01

Summary, consolidation and analysis of specifications, manufacturing process and test controls, and performance results for OAO-2 and OAO-3 lot 20 Amp-Hr sealed nickel cadmium cells and batteries are reported. Correlation of improvements in control requirements with performance is a key feature. Updates for a cell/battery computer model to improve performance prediction capability are included. Applicability of regression analysis computer techniques to relate process controls to performance is checked.

Portable Device Slices Thermoplastic Prepregs

NASA Technical Reports Server (NTRS)

Taylor, Beverly A.; Boston, Morton W.; Wilson, Maywood L.

1993-01-01

Prepreg slitter designed to slit various widths rapidly by use of slicing bar holding several blades, each capable of slicing strip of preset width in single pass. Produces material evenly sliced and does not contain jagged edges. Used for various applications in such batch processes involving composite materials as press molding and autoclaving, and in such continuous processes as pultrusion. Useful to all manufacturers of thermoplastic composites, and in slicing B-staged thermoset composites.

International Aviation (Selected Articles)

DTIC Science & Technology

1991-06-05

The Manufacturing Capabilities of the Shanghai Aviation Company Leap to a New Level, by Yang Xinbang Zhang Shiyuan , Zheng Huilin............9 Setting...international cooperation. 8 THE MANUFACTURING CAPABILITIES OF THE SHANGHAI AVIATION COMPANY LEAP TO A NEW LEVEL Yang Xinbang Zhang Shiyuan Zheng

Development of metrology for freeform optics in reflection mode

NASA Astrophysics Data System (ADS)

Burada, Dali R.; Pant, Kamal K.; Mishra, Vinod; Bichra, Mohamed; Khan, Gufran S.; Sinzinger, Stefan; Shakher, Chandra

2017-06-01

The increased range of manufacturable freeform surfaces offered by the new fabrication techniques is giving opportunities to incorporate them in the optical systems. However, the success of these fabrication techniques depends on the capabilities of metrology procedures and a feedback mechanism to CNC machines for optimizing the manufacturing process. Therefore, a precise and in-situ metrology technique for freeform optics is in demand. Though all the techniques available for aspheres have been extended for the freeform surfaces by the researchers, but none of the techniques has yet been incorporated into the manufacturing machine for in-situ measurement. The most obvious reason is the complexity involved in the optical setups to be integrated in the manufacturing platforms. The Shack-Hartmann sensor offers the potential to be incorporated into the machine environment due to its vibration insensitivity, compactness and 3D shape measurement capability from slope data. In the present work, a measurement scheme is reported in which a scanning Shack-Hartmann Sensor has been employed and used as a metrology tool for measurement of freeform surface in reflection mode. Simulation studies are conducted for analyzing the stitching accuracy in presence of various misalignment errors. The proposed scheme is experimentally verified on a freeform surface of cubic phase profile.

Chemistry, manufacturing and control (CMC) and clinical trial technical support for influenza vaccine manufacturers.

PubMed

Wahid, Rahnuma; Holt, Renee; Hjorth, Richard; Berlanda Scorza, Francesco

2016-10-26

With the support of the Biomedical Advanced Research and Development Authority (BARDA) of the US Department of Health and Human Services, PATH has contributed to the World Health Organization's (WHO's) Global Action Plan for Influenza Vaccines (GAP) by providing technical and clinical assistance to several developing country vaccine manufacturers (DCVMs). GAP builds regionally based independent and sustainable influenza vaccine production capacity to mitigate the overall global shortage of influenza vaccines. The program also ensures adequate influenza vaccine manufacturing capacity in the event of an influenza pandemic. Since 2009, PATH has worked closely with two DCVMs in Vietnam: the Institute of Vaccines and Medical Biologicals (IVAC) and VABIOTECH. Beginning in 2013, PATH also began working with Torlak Institute in Serbia; Instituto Butantan in Brazil; Serum Institute of India Private Ltd. in India; and Changchun BCHT Biotechnology Co. (BCHT) in China. The DCVMs supported under the GAP program all had existing influenza vaccine manufacturing capability and required technical support from PATH to improve vaccine yield, process efficiency, and product formulation. PATH has provided customized technical support for the manufacturing process to each DCVM based on their respective requirements. Additionally, PATH, working with BARDA and WHO, supported several DCVMs in the clinical development of influenza vaccine candidates progressing toward national licensure or WHO prequalification. As a result of the activities outlined in this review, several companies were able to make excellent progress in developing state-of-the-art manufacturing processes and completing early phase clinical trials. Licensure trials are currently ongoing or planned for several DCVMs. Copyright © 2016 Elsevier Ltd. All rights reserved.

Sensors for process control Focus Team report

NASA Astrophysics Data System (ADS)

At the Semiconductor Technology Workshop, held in November 1992, the Semiconductor Industry Association (SIA) convened 179 semiconductor technology experts to assess the 15-year outlook for the semiconductor manufacturing industry. The output of the Workshop, a document entitled 'Semiconductor Technology: Workshop Working Group Reports,' contained an overall roadmap for the technology characteristics envisioned in integrated circuits (IC's) for the period 1992-2007. In addition, the document contained individual roadmaps for numerous key areas in IC manufacturing, such as film deposition, thermal processing, manufacturing systems, exposure technology, etc. The SIA Report did not contain a separate roadmap for contamination free manufacturing (CFM). A key component of CFM for the next 15 years is the use of sensors for (1) defect reduction, (2) improved product quality, (3) improved yield, (4) improved tool utilization through contamination reduction, and (5) real time process control in semiconductor fabrication. The objective of this Focus Team is to generate a Sensors for Process Control Roadmap. Implicit in this objective is the identification of gaps in current sensor technology so that research and development activity in the sensor industry can be stimulated to develop sensor systems capable of meeting the projected roadmap needs. Sensor performance features of interest include detection limit, specificity, sensitivity, ease of installation and maintenance, range, response time, accuracy, precision, ease and frequency of calibration, degree of automation, and adaptability to in-line process control applications.

Pattern database applications from design to manufacturing

NASA Astrophysics Data System (ADS)

Zhuang, Linda; Zhu, Annie; Zhang, Yifan; Sweis, Jason; Lai, Ya-Chieh

2017-03-01

Pattern-based approaches are becoming more common and popular as the industry moves to advanced technology nodes. At the beginning of a new technology node, a library of process weak point patterns for physical and electrical verification are starting to build up and used to prevent known hotspots from re-occurring on new designs. Then the pattern set is expanded to create test keys for process development in order to verify the manufacturing capability and precheck new tape-out designs for any potential yield detractors. With the database growing, the adoption of pattern-based approaches has expanded from design flows to technology development and then needed for mass-production purposes. This paper will present the complete downstream working flows of a design pattern database(PDB). This pattern-based data analysis flow covers different applications across different functional teams from generating enhancement kits to improving design manufacturability, populating new testing design data based on previous-learning, generating analysis data to improve mass-production efficiency and manufacturing equipment in-line control to check machine status consistency across different fab sites.

Software for Managing the Process of Manpower Training for Economic and Industrial Development.

ERIC Educational Resources Information Center

Catoline, James E.

This document discusses the training capabilities, software, and related products of GTE Sylvania Training Operations (STO). With the rapid emergence and development of the Third World, the technical knowhow of large manufacturing industries has become a marketable commodity in the international transfer of technology. Manpower training and human…

SKYLAB (SL)-3 - EXPERIMENT HARDWARE

NASA Image and Video Library

1973-11-08

S74-19675 (1974) --- Medium close-up view of the M512 materials processing equipment storage assembly and the M518 electric furnace in the Multiple Docking Adapter (MDA), one of the primary elements of the Skylab space station. The assembly holds equipment designed to explore space manufacturing capability in a weightless state. Photo credit: NASA

Increased Reliability of Gas Turbine Components by Robust Coatings Manufacturing

NASA Astrophysics Data System (ADS)

Sharma, A.; Dudykevych, T.; Sansom, D.; Subramanian, R.

2017-08-01

The expanding operational windows of the advanced gas turbine components demand increasing performance capability from protective coating systems. This demand has led to the development of novel multi-functional, multi-materials coating system architectures over the last years. In addition, the increasing dependency of components exposed to extreme environment on protective coatings results in more severe penalties, in case of a coating system failure. This emphasizes that reliability and consistency of protective coating systems are equally important to their superior performance. By means of examples, this paper describes the effects of scatter in the material properties resulting from manufacturing variations on coating life predictions. A strong foundation in process-property-performance correlations as well as regular monitoring and control of the coating process is essential for robust and well-controlled coating process. Proprietary and/or commercially available diagnostic tools can help in achieving these goals, but their usage in industrial setting is still limited. Various key contributors to process variability are briefly discussed along with the limitations of existing process and product control methods. Other aspects that are important for product reliability and consistency in serial manufacturing as well as advanced testing methodologies to simplify and enhance product inspection and improve objectivity are briefly described.

Study of Out-Time on the Processing and Properties of IM7/977-3 Composites

NASA Technical Reports Server (NTRS)

Miller, Sandi G.; Sutter, James K.; Scheiman, Daniel A.; Maryanski, Michael; Schlea, Michelle

2010-01-01

The capability to manufacture large structures leads to weight savings and reduced risk relative to joining smaller components. However, manufacture of increasingly large composite components is pushing the out-life limits of epoxy/ carbon fiber prepreg. IM7/977-3 is an autoclave processable prepreg material, commonly used in aerospace structures. The out-life limit is reported as 30 days by the manufacturer. The purpose of this work was to evaluate the material processability and composite properties of 977-3 resin and IM7/977-3 prepreg that had been aged at room temperature for up to 60 days. The neat resin was evaluated by differential scanning calorimetry, DSC, to characterize cure behavior of the aged material, as well as any change in activation energy. The rise in the modulus of the uncured prepreg was monitored throughout the 60 days by dynamic mechanical analysis, DMA. Composite panels made of the fresh and aged prepreg material were also characterized by DMA. The overall test results suggested that IM7/977-3 was a robust material that offered quality laminates throughout this aging process when processed by autoclave.

Out-Life Characteristics of IM7/977-3 Composites

NASA Technical Reports Server (NTRS)

Miller, Sandi G.; Sutter, James K.; Hou, Tan-Hung; Scheiman, Daniel A.; Martin, Richard E.; Maryanski, Michael; Schlea, Michelle; Gardner, John M.; Schiferl, Zack R.

2010-01-01

The capability to manufacture large structures leads to weight savings and reduced risk relative to joining smaller components. However, manufacture of increasingly large composite components is pushing the out-time limits of epoxy/ carbon fiber prepreg. IM7/977-3 is an autoclave processable prepreg material, commonly used in aerospace structures. The out-time limit is reported as 30 days by the manufacturer. The purpose of this work was to evaluate the material processability and composite properties of 977-3 resin and IM7/977-3 prepreg that had been aged at room temperature for up to 60 days. The effects of room temperature aging on the thermal and visco-elastic properties of the materials were investigated. Neat resin was evaluated by differential scanning calorimetry to characterize thermal properties and change in activation energy of cure. Neat resin was also evaluated by rheometry to characterize its processability in composite fabrication. IM7/977-3 prepreg was evaluated by dynamic mechanical analysis to characterize the curing behavior. Prepreg tack was also evaluated over 60 days. The overall test results suggested that IM7/977-3 was a robust material that offered quality laminates throughout this aging process when processed by autoclave.

Capabilities of the Materials Contamination Team at Marshall Space Flight Center

NASA Technical Reports Server (NTRS)

Burns, H. D.; Finckenor, M. M.; Boothe, R. E.; Albyn, K. C.; Finchum, C. A.

2003-01-01

The Materials Contamination Team of the Environmental Effects Group, Materials, Processes, and Manufacturing Department, has been recognized for its contribution to space flight, including space transportation, space science and flight projects, such as the reusable solid rocket motor, Chandra X-Ray Observatory, and the International Space Station. The Materials Contamination Team s realm of responsibility encompasses all phases of hardware development including design, manufacturing, assembly, test, transportation, launch-site processing, on-orbit exposure, return, and refurbishment if required. Contamination is a concern in the Space Shuttle with sensitivity bondlines and reactive fluid (liquid oxygen) compatibility as well as for sensitive optics, particularly spacecraft such as Hubble Space Telescope and Chandra X-Ray Observatory. The Materials Contamination Team has a variety of facilities and instrumentation capable of contaminant detection identification, and monitoring. The team addresses material applications dealing with environments, including production facilities, clean rooms, and on-orbit exposure. The team of engineers and technicians also develop and evaluates new surface cleanliness inspection technologies. Databases are maintained by the team for proces! materials as well as outgassing and optical compatibility test results for specific environments.

Feasibility and Testing of Additive Manufactured Components

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

Dehoff, Ryan R.; Hummelt, Ed; Solovyeva, Lyudmila

2016-09-01

This project focused on demonstrating the ability to fabricate two parts with different geometry: an arc flash interrupter and a hydraulic manifold. Eaton Corporation provided ORNL solid models, information related to tolerances and sensitive parameters of the parts and provided testing and evaluation. ORNL successfully manufactured both components, provided cost models of the manufacturing (materials, labor, time and post processing) and delivered test components for Eaton evaluation. The arc flash suppressor was fabricated using the Renishaw laser powder bed technology in CoCrMo while the manifold was produced from Ti-6Al-4V using the Arcam electron beam melting technology. These manufacturing techniques weremore » selected based on the design and geometrical tolerances required. A full-scale manifold was produced on the Arcam A2 system (nearly 12 inches tall). A portion of the manifold was also produced in the Arcam Q10 system. Although a full scale manifold could not be produced in the system, a full scale manifold is expected to have similar material properties, geometric accuracy, and surface finish as could be fabricated on an Arcam Q20 system that is capable of producing four full scale manifolds in a production environment. In addition to the manifold, mechanical test specimens, geometric tolerance artifacts, and microstructure samples were produced alongside the manifold. The development and demonstration of these two key components helped Eaton understand the impact additive manufacturing can have on many of their existing products. By working within the MDF and leveraging ORNL’s manufacturing and characterization capabilities, the work will ensure the rapid insertion and commercialization of this technology.« less

Laser processing of ceramics for microelectronics manufacturing

NASA Astrophysics Data System (ADS)

Sposili, Robert S.; Bovatsek, James; Patel, Rajesh

2017-03-01

Ceramic materials are used extensively in the microelectronics, semiconductor, and LED lighting industries because of their electrically insulating and thermally conductive properties, as well as for their high-temperature-service capabilities. However, their brittleness presents significant challenges for conventional machining processes. In this paper we report on a series of experiments that demonstrate and characterize the efficacy of pulsed nanosecond UV and green lasers in machining ceramics commonly used in microelectronics manufacturing, such as aluminum oxide (alumina) and aluminum nitride. With a series of laser pocket milling experiments, fundamental volume ablation rate and ablation efficiency data were generated. In addition, techniques for various industrial machining processes, such as shallow scribing and deep scribing, were developed and demonstrated. We demonstrate that lasers with higher average powers offer higher processing rates with the one exception of deep scribes in aluminum nitride, where a lower average power but higher pulse energy source outperformed a higher average power laser.

Using Powder Cored Tubular Wire Technology to Enhance Electron Beam Freeform Fabricated Structures

NASA Technical Reports Server (NTRS)

Gonzales, Devon; Liu, Stephen; Domack, Marcia; Hafley, Robert

2016-01-01

Electron Beam Freeform Fabrication (EBF3) is an additive manufacturing technique, developed at NASA Langley Research Center, capable of fabricating large scale aerospace parts. Advantages of using EBF3 as opposed to conventional manufacturing methods include, decreased design-to-product time, decreased wasted material, and the ability to adapt controls to produce geometrically complex parts with properties comparable to wrought products. However, to fully exploit the potential of the EBF3 process development of materials tailored for the process is required. Powder cored tubular wire (PCTW) technology was used to modify Ti-6Al-4V and Al 6061 feedstock to enhance alloy content, refine grain size, and create a metal matrix composite in the as-solidified structures, respectively.

Additive Manufacturing and 3D Printing in NASA: An Overview of Current Projects and Future Initiatives for Space Exploration

NASA Technical Reports Server (NTRS)

Clinton, R. G., Jr.

2014-01-01

NASA, including each Mission Directorate, is investing in, experimenting with, and/or utilizing AM across a broad spectrum of applications and projects; Centers have created and are continuing to create partnerships with industry, other Government Agencies, other Centers, and Universities; In-house additive manufacturing capability enables rapid iteration of the entire design, development and testing process, increasing innovation and reducing risk and cost to projects; For deep space exploration, AM offers significant reduction to logistics costs and risk by providing ability to create on demand; There are challenges: Overwhelming message from recent JANNAF AM for Propulsion Applications TIM was "certification."; NASA will continue to work with our partners to address this and other challenges to advance the state of the art in AM and incorporate these capabilities into an array of applications from aerospace to science missions to deep space exploration.

Pressure sensitivity analysis of fiber Bragg grating sensors

NASA Astrophysics Data System (ADS)

Mrad, Nezih; Sridharan, Vasant; Kazemi, Alex

2014-09-01

Recent development in fiber optic sensing technology has mainly focused on discrete sensing, particularly, sensing systems with potential multiplexing and multi-parameter capabilities. Bragg grating fiber optic sensors have emerged as the non-disputed champion for multiplexing and simultaneous multi-parameter sensing for emerging high value structural components, advanced processing and manufacturing capabilities and increased critical infrastructure resilience applications. Although the number of potential applications for this sensing technology is large and spans the domains of medicine, manufacturing, aerospace, and public safety; critical issues such as fatigue life, sensitivity, accuracy, embeddability, material/sensor interface integrity, and universal demodulation systems still need to be addressed. The purpose of this paper is to primarily evaluate Commercial-Of-The-Shelf (COTS) Fiber Bragg Grating (FBG) sensors' sensitivity to pressure, often neglected in several applications. The COTS fiber sensitivity to pressure is further evaluated for two types of coatings (Polyimide and Acrylate), and different arrangements (arrayed and single).

Selective Laser Sintering of Porous Silica Enabled by Carbon Additive

PubMed Central

Chang, Shuai; Li, Liqun; Lu, Li

2017-01-01

The aim of this study is to investigate the possibility of a freeform fabrication of porous ceramic parts through selective laser sintering (SLS). SLS was proposed to manufacture ceramic green parts because this additive manufacturing technique can be used to fabricate three-dimensional objects directly without a mold, and the technique has the capability of generating porous ceramics with controlled porosity. However, ceramic printing has not yet fully achieved its 3D fabrication capabilities without using polymer binder. Except for the limitations of high melting point, brittleness, and low thermal shock resistance from ceramic material properties, the key obstacle lies in the very poor absorptivity of oxide ceramics to fiber laser, which is widely installed in commercial SLS equipment. An alternative solution to overcome the poor laser absorptivity via improving material compositions is presented in this study. The positive effect of carbon additive on the absorptivity of silica powder to fiber laser is discussed. To investigate the capabilities of the SLS process, 3D porous silica structures were successfully prepared and characterized. PMID:29144425

Replicating systems concepts: Self-replicating lunar factory and demonstration

NASA Technical Reports Server (NTRS)

1982-01-01

Automation of lunar mining and manufacturing facility maintenance and repair is addressed. Designing the factory as an automated, multiproduct, remotely controlled, reprogrammable Lunar Manufacturing Facility capable of constructing duplicates of itself which would themselves be capable of further replication is proposed.

[Fusion implants of carbon fiber reinforced plastic].

PubMed

Früh, H J; Liebetrau, A; Bertagnoli, R

2002-05-01

Carbon fiber reinforced plastics (CFRP) are used in the medical field when high mechanical strength, innovative design, and radiolucency (see spinal fusion implants) are needed. During the manufacturing process of the material CFRP carbon fibers are embedded into a resin matrix. This resin material could be thermoset (e.g., epoxy resin EPN/DDS) or thermoplastic (e.g., PEAK). CFRP is biocompatible, radiolucent, and has higher mechanical capabilities compared to other implant materials. This publication demonstrates the manufacturing process of fusion implants made of a thermoset matrix system using a fiber winding process. The material has been used clinically since 1994 for fusion implants of the cervical and lumbar spine. The results of the fusion systems CORNERSTONE-SR C (cervical) and UNION (lumbar) showed no implant-related complications. New implant systems made of this CFRP material are under investigation and are presented.

Perspectives on the manufacture of combination vaccines.

PubMed

Vose, J R

2001-12-15

Evolving regulatory requirements in the United States and Europe create major challenges for manufacturers tasked with production of vaccines that contain > or =9 separate antigens capable of protecting against infectious diseases, such as diphtheria, tetanus, pertussis, polio, hepatitis B, and Haemophilus influenza b, in a single shot. This article describes 10 steps that can facilitate the process of licensing these complex vaccines. It also points out problems associated with the use of animal tests for the crucial step of potency testing for batch release caused by the inherent variability of such tests and the difficulties of interpreting their results.

Using Laser Ultrasound to Detect Subsurface Defects in Metal Laser Powder Bed Fusion Components

NASA Astrophysics Data System (ADS)

Everton, Sarah; Dickens, Phill; Tuck, Chris; Dutton, Ben

2018-03-01

Laser powder bed fusion offers many advantages over conventional manufacturing methods, such as the integration of multiple parts that can result in significant weight-savings. The increased design freedom that layer-wise manufacture allows has also been seen to enhance component performance at little or no added cost. For such benefits to be realized, however, the material quality must first be assured. Laser ultrasonic testing is a noncontact inspection technique that has been proposed as suitable for in situ monitoring of metal additive manufacturing processes. This article explores the current capability of this technique to detect manufactured, subsurface defects in Ti-6Al-4V samples, ex situ. The results are compared with x-ray computed tomography reconstructions and focus variation microscopy. Although laser ultrasound has been used to identify material discontinuities, further work is required before this technique could be implemented in situ.

Atmospheric Release Advisory Capability Pilot Project at Two Nuclear Power Plants and Associated State Offices of Emergency Preparedness.

DTIC Science & Technology

1983-01-01

assumes any legal liability or responsibility for the accuracy, comn- pleteness. or usefulness of any information, apparatus, product. or process ...disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial products, process , or service...by trade name, trademark, manufacturer, or otherwise, does not necessarily constitute or imply. its endorsement. recommendation, or favoring by the U

Practical Framework: Implementing OEE Method in Manufacturing Process Environment

NASA Astrophysics Data System (ADS)

Maideen, N. C.; Sahudin, S.; Mohd Yahya, N. H.; Norliawati, A. O.

2016-02-01

Manufacturing process environment requires reliable machineries in order to be able to satisfy the market demand. Ideally, a reliable machine is expected to be operated and produce a quality product at its maximum designed capability. However, due to some reason, the machine usually unable to achieved the desired performance. Since the performance will affect the productivity of the system, a measurement technique should be applied. Overall Equipment Effectiveness (OEE) is a good method to measure the performance of the machine. The reliable result produced from OEE can then be used to propose a suitable corrective action. There are a lot of published paper mentioned about the purpose and benefit of OEE that covers what and why factors. However, the how factor not yet been revealed especially the implementation of OEE in manufacturing process environment. Thus, this paper presents a practical framework to implement OEE and a case study has been discussed to explain in detail each steps proposed. The proposed framework is beneficial to the engineer especially the beginner to start measure their machine performance and later improve the performance of the machine.

Laser micromachining of biofactory-on-a-chip devices

NASA Astrophysics Data System (ADS)

Burt, Julian P.; Goater, Andrew D.; Hayden, Christopher J.; Tame, John A.

2002-06-01

Excimer laser micromachining provides a flexible means for the manufacture and rapid prototyping of miniaturized systems such as Biofactory-on-a-Chip devices. Biofactories are miniaturized diagnostic devices capable of characterizing, manipulating, separating and sorting suspension of particles such as biological cells. Such systems operate by exploiting the electrical properties of microparticles and controlling particle movement in AC non- uniform stationary and moving electric fields. Applications of Biofactory devices are diverse and include, among others, the healthcare, pharmaceutical, chemical processing, environmental monitoring and food diagnostic markets. To achieve such characterization and separation, Biofactory devices employ laboratory-on-a-chip type components such as complex multilayer microelectrode arrays, microfluidic channels, manifold systems and on-chip detection systems. Here we discuss the manufacturing requirements of Biofactory devices and describe the use of different excimer laser micromachined methods both in stand-alone processes and also in conjunction with conventional fabrication processes such as photolithography and thermal molding. Particular attention is given to the production of large area multilayer microelectrode arrays and the manufacture of complex cross-section microfluidic channel systems for use in simple distribution and device interfacing.

Additive Manufacturing of Hierarchical Multi-Phase High-Entropy Alloys for Nuclear Component

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

Li, Nan

In recent years, high entropy alloys (HEAs), composed of four or more metallic elements mixed in equal or near equal atomic percent, have attracted significant attention due to their excellent mechanical properties and good corrosion resistance. They show significant promise as candidates for high temperature fission and fusion structural applications. However, the conventional synthesis methods are unlikely to present an industrially suitable route for the production and use of HEAs. Recognizing rapidly evolving additive manufacturing (AM) techniques, the goal of this proposal is to optimize the AM process to fabricate HEAs with predesigned chemical compositions and phase morphologies for nuclearmore » components. For this project, two HEAs FeCrNiMn and FeCrNiMnAl have been successfully synthesized. Correlated mechanical response has been systematically characterized under a variety of laser processing and ion irradiations. Both high entropy alloys are found to present comparable swelling and extraordinary irradiation tolerance (limited voids and stabilized phase structure under high irradiation dose). In addition, the microstructure and radiation-induced hardening can be tailored by laser processing under additive manufacturing. And we have assembled at LANL a unique database of HEAs containing a total of 674 compositions with Phase Stability information. Based on this, the machine learning and Artificial Intelligence capability now are established to predict the microstructure of casted HEAs by given chemical compositions. This unique integration will lead to an optimal AM recipe for fabricating radiation tolerant HEAs. The development of both modeling models and experimental capability will also benefit other programs at LANL.« less

The Effect of Ultrasonic Additive Manufacturing on Integrated Printed Electronic Conductors

NASA Astrophysics Data System (ADS)

Bournias-Varotsis, Alkaios; Wang, Shanda; Hutt, David; Engstrøm, Daniel S.

2018-07-01

Ultrasonic additive manufacturing (UAM) is a low temperature manufacturing method capable of embedding printed electronics in metal components. The effect of UAM processing on the resistivity of conductive tracks printed with five different conductive pastes based on silver, copper or carbon flakes/particles in either a thermoplastic or thermoset filler binder are investigated. For all but the carbon-based paste, the resistivity changed linearly with the UAM energy input. After UAM processing, a resistivity increase of more than 150 times was recorded for the copper based thermoset paste. The silver based pastes showed a resistivity increase of between 1.1 and 50 times from their initial values. The carbon-based paste showed no change in resistivity after UAM processing. Focussed ion beam microstructure analysis of the printed conductive tracks before and after UAM processing showed that the silver particles and flakes in at least one of the pastes partly dislodged from their thermoset filler creating voids, thereby increasing the resistivity, whereas the silver flakes in a thermoplastic filler did not dislodge due to material flow of the polymer binder. The lowest resistivity (8 × 10-5 Ω cm) after UAM processing was achieved for a thermoplastic paste with silver flakes at low UAM processing energy.

In Situ Fringe Projection Profilometry for Laser Power Bed Fusion Process

NASA Astrophysics Data System (ADS)

Zhang, Bin

Additive manufacturing (AM) offers an industrial solution to produce parts with complex geometries and internal structures that conventional manufacturing techniques cannot produce. However, current metal additive process, particularly the laser powder bed fusion (LPBF) process, suffers from poor surface finish and various material defects which hinder its wide applications. One way to solve this problem is by adding in situ metrology sensor onto the machine chamber. Matured manufacturing processes are tightly monitored and controlled, and instrumentation advances are needed to realize this same advantage for metal additive process. This encourages us to develop an in situ fringe projection system for the LPBF process. The development of such a system and the measurement capability are demonstrated in this dissertation. We show that this system can measure various powder bed signatures including powder layer variations, the average height drop between fused metal and unfused powder, and the height variations on the fused surfaces. The ability to measure textured surface is also evaluated through the instrument transfer function (ITF). We analyze the mathematical model of the proposed fringe projection system, and prove the linearity of the system through simulations. A practical ITF measurement technique using a stepped surface is also demonstrated. The measurement results are compared with theoretical predictions generated through the ITF simulations.

The Effect of Ultrasonic Additive Manufacturing on Integrated Printed Electronic Conductors

NASA Astrophysics Data System (ADS)

Bournias-Varotsis, Alkaios; Wang, Shanda; Hutt, David; Engstrøm, Daniel S.

2018-03-01

Ultrasonic additive manufacturing (UAM) is a low temperature manufacturing method capable of embedding printed electronics in metal components. The effect of UAM processing on the resistivity of conductive tracks printed with five different conductive pastes based on silver, copper or carbon flakes/particles in either a thermoplastic or thermoset filler binder are investigated. For all but the carbon-based paste, the resistivity changed linearly with the UAM energy input. After UAM processing, a resistivity increase of more than 150 times was recorded for the copper based thermoset paste. The silver based pastes showed a resistivity increase of between 1.1 and 50 times from their initial values. The carbon-based paste showed no change in resistivity after UAM processing. Focussed ion beam microstructure analysis of the printed conductive tracks before and after UAM processing showed that the silver particles and flakes in at least one of the pastes partly dislodged from their thermoset filler creating voids, thereby increasing the resistivity, whereas the silver flakes in a thermoplastic filler did not dislodge due to material flow of the polymer binder. The lowest resistivity (8 × 10-5 Ω cm) after UAM processing was achieved for a thermoplastic paste with silver flakes at low UAM processing energy.

Electro-deposition painting process improvement of cab truck by Six Sigma concept

NASA Astrophysics Data System (ADS)

Kawitu, Kitiya; Chutima, Parames

2017-06-01

The case study company is a manufacturer of trucks and currently facing a high rework cost due to the thickness of the electro-deposited paint (EDP) of the truck cab is lower than standard. In addition, the process capability is very low. The Six Sigma concept consisting of 5 phases (DMAIC) is applied to determine new parameter settings for each significant controllable factor. After the improvement, EDP thickness of the truck cab increases from 17.88μ to 20μ (i.e. standard = 20 ± 3μ). Moreover, the process capability indexes (Cp and Cpk) are increased from 0.9 to 1.43, and from 0.27 to 1.43, respectively. This improvement could save the rework cost about 1.6M THB per year.

Indirect Fabrication of Lattice Metals with Thin Sections Using Centrifugal Casting

PubMed Central

Mun, Jiwon; Ju, Jaehyung; Thurman, James

2016-01-01

One of the typical methods to manufacture 3D lattice metals is the direct-metal additive manufacturing (AM) process such as Selective Laser Melting (SLM) and Electron Beam Melting (EBM). In spite of its potential processing capability, the direct AM method has several disadvantages such as high cost, poor surface finish of final products, limitation in material selection, high thermal stress, and anisotropic properties of parts. We propose a cost-effective method to manufacture 3D lattice metals. The objective of this study is to provide a detailed protocol on fabrication of 3D lattice metals having a complex shape and a thin wall thickness; e.g., octet truss made of Al and Cu alloys having a unit cell length of 5 mm and a cell wall thickness of 0.5 mm. An overall experimental procedure is divided into eight sections: (a) 3D printing of sacrificial patterns (b) melt-out of support materials (c) removal of residue of support materials (d) pattern assembly (e) investment (f) burn-out of sacrificial patterns (g) centrifugal casting (h) post-processing for final products. The suggested indirect AM technique provides the potential to manufacture ultra-lightweight lattice metals; e.g., lattice structures with Al alloys. It appears that the process parameters should be properly controlled depending on materials and lattice geometry, observing the final products of octet truss metals by the indirect AM technique. PMID:27214495

Indirect Fabrication of Lattice Metals with Thin Sections Using Centrifugal Casting.

PubMed

Mun, Jiwon; Ju, Jaehyung; Thurman, James

2016-05-14

One of the typical methods to manufacture 3D lattice metals is the direct-metal additive manufacturing (AM) process such as Selective Laser Melting (SLM) and Electron Beam Melting (EBM). In spite of its potential processing capability, the direct AM method has several disadvantages such as high cost, poor surface finish of final products, limitation in material selection, high thermal stress, and anisotropic properties of parts. We propose a cost-effective method to manufacture 3D lattice metals. The objective of this study is to provide a detailed protocol on fabrication of 3D lattice metals having a complex shape and a thin wall thickness; e.g., octet truss made of Al and Cu alloys having a unit cell length of 5 mm and a cell wall thickness of 0.5 mm. An overall experimental procedure is divided into eight sections: (a) 3D printing of sacrificial patterns (b) melt-out of support materials (c) removal of residue of support materials (d) pattern assembly (e) investment (f) burn-out of sacrificial patterns (g) centrifugal casting (h) post-processing for final products. The suggested indirect AM technique provides the potential to manufacture ultra-lightweight lattice metals; e.g., lattice structures with Al alloys. It appears that the process parameters should be properly controlled depending on materials and lattice geometry, observing the final products of octet truss metals by the indirect AM technique.

Next Generation Loading System for Detonators and Primers

DTIC Science & Technology

Designed , fabricated and installed next generation tooling to provide additional manufacturing capabilities for new detonators and other small...prototype munitions on automated, semi-automated and manual machines. Lead design effort, procured and installed a primary explosive Drying Oven for a pilot...facility. Designed , fabricated and installed a Primary Explosives Waste Treatment System in a pilot environmental processing facility. Designed

Software System Architecture Modeling Methodology for Naval Gun Weapon Systems

DTIC Science & Technology

2010-12-01

Weapon System HAR Hazard Action Report HERO Hazards of Electromagnetic Radiation to Ordnance IOC Initial Operational Capability... radiation to ordnance ; and combinations therein. Equipment, systems, or procedures and processes whose malfunction would hazard the safe manufacturing...NDI Non-Development Item OPEVAL Operational Evaluation ORDALTS Ordnance Alterations O&SHA Operating and Support Hazard Analysis PDA

Performance Steel Castings

DTIC Science & Technology

2012-09-30

Development of Sand Properties 103 Advanced Modeling Dataset.. 105 High Strength Low Alloy (HSLA) Steels 107 Steel Casting and Engineering Support...to achieve the performance goals required for new systems. The dramatic reduction in weight and increase in capability will require high performance...for improved weapon system reliability. SFSA developed innovative casting design and manufacturing processes for high performance parts. SFSA is

Streamlining the Design-to-Build Transition with Build-Optimization Software Tools.

PubMed

Oberortner, Ernst; Cheng, Jan-Fang; Hillson, Nathan J; Deutsch, Samuel

2017-03-17

Scaling-up capabilities for the design, build, and test of synthetic biology constructs holds great promise for the development of new applications in fuels, chemical production, or cellular-behavior engineering. Construct design is an essential component in this process; however, not every designed DNA sequence can be readily manufactured, even using state-of-the-art DNA synthesis methods. Current biological computer-aided design and manufacture tools (bioCAD/CAM) do not adequately consider the limitations of DNA synthesis technologies when generating their outputs. Designed sequences that violate DNA synthesis constraints may require substantial sequence redesign or lead to price-premiums and temporal delays, which adversely impact the efficiency of the DNA manufacturing process. We have developed a suite of build-optimization software tools (BOOST) to streamline the design-build transition in synthetic biology engineering workflows. BOOST incorporates knowledge of DNA synthesis success determinants into the design process to output ready-to-build sequences, preempting the need for sequence redesign. The BOOST web application is available at https://boost.jgi.doe.gov and its Application Program Interfaces (API) enable integration into automated, customized DNA design processes. The herein presented results highlight the effectiveness of BOOST in reducing DNA synthesis costs and timelines.

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

Atomic layer deposition on polymer fibers and fabrics for multifunctional and electronic textiles

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

Brozena, Alexandra H.; Oldham, Christopher J.; Parsons, Gregory N., E-mail: gnp@ncsu.edu

Textile materials, including woven cotton, polymer knit fabrics, and synthetic nonwoven fiber mats, are being explored as low-cost, flexible, and light-weight platforms for wearable electronic sensing, communication, energy generation, and storage. The natural porosity and high surface area in textiles is also useful for new applications in environmental protection, chemical decontamination, pharmaceutical and chemical manufacturing, catalytic support, tissue regeneration, and others. These applications raise opportunities for new chemistries, chemical processes, biological coupling, and nanodevice systems that can readily combine with textile manufacturing to create new “multifunctional” fabrics. Atomic layer deposition (ALD) has a unique ability to form highly uniform andmore » conformal thin films at low processing temperature on nonuniform high aspect ratio surfaces. Recent research shows how ALD can coat, modify, and otherwise improve polymer fibers and textiles by incorporating new materials for viable electronic and other multifunctional capabilities. This article provides a current overview of the understanding of ALD coating and modification of textiles, including current capabilities and outstanding problems, with the goal of providing a starting point for further research and advances in this field. After a brief introduction to textile materials and current textile treatment methods, the authors discuss unique properties of ALD-coated textiles, followed by a review of recent electronic and multifunctional textiles that use ALD coatings either as direct functional components or as critical nucleation layers for active materials integration. The article concludes with possible future directions for ALD on textiles, including the challenges in materials, manufacturing, and manufacturing integration that must be overcome for ALD to reach its full potential in electronic and other emerging multifunctional textile systems.« less

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.

Out of bounds additive manufacturing

DOE PAGES

Holshouser, Chris; Newell, Clint; Palas, Sid; ...

2013-03-01

Lockheed Martin and Oak Ridge National Laboratory are working on an additive manufacturing system capable of manufacturing components measured not in terms of inches or feet, but multiple yards in all dimensions with the potential to manufacture parts that are completely unbounded in size.

CT-assisted agile manufacturing

NASA Astrophysics Data System (ADS)

Stanley, James H.; Yancey, Robert N.

1996-11-01

The next century will witness at least two great revolutions in the way goods are produced. First, workers will use the medium of virtual reality in all aspects of marketing, research, development, prototyping, manufacturing, sales and service. Second, market forces will drive manufacturing towards small-lot production and just-in-time delivery. Already, we can discern the merging of these megatrends into what some are calling agile manufacturing. Under this new paradigm, parts and processes will be designed and engineered within the mind of a computer, tooled and manufactured by the offspring of today's rapid prototyping equipment, and evaluated for performance and reliability by advanced nondestructive evaluation (NDE) techniques and sophisticated computational models. Computed tomography (CT) is the premier example of an NDE method suitable for future agile manufacturing activities. It is the only modality that provides convenient access to the full suite of engineering data that users will need to avail themselves of computer- aided design, computer-aided manufacturing, and computer- aided engineering capabilities, as well as newly emerging reverse engineering, rapid prototyping and solid freeform fabrication technologies. As such, CT is assured a central, utilitarian role in future industrial operations. An overview of this exciting future for industrial CT is presented.

Distributive Distillation Enabled by Microchannel Process Technology

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

Arora, Ravi

The application of microchannel technology for distributive distillation was studied to achieve the Grand Challenge goals of 25% energy savings and 10% return on investment. In Task 1, a detailed study was conducted and two distillation systems were identified that would meet the Grand Challenge goals if the microchannel distillation technology was used. Material and heat balance calculations were performed to develop process flow sheet designs for the two distillation systems in Task 2. The process designs were focused on two methods of integrating the microchannel technology 1) Integrating microchannel distillation to an existing conventional column, 2) Microchannel distillation formore » new plants. A design concept for a modular microchannel distillation unit was developed in Task 3. In Task 4, Ultrasonic Additive Machining (UAM) was evaluated as a manufacturing method for microchannel distillation units. However, it was found that a significant development work would be required to develop process parameters to use UAM for commercial distillation manufacturing. Two alternate manufacturing methods were explored. Both manufacturing approaches were experimentally tested to confirm their validity. The conceptual design of the microchannel distillation unit (Task 3) was combined with the manufacturing methods developed in Task 4 and flowsheet designs in Task 2 to estimate the cost of the microchannel distillation unit and this was compared to a conventional distillation column. The best results were for a methanol-water separation unit for the use in a biodiesel facility. For this application microchannel distillation was found to be more cost effective than conventional system and capable of meeting the DOE Grand Challenge performance requirements.« less

Using Additive Manufacturing to Print a CubeSat Propulsion System

NASA Technical Reports Server (NTRS)

Marshall, William M.; Zemba, Michael; Shemelya, Corey; Wicker, Ryan; Espalin, David; MacDonald, Eric; Keif, Craig; Kwas, Andrew

2015-01-01

Small satellites, such as CubeSats, are increasingly being called upon to perform missions traditionally ascribed to larger satellite systems. However, the market of components and hardware for small satellites, particularly CubeSats, still falls short of providing the necessary capabilities required by ever increasing mission demands. One way to overcome this shortfall is to develop the ability to customize every build. By utilizing fabrication methods such as additive manufacturing, mission specific capabilities can be built into a system, or into the structure, that commercial off-the-shelf components may not be able to provide. A partnership between the University of Texas at El Paso, COSMIAC at the University of New Mexico, Northrop Grumman, and the NASA Glenn Research Center is looking into using additive manufacturing techniques to build a complete CubeSat, under the Small Spacecraft Technology Program. The W. M. Keck Center at the University of Texas at El Paso has previously demonstrated the ability to embed electronics and wires into the addtively manufactured structures. Using this technique, features such as antennas and propulsion systems can be included into the CubeSat structural body. Of interest to this paper, the team is investigating the ability to take a commercial micro pulsed plasma thruster and embed it into the printing process. Tests demonstrating the dielectric strength of the printed material and proof-of-concept demonstration of the printed thruster will be shown.

Design of intelligent composites with life-cycle health management capabilities

NASA Astrophysics Data System (ADS)

Rosania, Colleen L.; Larrosa, Cecilia C.; Chang, Fu-Kuo

2015-03-01

Use of carbon fiber reinforced polymers (CFRPs) presents challenges because of their complex manufacturing processes and different damage mechanics in relation to legacy metal materials. New monitoring methods for manufacturing, quality verification, damage estimation, and prognosis are needed to use CFRPs safely and efficiently. This work evaluates the development of intelligent composite materials using integrated piezoelectric sensors to monitor the material during cure and throughout service life. These sensors are used to propagate ultrasonic waves through the structure for health monitoring. During manufacturing, data is collected at different stages during the cure cycle, detecting the changing material properties during cure and verifying quality and degree of cure. The same sensors can then be used with previously developed techniques to perform damage detection, such as impact detection and matrix crack density estimation. Real-time damage estimation can be combined with prognostic models to predict future propagation of damage in the material. In this work experimental results will be presented from composite coupons with embedded piezoelectric sensors. Cure monitoring and damage detection results derived from analysis of the ultrasonic sensor signal will be shown. Sensitive signal parameters to the different stimuli in both the time and frequency domains will be explored for this analysis. From these results, use of the same sensor networks from manufacturing throughout the life of the composite material will demonstrate the full life-cycle monitoring capability of these intelligent materials.

European display scene

NASA Astrophysics Data System (ADS)

Bartlett, Christopher T.

2000-08-01

The manufacture of Flat Panel Displays (FPDs) is dominated by Far Eastern sources, particularly in Active Matrix Liquid Crystal Displays (AMLCD) and Plasma. The United States has a very powerful capability in micro-displays. It is not well known that Europe has a very active research capability which has lead to many innovations in display technology. In addition there is a capability in display manufacturing of organic technologies as well as the licensed build of Japanese or Korean designs. Finally, Europe has a display systems capability in military products which is world class.

A novel microgrid demand-side management system for manufacturing facilities

NASA Astrophysics Data System (ADS)

Harper, Terance J.

Thirty-one percent of annual energy consumption in the United States occurs within the industrial sector, where manufacturing processes account for the largest amount of energy consumption and carbon emissions. For this reason, energy efficiency in manufacturing facilities is increasingly important for reducing operating costs and improving profits. Using microgrids to generate local sustainable power should reduce energy consumption from the main utility grid along with energy costs and carbon emissions. Also, microgrids have the potential to serve as reliable energy generators in international locations where the utility grid is often unstable. For this research, a manufacturing process that had approximately 20 kW of peak demand was matched with a solar photovoltaic array that had a peak output of approximately 3 KW. An innovative Demand-Side Management (DSM) strategy was developed to manage the process loads as part of this smart microgrid system. The DSM algorithm managed the intermittent nature of the microgrid and the instantaneous demand of the manufacturing process. The control algorithm required three input signals; one from the microgrid indicating the availability of renewable energy, another from the manufacturing process indicating energy use as a percent of peak production, and historical data for renewable sources and facility demand. Based on these inputs the algorithm had three modes of operation: normal (business as usual), curtailment (shutting off non-critical loads), and energy storage. The results show that a real-time management of a manufacturing process with a microgrid will reduce electrical consumption and peak demand. The renewable energy system for this research was rated to provide up to 13% of the total manufacturing capacity. With actively managing the process loads with the DSM program alone, electrical consumption from the utility grid was reduced by 17% on average. An additional 24% reduction was accomplished when the microgrid and DSM program was enabled together, resulting in a total reduction of 37%. On average, peak demand was reduced by 6%, but due to the intermittency of the renewable source and the billing structure for peak demand, only a 1% reduction was obtained. During a billing period, it only takes one day when solar irradiance is poor to affect the demand reduction capabilities. To achieve further demand reduction, energy storage should be introduced and integrated.

32 CFR 507.6 - Authority to manufacture.

Code of Federal Regulations, 2011 CFR

2011-07-01

... companies who have manufacturing capability and agree to manufacture heraldic items according to applicable... to the Army and Air Force Exchange Service and, upon request, to Army and Air Force commanders. ...

32 CFR 507.6 - Authority to manufacture.

Code of Federal Regulations, 2013 CFR

2013-07-01

... companies who have manufacturing capability and agree to manufacture heraldic items according to applicable... to the Army and Air Force Exchange Service and, upon request, to Army and Air Force commanders. ...

A novel scalable manufacturing process for the production of hydrogel-forming microneedle arrays.

PubMed

Lutton, Rebecca E M; Larrañeta, Eneko; Kearney, Mary-Carmel; Boyd, Peter; Woolfson, A David; Donnelly, Ryan F

2015-10-15

A novel manufacturing process for fabricating microneedle arrays (MN) has been designed and evaluated. The prototype is able to successfully produce 14×14 MN arrays and is easily capable of scale-up, enabling the transition from laboratory to industry and subsequent commercialisation. The method requires the custom design of metal MN master templates to produce silicone MN moulds using an injection moulding process. The MN arrays produced using this novel method was compared with centrifugation, the traditional method of producing aqueous hydrogel-forming MN arrays. The results proved that there was negligible difference between either methods, with each producing MN arrays with comparable quality. Both types of MN arrays can be successfully inserted in a skin simulant. In both cases the insertion depth was approximately 60% of the needle length and the height reduction after insertion was in both cases approximately 3%. Copyright © 2015 Elsevier B.V. All rights reserved.

Solar breeder: Energy payback time for silicon photovoltaic systems

NASA Technical Reports Server (NTRS)

Lindmayer, J.

1977-01-01

The energy expenditures of the prevailing manufacturing technology of terrestrial photovoltaic cells and panels were evaluated, including silicon reduction, silicon refinement, crystal growth, cell processing and panel building. Energy expenditures include direct energy, indirect energy, and energy in the form of equipment and overhead expenses. Payback times were development using a conventional solar cell as a test vehicle which allows for the comparison of its energy generating capability with the energies expended during the production process. It was found that the energy payback time for a typical solar panel produced by the prevailing technology is 6.4 years. Furthermore, this value drops to 3.8 years under more favorable conditions. Moreover, since the major energy use reductions in terrestrial manufacturing have occurred in cell processing, this payback time directly illustrates the areas where major future energy reductions can be made -- silicon refinement, crystal growth, and panel building.

Thin EFG octagons

NASA Astrophysics Data System (ADS)

Kalejs, J. P.

1994-03-01

This report describes work to advance the manufacturing line capabilities in crystal growth and laser cutting of Mobil Solar's unique edge-defined film-fed growth (EFG) octagon technology and to reduce the manufacturing costs of 10 cm x 10 cm polycrystalline silicon EFG wafers. The report summarizes the significant technical improvements in EFG technology achieved in the first 6 months of the PVMaT Phase 2 and the success in meeting program milestones. Technical results are reported for each of the three main pregrain areas: Task 5 -- Thin octagon growth (crystal growth) to reduce the thickness of the octagon to 200 microns; Task 6 -- Laser cutting-to improve the laser cutting process so as to produce wafers with decreased laser cutting damage at increased wafer throughput rates; and Task 7 -- Process control and product specification to implement advanced strategies in crystal growth process control and productivity designed to increase wafer yields.

A novel scalable manufacturing process for the production of hydrogel-forming microneedle arrays

PubMed Central

Lutton, Rebecca E.M.; Larrañeta, Eneko; Kearney, Mary-Carmel; Boyd, Peter; Woolfson, A.David; Donnelly, Ryan F.

2015-01-01

A novel manufacturing process for fabricating microneedle arrays (MN) has been designed and evaluated. The prototype is able to successfully produce 14 × 14 MN arrays and is easily capable of scale-up, enabling the transition from laboratory to industry and subsequent commercialisation. The method requires the custom design of metal MN master templates to produce silicone MN moulds using an injection moulding process. The MN arrays produced using this novel method was compared with centrifugation, the traditional method of producing aqueous hydrogel-forming MN arrays. The results proved that there was negligible difference between either methods, with each producing MN arrays with comparable quality. Both types of MN arrays can be successfully inserted in a skin simulant. In both cases the insertion depth was approximately 60% of the needle length and the height reduction after insertion was in both cases approximately 3%. PMID:26302858

Quantitative evaluation of manufacturability and performance for ILT produced mask shapes using a single-objective function

NASA Astrophysics Data System (ADS)

Choi, Heon; Wang, Wei-long; Kallingal, Chidam

2015-03-01

The continuous scaling of semiconductor devices is quickly outpacing the resolution improvements of lithographic exposure tools and processes. This one-sided progression has pushed optical lithography to its limits, resulting in the use of well-known techniques such as Sub-Resolution Assist Features (SRAF's), Source-Mask Optimization (SMO), and double-patterning, to name a few. These techniques, belonging to a larger category of Resolution Enhancement Techniques (RET), have extended the resolution capabilities of optical lithography at the cost of increasing mask complexity, and therefore cost. One such technique, called Inverse Lithography Technique (ILT), has attracted much attention for its ability to produce the best possible theoretical mask design. ILT treats the mask design process as an inverse problem, where the known transformation from mask to wafer is carried out backwards using a rigorous mathematical approach. One practical problem in the application of ILT is the resulting contour-like mask shapes that must be "Manhattanized" (composed of straight edges and 90-deg corners) in order to produce a manufacturable mask. This conversion process inherently degrades the mask quality as it is a departure from the "optimal mask" represented by the continuously curved shapes produced by ILT. However, simpler masks composed of longer straight edges reduce the mask cost as it lowers the shot count and saves mask writing time during mask fabrication, resulting in a conflict between manufacturability and performance for ILT produced masks1,2. In this study, various commonly used metrics will be combined into an objective function to produce a single number to quantitatively measure a particular ILT solution's ability to balance mask manufacturability and RET performance. Several metrics that relate to mask manufacturing costs (i.e. mask vertex count, ILT computation runtime) are appropriately weighted against metrics that represent RET capability (i.e. process-variation band, edge-placement-error) in order to reflect the desired practical balance. This well-defined scoring system allows direct comparison of several masks with varying degrees of complexities. Using this method, ILT masks produced with increasing mask constraints will be compared, and it will be demonstrated that using the smallest minimum width for mask shapes does not always produce the optimal solution.

Food equipment manufacturer takes a slice out of its scrap rate

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

Bernard, D.; Hannahs, J.; Carter, M.

1996-09-01

The PMI Food Equipment Group began manufacturing circular slicer knives for its commercial Hobart line of slicers in the early 1930s. The company manufacturers the only cast knife in the food industry. The cast knives offer superior edge retention and overall corrosion resistance. The slicer knives are cast in PMI`s foundry. The casting process sometimes produces shrinkage voids or gas bubbles in the knife blank. Surface discontinuities often do not appear until rough cutting or final machining, i.e., after several hours of value-added manufacturing. Knife blanks with these discontinuities were scrapped and sent back to the foundry for remelting. Tomore » scrap the knives at that point meant the cost for casting plus the value-added machining added up to a considerable amount. Weld repair allows the recovery of casting and machining expenses equal to a significant percentage of the total manufacturing cost of slicer knives. Repair costs include welding, grinding, shipping, surface finishing and material handling. Other good applications for this GMAW-P process include repair of jet engine components, rotating process industry equipment, and hardfacing of cutting tools and dies. In addition, dissimilar metals and any material that is heat treated to develop its properties such as precision investment castings are excellent applications. The low resultant distortion, elimination of postweld heat treatment and non-line-of-site welding capability solves thin wall, limited access and precision machined component repair challenges.« less

Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering

NASA Astrophysics Data System (ADS)

Yang, Nancy; Yee, J.; Zheng, B.; Gaiser, K.; Reynolds, T.; Clemon, L.; Lu, W. Y.; Schoenung, J. M.; Lavernia, E. J.

2017-04-01

We investigate the process-structure-property relationships for 316L stainless steel prototyping utilizing 3-D laser engineered net shaping (LENS), a commercial direct energy deposition additive manufacturing process. The study concluded that the resultant physical metallurgy of 3-D LENS 316L prototypes is dictated by the interactive metallurgical reactions, during instantaneous powder feeding/melting, molten metal flow and liquid metal solidification. The study also showed 3-D LENS manufacturing is capable of building high strength and ductile 316L prototypes due to its fine cellular spacing from fast solidification cooling, and the well-fused epitaxial interfaces at metal flow trails and interpass boundaries. However, without further LENS process control and optimization, the deposits are vulnerable to localized hardness variation attributed to heterogeneous microstructure, i.e., the interpass heat-affected zone (HAZ) from repetitive thermal heating during successive layer depositions. Most significantly, the current deposits exhibit anisotropic tensile behavior, i.e., lower strain and/or premature interpass delamination parallel to build direction (axial). This anisotropic behavior is attributed to the presence of interpass HAZ, which coexists with flying feedstock inclusions and porosity from incomplete molten metal fusion. The current observations and findings contribute to the scientific basis for future process control and optimization necessary for material property control and defect mitigation.

Making vaccines "on demand": a potential solution for emerging pathogens and biodefense?

PubMed

De Groot, Anne S; Einck, Leo; Moise, Leonard; Chambers, Michael; Ballantyne, John; Malone, Robert W; Ardito, Matthew; Martin, William

2013-09-01

The integrated US Public Health Emergency Medical Countermeasures Enterprise (PHEMCE) has made great strides in strategic preparedness and response capabilities. There have been numerous advances in planning, biothreat countermeasure development, licensure, manufacturing, stockpiling and deployment. Increased biodefense surveillance capability has dramatically improved, while new tools and increased awareness have fostered rapid identification of new potential public health pathogens. Unfortunately, structural delays in vaccine design, development, manufacture, clinical testing and licensure processes remain significant obstacles to an effective national biodefense rapid response capability. This is particularly true for the very real threat of "novel pathogens" such as the avian-origin influenzas H7N9 and H5N1, and new coronaviruses such as hCoV-EMC. Conventional approaches to vaccine development, production, clinical testing and licensure are incompatible with the prompt deployment needed for an effective public health response. An alternative approach, proposed here, is to apply computational vaccine design tools and rapid production technologies that now make it possible to engineer vaccines for novel emerging pathogen and WMD biowarfare agent countermeasures in record time. These new tools have the potential to significantly reduce the time needed to design string-of-epitope vaccines for previously unknown pathogens. The design process-from genome to gene sequence, ready to insert in a DNA plasmid-can now be accomplished in less than 24 h. While these vaccines are by no means "standard," the need for innovation in the vaccine design and production process is great. Should such vaccines be developed, their 60-d start-to-finish timeline would represent a 2-fold faster response than the current standard.

Orbital management and design considerations for NiCd satellite power systems

NASA Technical Reports Server (NTRS)

Tausch, Benjamin J., II

1994-01-01

Several recently manufactured 50 and 60 ampere hour aerospace NiCd battery cell lots, produced by Gates Aerospace Batteries, are prone to premature on orbit performance degradation. The failure mechanism is cadmium migration, and the consequent development of soft shorts. A Martin Marietta Astronautics satellite program instituted an orbital management strategy for a set of these batteries that reduced the rate of degradation and brought the system to stable operation. This strategy involves: (1) minimizing the accumulated battery overcharge; (2) regular discharge exercises; and (3) periodic battery reconditioning. Because of changes in the NiCd cell manufacturing process, the actual performance of subsequent lots of NiCd cells is open to question. Future NiCd based power system designs should therefore allow for fine control of charge parameters, and an on orbit battery reconditioning capability. To minimize risk, it is much better to perform a full life test to qualify the cells before launch, rather than in parallel with orbital operations. If there are any changes in the manufacturing process of cells, it is extremely important to maintain very strong cognizance of secondary subcontractors, recognizing that the cell and battery manufacturing discipline is easily atrophied.

Load-adaptive scaffold architecturing: a bioinspired approach to the design of porous additively manufactured scaffolds with optimized mechanical properties.

PubMed

Rainer, Alberto; Giannitelli, Sara M; Accoto, Dino; De Porcellinis, Stefano; Guglielmelli, Eugenio; Trombetta, Marcella

2012-04-01

Computer-Aided Tissue Engineering (CATE) is based on a set of additive manufacturing techniques for the fabrication of patient-specific scaffolds, with geometries obtained from medical imaging. One of the main issues regarding the application of CATE concerns the definition of the internal architecture of the fabricated scaffolds, which, in turn, influences their porosity and mechanical strength. The present study envisages an innovative strategy for the fabrication of highly optimized structures, based on the a priori finite element analysis (FEA) of the physiological load set at the implant site. The resulting scaffold micro-architecture does not follow a regular geometrical pattern; on the contrary, it is based on the results of a numerical study. The algorithm was applied to a solid free-form fabrication process, using poly(ε-caprolactone) as the starting material for the processing of additive manufactured structures. A simple and intuitive geometry was chosen as a proof-of-principle application, on which finite element simulations and mechanical testing were performed. Then, to demonstrate the capability in creating mechanically biomimetic structures, the proximal femur subjected to physiological loading conditions was considered and a construct fitting a femur head portion was designed and manufactured.

Integration of design and inspection

NASA Astrophysics Data System (ADS)

Simmonds, William H.

1990-08-01

Developments in advanced computer integrated manufacturing technology, coupled with the emphasis on Total Quality Management, are exposing needs for new techniques to integrate all functions from design through to support of the delivered product. One critical functional area that must be integrated into design is that embracing the measurement, inspection and test activities necessary for validation of the delivered product. This area is being tackled by a collaborative project supported by the UK Government Department of Trade and Industry. The project is aimed at developing techniques for analysing validation needs and for planning validation methods. Within the project an experimental Computer Aided Validation Expert system (CAVE) is being constructed. This operates with a generalised model of the validation process and helps with all design stages: specification of product requirements; analysis of the assurance provided by a proposed design and method of manufacture; development of the inspection and test strategy; and analysis of feedback data. The kernel of the system is a knowledge base containing knowledge of the manufacturing process capabilities and of the available inspection and test facilities. The CAVE system is being integrated into a real life advanced computer integrated manufacturing facility for demonstration and evaluation.

Injection and injection-compression moulding replication capability for the production of polymer lab-on-a-chip with nano structures

NASA Astrophysics Data System (ADS)

Calaon, M.; Tosello, G.; Garnaes, J.; Hansen, H. N.

2017-10-01

The manufacturing precision and accuracy in the production of polymer lab-on-a-chip components with 100-130 nm deep nanochannels are evaluated using a metrological approach. Replication fidelity on corresponding process fingerprint test nanostructures over different substrates (nickel tool and polymer part) is quantified through traceable atomic force microscope measurements. Dimensions of injection moulded (IM) and injection-compression moulded (ICM) thermoplastic cyclic olefin copolymer nanofeatures are characterized depending on process parameters and four different features positions on a 30  ×  80 mm2 area. Replication capability of IM and ICM technologies are quantified and the products tolerance at the nanometre dimensional scale verified.

Mask manufacturing improvement through capability definition and bottleneck line management

NASA Astrophysics Data System (ADS)

Strott, Al

1994-02-01

In 1989, Intel's internal mask operation limited itself to research and development activities and re-inspection and pellicle application of externally manufactured masks. Recognizing the rising capital cost of mask manufacturing at the leading edge, Intel's Mask Operation management decided to offset some of these costs by manufacturing more masks internally. This was the beginning of the challenge they set to manufacture at least 50% of Intel's mask volume internally, at world class performance levels. The first step in responding to this challenge was the completion of a comprehensive operation capability analysis. A series of bottleneck improvements by focus teams resulted in an average cycle time improvement to less than five days on all product and less than two days on critical products.

Planning for the semiconductor manufacturer of the future

NASA Technical Reports Server (NTRS)

Fargher, Hugh E.; Smith, Richard A.

1992-01-01

Texas Instruments (TI) is currently contracted by the Air Force Wright Laboratory and the Defense Advanced Research Projects Agency (DARPA) to develop the next generation flexible semiconductor wafer fabrication system called Microelectronics Manufacturing Science & Technology (MMST). Several revolutionary concepts are being pioneered on MMST, including the following: new single-wafer rapid thermal processes, in-situ sensors, cluster equipment, and advanced Computer Integrated Manufacturing (CIM) software. The objective of the project is to develop a manufacturing system capable of achieving an order of magnitude improvement in almost all aspects of wafer fabrication. TI was awarded the contract in Oct., 1988, and will complete development with a fabrication facility demonstration in April, 1993. An important part of MMST is development of the CIM environment responsible for coordinating all parts of the system. The CIM architecture being developed is based on a distributed object oriented framework made of several cooperating subsystems. The software subsystems include the following: process control for dynamic control of factory processes; modular processing system for controlling the processing equipment; generic equipment model which provides an interface between processing equipment and the rest of the factory; specification system which maintains factory documents and product specifications; simulator for modelling the factory for analysis purposes; scheduler for scheduling work on the factory floor; and the planner for planning and monitoring of orders within the factory. This paper first outlines the division of responsibility between the planner, scheduler, and simulator subsystems. It then describes the approach to incremental planning and the way in which uncertainty is modelled within the plan representation. Finally, current status and initial results are described.

76 FR 785 - Notice of Nationwide Waiver of Section 1605 (Buy American Requirement) of the American Recovery...

Federal Register 2010, 2011, 2012, 2013, 2014

2011-01-06

... manufacturer with manufacturing capability in the U.S., who does not manufacture nor intend to manufacture VHS... production facilities in the U.S. to manufacture VHS electric motors in sizes less than 40 HP. While EPA did... waiver based on new developments or changes in the domestic manufacturing capacity for these items. DATES...

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

Measurement Science for Prognostics and Health Management for Smart Manufacturing Systems: Key Findings from a Roadmapping Workshop

PubMed Central

Weiss, Brian A.; Vogl, Gregory; Helu, Moneer; Qiao, Guixiu; Pellegrino, Joan; Justiniano, Mauricio; Raghunathan, Anand

2017-01-01

The National Institute of Standards and Technology (NIST) hosted the Roadmapping Workshop – Measurement Science for Prognostics and Health Management for Smart Manufacturing Systems (PHM4SMS) in Fall 2014 to discuss the needs and priorities of stakeholders in the PHM4SMS technology area. The workshop brought together over 70 members of the PHM community. The attendees included representatives from small, medium, and large manufacturers; technology developers and integrators; academic researchers; government organizations; trade associations; and standards bodies. The attendees discussed the current and anticipated measurement science challenges to advance PHM methods and techniques for smart manufacturing systems; the associated research and development needed to implement condition monitoring, diagnostic, and prognostic technologies within manufacturing environments; and the priorities to meet the needs of PHM in manufacturing. This paper will summarize the key findings of this workshop, and present some of the critical measurement science challenges and corresponding roadmaps, i.e., suggested courses of action, to advance PHM for manufacturing. Milestones and targeted capabilities will be presented for each roadmap across three areas: PHM Manufacturing Process Techniques; PHM Performance Assessment; and PHM Infrastructure – Hardware, Software, and Integration. An analysis of these roadmaps and crosscutting themes seen across the breakout sessions is also discussed. PMID:28664163

Design and development of a layer-based additive manufacturing process for the realization of metal parts of designed mesostructure

NASA Astrophysics Data System (ADS)

Williams, Christopher Bryant

Low-density cellular materials, metallic bodies with gaseous voids, are a unique class of materials that are characterized by their high strength, low mass, good energy absorption characteristics, and good thermal and acoustic insulation properties. In an effort to take advantage of this entire suite of positive mechanical traits, designers are tailoring the cellular mesostructure for multiple design objectives. Unfortunately, existing cellular material manufacturing technologies limit the design space as they are limited to certain part mesostructure, material type, and macrostructure. The opportunity that exists to improve the design of existing products, and the ability to reap the benefits of cellular materials in new applications is the driving force behind this research. As such, the primary research goal of this work is to design, embody, and analyze a manufacturing process that provides a designer the ability to specify the material type, material composition, void morphology, and mesostructure topology for any conceivable part geometry. The accomplishment of this goal is achieved in three phases of research: (1) Design---Following a systematic design process and a rigorous selection exercise, a layer-based additive manufacturing process is designed that is capable of meeting the unique requirements of fabricating cellular material geometry. Specifically, metal parts of designed mesostructure are fabricated via three-dimensional printing of metal oxide ceramic powder followed by post-processing in a reducing atmosphere. (2) Embodiment ---The primary research hypothesis is verified through the use of the designed manufacturing process chain to successfully realize metal parts of designed mesostructure. (3) Modeling & Evaluation ---The designed manufacturing process is modeled in this final research phase so as to increase understanding of experimental results and to establish a foundation for future analytical modeling research. In addition to an analysis of the physics of primitive creation and an investigation of failure modes during the layered fabrication of thin trusses, build time and cost models are presented in order to verify claims of the process's economic benefits. The main contribution of this research is the embodiment of a novel manner for realizing metal parts of designed mesostructure.

Surface Modeling, Solid Modeling and Finite Element Modeling. Analysis Capabilities of Computer-Assisted Design and Manufacturing Systems.

ERIC Educational Resources Information Center

Nee, John G.; Kare, Audhut P.

1987-01-01

Explores several concepts in computer assisted design/computer assisted manufacturing (CAD/CAM). Defines, evaluates, reviews and compares advanced computer-aided geometric modeling and analysis techniques. Presents the results of a survey to establish the capabilities of minicomputer based-systems with the CAD/CAM packages evaluated. (CW)

Encapsulation Processing and Manufacturing Yield Analysis

NASA Technical Reports Server (NTRS)

Willis, P.

1985-01-01

Evaluation of the ethyl vinyl acetate (EVA) encapsulation system is presented. This work is part of the materials baseline needed to demonstrate a 30 year module lifetime capability. Process and compound variables are both being studied along with various module materials. Results have shown that EVA should be stored rolled up, and enclosed in a plastic bag to retard loss of peroxide curing agents. The TBEC curing agent has superior shelf life and processing than the earlier Lupersol-101 curing agent. Analytical methods were developed to test for peroxide content, and experimental methodologies were formalized.

Microgravity

NASA Image and Video Library

1998-09-30

Dr. Jan Rogers (left) and Larry Savage (foreground) of the Science Directorate at NASA's Marshall Space Flight Center (MSFC) are joined by Dr. Richard Weber (center) and April Hixon of Containerless Research Inc. of Evanston, Ill., in conducting an experiment run of the Electrostatic Levitator (ESL) using insulating materials. Materials researchers use unique capabilities of the facility to levitate and study the properties of various materials important in manufacturing processes.

Materials and processing approaches for foundry-compatible transient electronics.

PubMed

Chang, Jan-Kai; Fang, Hui; Bower, Christopher A; Song, Enming; Yu, Xinge; Rogers, John A

2017-07-11

Foundry-based routes to transient silicon electronic devices have the potential to serve as the manufacturing basis for "green" electronic devices, biodegradable implants, hardware secure data storage systems, and unrecoverable remote devices. This article introduces materials and processing approaches that enable state-of-the-art silicon complementary metal-oxide-semiconductor (CMOS) foundries to be leveraged for high-performance, water-soluble forms of electronics. The key elements are ( i ) collections of biodegradable electronic materials (e.g., silicon, tungsten, silicon nitride, silicon dioxide) and device architectures that are compatible with manufacturing procedures currently used in the integrated circuit industry, ( ii ) release schemes and transfer printing methods for integration of multiple ultrathin components formed in this way onto biodegradable polymer substrates, and ( iii ) planarization and metallization techniques to yield interconnected and fully functional systems. Various CMOS devices and circuit elements created in this fashion and detailed measurements of their electrical characteristics highlight the capabilities. Accelerated dissolution studies in aqueous environments reveal the chemical kinetics associated with the underlying transient behaviors. The results demonstrate the technical feasibility for using foundry-based routes to sophisticated forms of transient electronic devices, with functional capabilities and cost structures that could support diverse applications in the biomedical, military, industrial, and consumer industries.

SIERRA Multimechanics Module: Aria User Manual Version 4.44

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

Sierra Thermal /Fluid Team

2017-04-01

Aria is a Galerkin fnite element based program for solving coupled-physics problems described by systems of PDEs and is capable of solving nonlinear, implicit, transient and direct-to-steady state problems in two and three dimensions on parallel architectures. The suite of physics currently supported by Aria includes thermal energy transport, species transport, and electrostatics as well as generalized scalar, vector and tensor transport equations. Additionally, Aria includes support for manufacturing process fows via the incompressible Navier-Stokes equations specialized to a low Reynolds number ( %3C 1 ) regime. Enhanced modeling support of manufacturing processing is made possible through use of eithermore » arbitrary Lagrangian- Eulerian (ALE) and level set based free and moving boundary tracking in conjunction with quasi-static nonlinear elastic solid mechanics for mesh control. Coupled physics problems are solved in several ways including fully-coupled Newton's method with analytic or numerical sensitivities, fully-coupled Newton- Krylov methods and a loosely-coupled nonlinear iteration about subsets of the system that are solved using combinations of the aforementioned methods. Error estimation, uniform and dynamic h -adaptivity and dynamic load balancing are some of Aria's more advanced capabilities. Aria is based upon the Sierra Framework.« less

Materials and processing approaches for foundry-compatible transient electronics

NASA Astrophysics Data System (ADS)

Chang, Jan-Kai; Fang, Hui; Bower, Christopher A.; Song, Enming; Yu, Xinge; Rogers, John A.

2017-07-01

Foundry-based routes to transient silicon electronic devices have the potential to serve as the manufacturing basis for “green” electronic devices, biodegradable implants, hardware secure data storage systems, and unrecoverable remote devices. This article introduces materials and processing approaches that enable state-of-the-art silicon complementary metal-oxide-semiconductor (CMOS) foundries to be leveraged for high-performance, water-soluble forms of electronics. The key elements are (i) collections of biodegradable electronic materials (e.g., silicon, tungsten, silicon nitride, silicon dioxide) and device architectures that are compatible with manufacturing procedures currently used in the integrated circuit industry, (ii) release schemes and transfer printing methods for integration of multiple ultrathin components formed in this way onto biodegradable polymer substrates, and (iii) planarization and metallization techniques to yield interconnected and fully functional systems. Various CMOS devices and circuit elements created in this fashion and detailed measurements of their electrical characteristics highlight the capabilities. Accelerated dissolution studies in aqueous environments reveal the chemical kinetics associated with the underlying transient behaviors. The results demonstrate the technical feasibility for using foundry-based routes to sophisticated forms of transient electronic devices, with functional capabilities and cost structures that could support diverse applications in the biomedical, military, industrial, and consumer industries.

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

Sierra Thermal/Fluid Team

Aria is a Galerkin fnite element based program for solving coupled-physics problems described by systems of PDEs and is capable of solving nonlinear, implicit, transient and direct-to-steady state problems in two and three dimensions on parallel architectures. The suite of physics currently supported by Aria includes thermal energy transport, species transport, and electrostatics as well as generalized scalar, vector and tensor transport equations. Additionally, Aria includes support for manufacturing process fows via the incompressible Navier-Stokes equations specialized to a low Reynolds number ( %3C 1 ) regime. Enhanced modeling support of manufacturing processing is made possible through use of eithermore » arbitrary Lagrangian- Eulerian (ALE) and level set based free and moving boundary tracking in conjunction with quasi-static nonlinear elastic solid mechanics for mesh control. Coupled physics problems are solved in several ways including fully-coupled Newton's method with analytic or numerical sensitivities, fully-coupled Newton- Krylov methods and a loosely-coupled nonlinear iteration about subsets of the system that are solved using combinations of the aforementioned methods. Error estimation, uniform and dynamic h -adaptivity and dynamic load balancing are some of Aria's more advanced capabilities. Aria is based upon the Sierra Framework.« less

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

Sierra Thermal /Fluid Team

Aria is a Galerkin finite element based program for solving coupled-physics problems described by systems of PDEs and is capable of solving nonlinear, implicit, transient and direct-to-steady state problems in two and three dimensions on parallel architectures. The suite of physics currently supported by Aria includes thermal energy transport, species transport, and electrostatics as well as generalized scalar, vector and tensor transport equations. Additionally, Aria includes support for manufacturing process flows via the incompressible Navier-Stokes equations specialized to a low Reynolds number (Re %3C 1) regime. Enhanced modeling support of manufacturing processing is made possible through use of either arbitrarymore » Lagrangian- Eulerian (ALE) and level set based free and moving boundary tracking in conjunction with quasi-static nonlinear elastic solid mechanics for mesh control. Coupled physics problems are solved in several ways including fully-coupled Newton's method with analytic or numerical sensitivities, fully-coupled Newton- Krylov methods and a loosely-coupled nonlinear iteration about subsets of the system that are solved using combinations of the aforementioned methods. Error estimation, uniform and dynamic h-adaptivity and dynamic load balancing are some of Aria's more advanced capabilities. Aria is based upon the Sierra Framework.« less

The need for artificial intelligence as an aid in controlling a manufacturing operation

NASA Astrophysics Data System (ADS)

Weyand, J.

AI applications to industrial production and planning are discussed and illustrated with diagrams and drawings. Applications examined include flexible automation of manufacturing processes (robots with open manual control, robots programmable to meet product specifications, self-regulated robots, and robots capable of learning), flexible fault detection and diagnostics, production control, and overall planning and management (product strategies, marketing, determination of development capacity, site selection, project organization, and technology investment strategies). For the case of robots, problems in the design and operation of a state-of-the-art machine-tool cell (for hole boring, milling, and joining) are analyzed in detail.

SDIO Producibility and Manufacturing Intelligent Processing Programs

NASA Technical Reports Server (NTRS)

Stottlemyer, Greg

1992-01-01

SDIO has to fashion a comprehensive strategy to insert the capability of an industrial base into ongoing design tradeoffs. This means that there is not only a need to determine if something can be made to the precision needed to meet system performance, but also what changes need to be made in that industry sector to develop a deterministic approach to fabrication precision components. Developing and introducing advanced production and quality control systems is part of this success. To address this situation, SDIO has developed the MODIL (Manufacturing Operations Development and Integration Labs) program. MODILs were developed into three areas: Survivable Optics, Electronics and Sensors, and Spacecraft Fabrication and Test.

3D Systems' Technology Overview and New Applications in Manufacturing, Engineering, Science, and Education

PubMed Central

Andrews, Mike; Weislogel, Mark; Moeck, Peter; Stone-Sundberg, Jennifer; Birkes, Derek; Hoffert, Madeline Paige; Lindeman, Adam; Morrill, Jeff; Fercak, Ondrej; Friedman, Sasha; Gunderson, Jeff; Ha, Anh; McCollister, Jack; Chen, Yongkang; Geile, John; Wollman, Andrew; Attari, Babak; Botnen, Nathan; Vuppuluri, Vasant; Shim, Jennifer; Kaminsky, Werner; Adams, Dustin; Graft, John

2014-01-01

Abstract Since the inception of 3D printing, an evolutionary process has taken place in which specific user and customer needs have crossed paths with the capabilities of a growing number of machines to create value-added businesses. Even today, over 30 years later, the growth of 3D printing and its utilization for the good of society is often limited by the various users' understanding of the technology for their specific needs. This article presents an overview of current 3D printing technologies and shows numerous examples from a multitude of fields from manufacturing to education. PMID:28473997

Predictive Simulation of Process Windows for Powder Bed Fusion Additive Manufacturing: Influence of the Powder Bulk Density.

PubMed

Rausch, Alexander M; Küng, Vera E; Pobel, Christoph; Markl, Matthias; Körner, Carolin

2017-09-22

The resulting properties of parts fabricated by powder bed fusion additive manufacturing processes are determined by their porosity, local composition, and microstructure. The objective of this work is to examine the influence of the stochastic powder bed on the process window for dense parts by means of numerical simulation. The investigations demonstrate the unique capability of simulating macroscopic domains in the range of millimeters with a mesoscopic approach, which resolves the powder bed and the hydrodynamics of the melt pool. A simulated process window reveals the influence of the stochastic powder layer. The numerical results are verified with an experimental process window for selective electron beam-melted Ti-6Al-4V. Furthermore, the influence of the powder bulk density is investigated numerically. The simulations predict an increase in porosity and surface roughness for samples produced with lower powder bulk densities. Due to its higher probability for unfavorable powder arrangements, the process stability is also decreased. This shrinks the actual parameter range in a process window for producing dense parts.

Predictive Simulation of Process Windows for Powder Bed Fusion Additive Manufacturing: Influence of the Powder Bulk Density

PubMed Central

Rausch, Alexander M.; Küng, Vera E.; Pobel, Christoph; Körner, Carolin

2017-01-01

The resulting properties of parts fabricated by powder bed fusion additive manufacturing processes are determined by their porosity, local composition, and microstructure. The objective of this work is to examine the influence of the stochastic powder bed on the process window for dense parts by means of numerical simulation. The investigations demonstrate the unique capability of simulating macroscopic domains in the range of millimeters with a mesoscopic approach, which resolves the powder bed and the hydrodynamics of the melt pool. A simulated process window reveals the influence of the stochastic powder layer. The numerical results are verified with an experimental process window for selective electron beam-melted Ti-6Al-4V. Furthermore, the influence of the powder bulk density is investigated numerically. The simulations predict an increase in porosity and surface roughness for samples produced with lower powder bulk densities. Due to its higher probability for unfavorable powder arrangements, the process stability is also decreased. This shrinks the actual parameter range in a process window for producing dense parts. PMID:28937633

Adapting viral safety assurance strategies to continuous processing of biological products.

PubMed

Johnson, Sarah A; Brown, Matthew R; Lute, Scott C; Brorson, Kurt A

2017-01-01

There has been a recent drive in commercial large-scale production of biotechnology products to convert current batch mode processing to continuous processing manufacturing. There have been reports of model systems capable of adapting and linking upstream and downstream technologies into a continuous manufacturing pipeline. However, in many of these proposed continuous processing model systems, viral safety has not been comprehensively addressed. Viral safety and detection is a highly important and often expensive regulatory requirement for any new biological product. To ensure success in the adaption of continuous processing to large-scale production, there is a need to consider the development of approaches that allow for seamless incorporation of viral testing and clearance/inactivation methods. In this review, we outline potential strategies to apply current viral testing and clearance/inactivation technologies to continuous processing, as well as modifications of existing unit operations to ensure the successful integration of viral clearance into the continuous processing of biological products. Biotechnol. Bioeng. 2017;114: 21-32. © 2016 Wiley Periodicals, Inc. © 2016 Wiley Periodicals, Inc.

The Factory of the Future

NASA Technical Reports Server (NTRS)

Byman, J. E.

1985-01-01

A brief history of aircraft production techniques is given. A flexible machining cell is then described. It is a computer controlled system capable of performing 4-axis machining part cleaning, dimensional inspection and materials handling functions in an unmanned environment. The cell was designed to: allow processing of similar and dissimilar parts in random order without disrupting production; allow serial (one-shipset-at-a-time) manufacturing; reduce work-in-process inventory; maximize machine utilization through remote set-up; maximize throughput and minimize labor.

Structure Property Studies for Additively Manufactured Parts

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

Milenski, Helen M; Schmalzer, Andrew Michael; Kelly, Daniel

2015-08-17

Since the invention of modern Additive Manufacturing (AM) processes engineers and designers have worked hard to capitalize on the unique building capabilities that AM allows. By being able to customize the interior fill of parts it is now possible to design components with a controlled density and customized internal structure. The creation of new polymers and polymer composites allow for even greater control over the mechanical properties of AM parts. One of the key reasons to explore AM, is to bring about a new paradigm in part design, where materials can be strategically optimized in a way that conventional subtractivemore » methods cannot achieve. The two processes investigated in my research were the Fused Deposition Modeling (FDM) process and the Direct Ink Write (DIW) process. The objectives of the research were to determine the impact of in-fill density and morphology on the mechanical properties of FDM parts, and to determine if DIW printed samples could be produced where the filament diameter was varied while the overall density remained constant.« less

Performance Optimization Control of ECH using Fuzzy Inference Application

NASA Astrophysics Data System (ADS)

Dubey, Abhay Kumar

Electro-chemical honing (ECH) is a hybrid electrolytic precision micro-finishing technology that, by combining physico-chemical actions of electro-chemical machining and conventional honing processes, provides the controlled functional surfaces-generation and fast material removal capabilities in a single operation. Process multi-performance optimization has become vital for utilizing full potential of manufacturing processes to meet the challenging requirements being placed on the surface quality, size, tolerances and production rate of engineering components in this globally competitive scenario. This paper presents an strategy that integrates the Taguchi matrix experimental design, analysis of variances and fuzzy inference system (FIS) to formulate a robust practical multi-performance optimization methodology for complex manufacturing processes like ECH, which involve several control variables. Two methodologies one using a genetic algorithm tuning of FIS (GA-tuned FIS) and another using an adaptive network based fuzzy inference system (ANFIS) have been evaluated for a multi-performance optimization case study of ECH. The actual experimental results confirm their potential for a wide range of machining conditions employed in ECH.

The importance of basic factors in innovation processes and their effects on innovation capability of Malaysian-owned manufacturing companies

NASA Astrophysics Data System (ADS)

Suradi, Nur Riza Mohd; Omar, Aminuddin; Shahabuddin, Faridatulazna Ahmad

2015-02-01

Innovation is the core ingredient in the competitiveness of today's businesses. Any company that cannot innovate will be losing its competitiveness. While the study on innovation at conceptual level is widely available, there is still lack of deep understanding of how innovation factors impact each stage of the processes of innovation that happen in Malaysian companies. This process-factor approach and understanding may help the government focuses its assistance on relevant factors at relevant process according to the size of the company. This study examines how companies are affected by fundamental factors needed in innovation. Based on results of MYTIC Study 2012 on the level of Technological Innovation Capability (TIC) of Malaysian companies using the RDCB framework, the significance of each innovation factor in each innovation process is determined. This study shows that human resource factor gives more impact than other factors in most processes. Also, financial and human resource factors are likely dictated by the size of the company.

Argon-oxygen atmospheric pressure plasma treatment on carbon fiber reinforced polymer for improved bonding

NASA Astrophysics Data System (ADS)

Chartosias, Marios

Acceptance of Carbon Fiber Reinforced Polymer (CFRP) structures requires a robust surface preparation method with improved process controls capable of ensuring high bond quality. Surface preparation in a production clean room environment prior to applying adhesive for bonding would minimize risk of contamination and reduce cost. Plasma treatment is a robust surface preparation process capable of being applied in a production clean room environment with process parameters that are easily controlled and documented. Repeatable and consistent processing is enabled through the development of a process parameter window utilizing techniques such as Design of Experiments (DOE) tailored to specific adhesive and substrate bonding applications. Insight from respective plasma treatment Original Equipment Manufacturers (OEMs) and screening tests determined critical process factors from non-factors and set the associated factor levels prior to execution of the DOE. Results from mode I Double Cantilever Beam (DCB) testing per ASTM D 5528 [1] standard and DOE statistical analysis software are used to produce a regression model and determine appropriate optimum settings for each factor.

Advanced Continuous Flow Platform for On-Demand Pharmaceutical Manufacturing.

PubMed

Zhang, Ping; Weeranoppanant, Nopphon; Thomas, Dale A; Tahara, Kohei; Stelzer, Torsten; Russell, Mary Grace; O'Mahony, Marcus; Myerson, Allan S; Lin, Hongkun; Kelly, Liam P; Jensen, Klavs F; Jamison, Timothy F; Dai, Chunhui; Cui, Yuqing; Briggs, Naomi; Beingessner, Rachel L; Adamo, Andrea

2018-02-21

As a demonstration of an alternative to the challenges faced with batch pharmaceutical manufacturing including the large production footprint and lengthy time-scale, we previously reported a refrigerator-sized continuous flow system for the on-demand production of essential medicines. Building on this technology, herein we report a second-generation, reconfigurable and 25 % smaller (by volume) continuous flow pharmaceutical manufacturing platform featuring advances in reaction and purification equipment. Consisting of two compact [0.7 (L)×0.5 (D)×1.3 m (H)] stand-alone units for synthesis and purification/formulation processes, the capabilities of this automated system are demonstrated with the synthesis of nicardipine hydrochloride and the production of concentrated liquid doses of ciprofloxacin hydrochloride, neostigmine methylsulfate and rufinamide that meet US Pharmacopeia standards. © 2018 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim.

Selective Laser Melting: a regular unit cell approach for the manufacture of porous, titanium, bone in-growth constructs, suitable for orthopedic applications.

PubMed

Mullen, Lewis; Stamp, Robin C; Brooks, Wesley K; Jones, Eric; Sutcliffe, Christopher J

2009-05-01

In this study, a novel porous titanium structure for the purpose of bone in-growth has been designed, manufactured and evaluated. The structure was produced by Selective Laser Melting (SLM); a rapid manufacturing process capable of producing highly intricate, functionally graded parts. The technique described utilizes an approach based on a defined regular unit cell to design and produce structures with a large range of both physical and mechanical properties. These properties can be tailored to suit specific requirements; in particular, functionally graded structures with bone in-growth surfaces exhibiting properties comparable to those of human bone have been manufactured. The structures were manufactured and characterized by unit cell size, strand diameter, porosity, and compression strength. They exhibited a porosity (10-95%) dependant compression strength (0.5-350 Mpa) comparable to the typical naturally occurring range. It is also demonstrated that optimized structures have been produced that possesses ideal qualities for bone in-growth applications and that these structures can be applied in the production of orthopedic devices. (c) 2008 Wiley Periodicals, Inc.

The scope of additive manufacturing in cryogenics, component design, and applications

NASA Astrophysics Data System (ADS)

Stautner, W.; Vanapalli, S.; Weiss, K.-P.; Chen, R.; Amm, K.; Budesheim, E.; Ricci, J.

2017-12-01

Additive manufacturing techniques using composites or metals are rapidly gaining momentum in cryogenic applications. Small or large, complex structural components are now no longer limited to mere design studies but can now move into the production stream thanks to new machines on the market that allow for light-weight, cost optimized designs with short turnaround times. The potential for cost reductions from bulk materials machined to tight tolerances has become obvious. Furthermore, additive manufacturing opens doors and design space for cryogenic components that to date did not exist or were not possible in the past, using bulk materials along with elaborate and expensive machining processes, e.g. micromachining. The cryogenic engineer now faces the challenge to design toward those new additive manufacturing capabilities. Additionally, re-thinking designs toward cost optimization and fast implementation also requires detailed knowledge of mechanical and thermal properties at cryogenic temperatures. In the following we compile the information available to date and show a possible roadmap for additive manufacturing applications of parts and components typically used in cryogenic engineering designs.

Six Sigma methods applied to cryogenic coolers assembly line

NASA Astrophysics Data System (ADS)

Ventre, Jean-Marc; Germain-Lacour, Michel; Martin, Jean-Yves; Cauquil, Jean-Marc; Benschop, Tonny; Griot, René

2009-05-01

Six Sigma method have been applied to manufacturing process of a rotary Stirling cooler: RM2. Name of the project is NoVa as main goal of the Six Sigma approach is to reduce variability (No Variability). Project has been based on the DMAIC guideline following five stages: Define, Measure, Analyse, Improve, Control. Objective has been set on the rate of coolers succeeding performance at first attempt with a goal value of 95%. A team has been gathered involving people and skills acting on the RM2 manufacturing line. Measurement System Analysis (MSA) has been applied to test bench and results after R&R gage show that measurement is one of the root cause for variability in RM2 process. Two more root causes have been identified by the team after process mapping analysis: regenerator filling factor and cleaning procedure. Causes for measurement variability have been identified and eradicated as shown by new results from R&R gage. Experimental results show that regenerator filling factor impacts process variability and affects yield. Improved process haven been set after new calibration process for test bench, new filling procedure for regenerator and an additional cleaning stage have been implemented. The objective for 95% coolers succeeding performance test at first attempt has been reached and kept for a significant period. RM2 manufacturing process is now managed according to Statistical Process Control based on control charts. Improvement in process capability have enabled introduction of sample testing procedure before delivery.

Additively Manufactured, Net Shape Powder Metallurgy Cans for Valves Used in Energy Production

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

Peter, William H.; Gandy, David; Lannom, Robert

This CRADA NFE-14-05241 was conducted as a Technical Collaboration project within the Oak Ridge National Laboratory (ORNL) Manufacturing Demonstration Facility (MDF) sponsored by the US Department of Energy Advanced Manufacturing Office (CPS Agreement Number 24761). Opportunities for MDF technical collaborations are listed in the announcement “Manufacturing Demonstration Facility Technology Collaborations for US Manufacturers in Advanced Manufacturing and Materials Technologies” posted at http://web.ornl.gov/sci/manufacturing/docs/FBO-ORNL-MDF-2013-2.pdf. The goal of technical collaborations is to engage industry partners to participate in short-term, collaborative projects within the Manufacturing Demonstration Facility (MDF) to assess applicability and of new energy efficient manufacturing technologies. Research sponsored by the U.S. Departmentmore » of Energy, Office of Energy Efficiency and Renewable Energy, Advanced Manufacturing Office, under contract DE-AC05-00OR22725 with UT-Battelle, LLC.ORNL would like to acknowledge the leadership of EPRI in pulling together the extensive team and managing the execution of the project. In addition, ORNL would like to acknowledge the other contributions of the team members associated with this project. Quintus provided time, access, expertise, and labor of their hydro forming capabilities to evaluate both conventional and additively manufactured tools through this process. Crane ChemPharma Energy provided guidance and information on valve geometries. Carpenter Powder Products was involved with the team providing information on powder processing as it pertains to the canning and hot isostatic pressing of powder. on providing powder and knowledge as it pertains to powder supply for hot isostatic pressing; they also provided powder for the test trials by the industrial team. Bodycote provided guidance on hot isostatic pressing and can requirements. They were also responsible for the hot isostatic pressing of the test valve performed by the industrial team.« less

Design, fabrication and delivery of a miniature Cassegrainian concentrator solar array system

NASA Technical Reports Server (NTRS)

Kruer, Mark A.

1987-01-01

The optical design of the miniature Cassegrainian concentrator (MCC) element was improved for both offpoint and onpoint power capability. The cell stack design has shown no losses under the high short term thermal stresses imposed by component level test and is projected to be capable of greater than five years thermal cycle life in low Earth orbit. The structural design met all requirements for stiffness and flatness and requires adjustable inserts for fine tuning of the GFRP structure to meet flatness goals. The completed, fully populated small and large MCC panels deliverable under this contract perform electrically as expected. A solid acceptance inspection program to guarantee quality of all purchased parts, and continued manufacturing process improvements will make the MCC design a viable low cost alternative to standard flat panel technology. Minor improvements to the cell stack design of the MCC element can make significant improvements in both the performance and manufacturability of the MCC system.

3D printing of soft robotic systems

NASA Astrophysics Data System (ADS)

Wallin, T. J.; Pikul, J.; Shepherd, R. F.

2018-06-01

Soft robots are capable of mimicking the complex motion of animals. Soft robotic systems are defined by their compliance, which allows for continuous and often responsive localized deformation. These features make soft robots especially interesting for integration with human tissues, for example, the implementation of biomedical devices, and for robotic performance in harsh or uncertain environments, for example, exploration in confined spaces or locomotion on uneven terrain. Advances in soft materials and additive manufacturing technologies have enabled the design of soft robots with sophisticated capabilities, such as jumping, complex 3D movements, gripping and releasing. In this Review, we examine the essential soft material properties for different elements of soft robots, highlighting the most relevant polymer systems. Advantages and limitations of different additive manufacturing processes, including 3D printing, fused deposition modelling, direct ink writing, selective laser sintering, inkjet printing and stereolithography, are discussed, and the different techniques are investigated for their application in soft robotic fabrication. Finally, we explore integrated robotic systems and give an outlook for the future of the field and remaining challenges.

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.

Multivariate statistical process control in product quality review assessment - A case study.

PubMed

Kharbach, M; Cherrah, Y; Vander Heyden, Y; Bouklouze, A

2017-11-01

According to the Food and Drug Administration and the European Good Manufacturing Practices (GMP) guidelines, Annual Product Review (APR) is a mandatory requirement in GMP. It consists of evaluating a large collection of qualitative or quantitative data in order to verify the consistency of an existing process. According to the Code of Federal Regulation Part 11 (21 CFR 211.180), all finished products should be reviewed annually for the quality standards to determine the need of any change in specification or manufacturing of drug products. Conventional Statistical Process Control (SPC) evaluates the pharmaceutical production process by examining only the effect of a single factor at the time using a Shewhart's chart. It neglects to take into account the interaction between the variables. In order to overcome this issue, Multivariate Statistical Process Control (MSPC) can be used. Our case study concerns an APR assessment, where 164 historical batches containing six active ingredients, manufactured in Morocco, were collected during one year. Each batch has been checked by assaying the six active ingredients by High Performance Liquid Chromatography according to European Pharmacopoeia monographs. The data matrix was evaluated both by SPC and MSPC. The SPC indicated that all batches are under control, while the MSPC, based on Principal Component Analysis (PCA), for the data being either autoscaled or robust scaled, showed four and seven batches, respectively, out of the Hotelling T 2 95% ellipse. Also, an improvement of the capability of the process is observed without the most extreme batches. The MSPC can be used for monitoring subtle changes in the manufacturing process during an APR assessment. Copyright © 2017 Académie Nationale de Pharmacie. Published by Elsevier Masson SAS. All rights reserved.

Integrated continuous processing of proteins expressed as inclusion bodies: GCSF as a case study.

PubMed

Kateja, Nikhil; Agarwal, Harshit; Hebbi, Vishwanath; Rathore, Anurag S

2017-07-01

Affordability of biopharmaceuticals continues to be a challenge, particularly in developing economies. This has fuelled advancements in manufacturing that can offer higher productivity and better economics without sacrificing product quality in the form of an integrated continuous manufacturing platform. While platform processes for monoclonal antibodies have existed for more than a decade, development of an integrated continuous manufacturing process for bacterial proteins has received relatively scant attention. In this study, we propose an end-to-end integrated continuous downstream process (from inclusion bodies to unformulated drug substance) for a therapeutic protein expressed in Escherichia coli as inclusion body. The final process consisted of a continuous refolding in a coiled flow inverter reactor directly coupled to a three-column periodic counter-current chromatography for capture of the product followed by a three-column con-current chromatography for polishing. The continuous bioprocessing train was run uninterrupted for 26 h to demonstrate its capability and the resulting output was analyzed for the various critical quality attributes, namely product purity (>99%), high molecular weight impurities (<0.5%), host cell proteins (<100 ppm), and host cell DNA (<10 ppb). All attributes were found to be consistent over the period of operation. The developed assembly offers smaller facility footprint, higher productivity, fewer hold steps, and significantly higher equipment and resin utilization. The complexities of process integration in the context of continuous processing have been highlighted. We hope that the study presented here will promote development of highly efficient, universal, end-to-end, fully continuous platforms for manufacturing of biotherapeutics. © 2016 American Institute of Chemical Engineers Biotechnol. Prog., 33:998-1009, 2017. © 2016 American Institute of Chemical Engineers.

Investigation into the use of microwave sensors to monitor particulate manufacturing processes

NASA Astrophysics Data System (ADS)

Austin, John Samuel, III

Knowledge of a material's properties in-line during manufacture is of critical importance to many industries, including the pharmaceutical industry, and can be used for either process or quality control. Different microwave sensor configurations were tested to determine both the moisture content and the bulk density in pharmaceutical powders during processing on-line. Although these parameters can significantly affect a material's flowability, compressibility, and cohesivity, in the presence of blends, the picture is incomplete. Due to the ease with which particulate blends tend to segregate, blend uniformity and chemical composition are two critical parameters in nearly all solids manufacturing industries. The prevailing wisdom has been that microwave sensors are not capable of or sensitive enough to measure the relative concentrations of components in a blend. Consequently, it is common to turn to near infrared sensing to determine material composition on-line. In this study, a novel microwave sensor was designed and utilized to determine, separately, the concentrations of different components in a blend of pharmaceutical powders. This custom microwave sensor was shown to have comparable accuracy to the state-of-the-art for both chemical composition and moisture content determination.

High speed micromachining with high power UV laser

NASA Astrophysics Data System (ADS)

Patel, Rajesh S.; Bovatsek, James M.

2013-03-01

Increasing demand for creating fine features with high accuracy in manufacturing of electronic mobile devices has fueled growth for lasers in manufacturing. High power, high repetition rate ultraviolet (UV) lasers provide an opportunity to implement a cost effective high quality, high throughput micromachining process in a 24/7 manufacturing environment. The energy available per pulse and the pulse repetition frequency (PRF) of diode pumped solid state (DPSS) nanosecond UV lasers have increased steadily over the years. Efficient use of the available energy from a laser is important to generate accurate fine features at a high speed with high quality. To achieve maximum material removal and minimal thermal damage for any laser micromachining application, use of the optimal process parameters including energy density or fluence (J/cm2), pulse width, and repetition rate is important. In this study we present a new high power, high PRF QuasarR 355-40 laser from Spectra-Physics with TimeShiftTM technology for unique software adjustable pulse width, pulse splitting, and pulse shaping capabilities. The benefits of these features for micromachining include improved throughput and quality. Specific example and results of silicon scribing are described to demonstrate the processing benefits of the Quasar's available power, PRF, and TimeShift technology.

Exploring Competencies for Manufacturing Education Partnership Centers

ERIC Educational Resources Information Center

Chapman, Diane D.; Guerdat, Kate G.

2012-01-01

The National Institute of Standards and Technology's Hollings Manufacturing Extension Partnership works with U.S. manufacturers to help them create and retain jobs, increase profits, and save time and money. Members of the Manufacturing Extension Partnership recognized the need to expand capacity and capabilities of their network to address the…

Opportunities for Collaboration at the Interface of Pharmacovigilance and Manufacturing.

PubMed

Beninger, Paul

2017-04-01

A case can be made that much common ground exists between pharmacovigilance and pharmaceutical manufacturing. Of the 8 major US statutes that shaped the pharmaceutical industry since early in the 20th Century, 7 followed fatally catastrophic events related to the use of a manufactured product, and 1 followed the discovery of a counterfeit product. To facilitate an understanding of the interplay between pharmacovigilance and manufacturing, it is convenient to divide manufacturing into 3 categories: (1) upstream sourcing of materials: pharmacovigilance plays an important role when adverse event clusters are seen during routine vigilance detection processes and the suspicion turns to possibly contaminated source material, (2) the manufacturing process itself: pharmacovigilance may be called on to conduct a health hazard evaluation if a manufacturing deviation is detected after product release (the assessment can inform the depth of a recall), and (3) downstream distribution and product use: there is only light regulation of the interval between product distribution after manufacturing release and just before administration to patients, a time during which product may be subject to an out-of-specification determination for environmental controls or subject to malfeasant activities, such as counterfeit substitution or product diversion. Recently introduced statutory remedies, including the FDA Safety and Innovation Act and the Drug Supply Chain Security Act in the United States and the Falsified Medicines Directive (directive 2011/62/EC) in the European Union, can provide capabilities to support pharmacovigilance signal management activities that have the potential to reduce the risk to patients of experiencing adverse events caused by counterfeit, diverted, or tampered product. Copyright © 2017 Elsevier HS Journals, Inc. All rights reserved.

Additive-manufactured sandwich lattice structures: A numerical and experimental investigation

NASA Astrophysics Data System (ADS)

Fergani, Omar; Tronvoll, Sigmund; Brøtan, Vegard; Welo, Torgeir; Sørby, Knut

2017-10-01

The utilization of additive-manufactured lattice structures in engineered products is becoming more and more common as the competitiveness of AM as a production technology has increased during the past several years. Lattice structures may enable important weight reductions as well as open opportunities to build products with customized functional properties, thanks to the flexibility of AM for producing complex geometrical configurations. One of the most critical aspects related to taking AM into new application areas—such as safety critical products—is currently the limited understanding of the mechanical behavior of sandwich-based lattice structure mechanical under static and dynamic loading. In this study, we evaluate manufacturability of lattice structures and the impact of AM processing parameters on the structural behavior of this type of sandwich structures. For this purpose, we conducted static compression testing for a variety of geometry and manufacturing parameters. Further, the study discusses a numerical model capable of predicting the behavior of different lattice structure. A reasonably good correlation between the experimental and numerical results was observed.

Production Process of Biocompatible Magnesium Alloy Tubes Using Extrusion and Dieless Drawing Processes

NASA Astrophysics Data System (ADS)

Kustra, Piotr; Milenin, Andrij; Płonka, Bartłomiej; Furushima, Tsuyoshi

2016-06-01

Development of technological production process of biocompatible magnesium tubes for medical applications is the subject of the present paper. The technology consists of two stages—extrusion and dieless drawing process, respectively. Mg alloys for medical applications such as MgCa0.8 are characterized by low technological plasticity during deformation that is why optimization of production parameters is necessary to obtain good quality product. Thus, authors developed yield stress and ductility model for the investigated Mg alloy and then used the numerical simulations to evaluate proper manufacturing conditions. Grid Extrusion3d software developed by authors was used to determine optimum process parameters for extrusion—billet temperature 400 °C and extrusion velocity 1 mm/s. Based on those parameters the tube with external diameter 5 mm without defects was manufactured. Then, commercial Abaqus software was used for modeling dieless drawing. It was shown that the reduction in the area of 60% can be realized for MgCa0.8 magnesium alloy. Tubes with the final diameter of 3 mm were selected as a case study, to present capabilities of proposed processes.

Unintended Consequences: How Qualification Constrains Innovation

NASA Technical Reports Server (NTRS)

Brice, Craig A.

2011-01-01

The development and implementation of new materials and manufacturing processes for aerospace application is often hindered by the high cost and long time span associated with current qualification procedures. The data requirements necessary for material and process qualification are extensive and often require millions of dollars and multiple years to complete. Furthermore, these qualification data can become obsolete for even minor changes to the processing route. This burden is a serious impediment to the pursuit of revolutionary new materials and more affordable processing methods for air vehicle structures. The application of integrated computational materials engineering methods to this problem can help to reduce the barriers to rapid insertion of new materials and processes. By establishing predictive capability for the development of microstructural features in relation to processing and relating this to critical property characteristics, a streamlined approach to qualification is possible. This paper critically examines the advantages and challenges to a modeling-assisted qualification approach for aerospace structural materials. An example of how this approach might apply towards the emerging field of additive manufacturing is discussed in detail.

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.

Simulation on turning aspheric surface method via oscillating feed

NASA Astrophysics Data System (ADS)

Kong, Fanxing; Li, Zengqiang; Sun, Tao

2014-08-01

It is quite difficult to manufacturing optical components, the combination of high gradient ellipsoid and hyperboloid, with high machining surface requirements. To solve the problem, in this paper we present a turning and forming method via oscillating feed of R-θ layout lathe, analyze machining ellipsoid segment and hyperboloid segment separately through oscillating feed. Also calculate parameters on each trajectory during processing respectively and obtain displacement, velocity, acceleration and other parameters. The simulation result shows that this rotary turning method is capable of ensuring that the cutter is on the equidistance line of meridian cross section curve of work piece during processing high gradient aspheric surface, which helps getting high quality surface. Also the method provides a new approach and a theory basis for manufacturing high quality aspheric surface and extending function of the available twin-spindle lathe as well.

Advances in the production of freeform optical surfaces

NASA Astrophysics Data System (ADS)

Tohme, Yazid E.; Luniya, Suneet S.

2007-05-01

Recent market demands for free-form optics have challenged the industry to find new methods and techniques to manufacture free-form optical surfaces with a high level of accuracy and reliability. Production techniques are becoming a mix of multi-axis single point diamond machining centers or deterministic ultra precision grinding centers coupled with capable measurement systems to accomplish the task. It has been determined that a complex software tool is required to seamlessly integrate all aspects of the manufacturing process chain. Advances in computational power and improved performance of computer controlled precision machinery have driven the use of such software programs to measure, visualize, analyze, produce and re-validate the 3D free-form design thus making the process of manufacturing such complex surfaces a viable task. Consolidation of the entire production cycle in a comprehensive software tool that can interact with all systems in design, production and measurement phase will enable manufacturers to solve these complex challenges providing improved product quality, simplified processes, and enhanced performance. The work being presented describes the latest advancements in developing such software package for the entire fabrication process chain for aspheric and free-form shapes. It applies a rational B-spline based kernel to transform an optical design in the form of parametrical definition (optical equation), standard CAD format, or a cloud of points to a central format that drives the simulation. This software tool creates a closed loop for the fabrication process chain. It integrates surface analysis and compensation, tool path generation, and measurement analysis in one package.

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

Bates, Robert; McConnell, Elizabeth

Machining methods across many industries generally require multiple operations to machine and process advanced materials, features with micron precision, and complex shapes. The resulting multiple machining platforms can significantly affect manufacturing cycle time and the precision of the final parts, with a resultant increase in cost and energy consumption. Ultrafast lasers represent a transformative and disruptive technology that removes material with micron precision and in a single step manufacturing process. Such precision results from athermal ablation without modification or damage to the remaining material which is the key differentiator between ultrafast laser technologies and traditional laser technologies or mechanical processes.more » Athermal ablation without modification or damage to the material eliminates post-processing or multiple manufacturing steps. Combined with the appropriate technology to control the motion of the work piece, ultrafast lasers are excellent candidates to provide breakthrough machining capability for difficult-to-machine materials. At the project onset in early 2012, the project team recognized that substantial effort was necessary to improve the application of ultrafast laser and precise motion control technologies (for micromachining difficult-to-machine materials) to further the aggregate throughput and yield improvements over conventional machining methods. The project described in this report advanced these leading-edge technologies thru the development and verification of two platforms: a hybrid enhanced laser chassis and a multi-application testbed.« less

Chitosan scaffolds containing calcium phosphate salts and rhBMP-2: in vitro and in vivo testing for bone tissue regeneration.

PubMed

Guzmán, Rodrigo; Nardecchia, Stefania; Gutiérrez, María C; Ferrer, María Luisa; Ramos, Viviana; del Monte, Francisco; Abarrategi, Ander; López-Lacomba, José Luis

2014-01-01

Numerous strategies that are currently used to regenerate bone depend on employing biocompatible materials exhibiting a scaffold structure. These scaffolds can be manufactured containing particular active compounds, such as hydroxyapatite precursors and/or different growth factors to enhance bone regeneration process. Herein, we have immobilized calcium phosphate salts (CPS) and bone morphogenetic protein 2 (BMP-2)--combined or alone--into chitosan scaffolds using ISISA process. We have analyzed whether the immobilized bone morphogenetic protein preserved its osteoinductive capability after manufacturing process as well as BMP-2 in vitro release kinetic. We have also studied both the in vitro and in vivo biocompatibility of the resulting scaffolds using a rabbit model. Results indicated that rhBMP-2 remained active in the scaffolds after the manufacturing process and that its release kinetic was different depending on the presence of CPS. In vitro and in vivo findings showed that cells grew more in scaffolds with both CPS and rhBMP-2 and that these scaffolds induced more bone formation in rabbit tibia. Thus chitosan scaffolds containing both CPS and rhBMP-2 were more osteoinductive than their counterparts alone indicating that could be useful for bone regeneration purposes, such as some applications in dentistry.

49 CFR 594.7 - Fee for filing petitions for a determination whether a vehicle is eligible for importation.

Code of Federal Regulations, 2010 CFR

2010-10-01

... originally manufactured for importation into and sale in the United States and of the same model year as the model for which petition is made, and is capable of being readily modified to conform to all applicable... standards, shall pay a fee based upon the direct and indirect costs of processing and acting upon such...

MANUFACTURING PROCESS FUNCTIONS--I. AN ALTERNATIVE MODEL AND ITS COMPARISON WITH EXISTING FUNCTIONS (AND)II. SELECTION OF TRAINEES AND CONTROL OF THEIR PROGRESS.

ERIC Educational Resources Information Center

GLOVER, J.H.

THE CHIEF OBJECTIVE OF THIS STUDY OF SPEED-SKILL ACQUISITION WAS TO FIND A MATHEMATICAL MODEL CAPABLE OF SIMPLE GRAPHIC INTERPRETATION FOR INDUSTRIAL TRAINING AND PRODUCTION SCHEDULING AT THE SHOP FLOOR LEVEL. STUDIES OF MIDDLE SKILL DEVELOPMENT IN MACHINE AND VEHICLE ASSEMBLY, AIRCRAFT PRODUCTION, SPOOLMAKING AND THE MACHINING OF PARTS CONFIRMED…

Automotive Manufacturing Assessment System : Volume 4. Engine Manufacturing Analysis.

DOT National Transportation Integrated Search

1979-11-01

Volume IV represents the results of one of four major study areas under the Automotive Manufacturing Assessment System (AMAS) sponsored by the DOT/Transportation Systems Center. AMAS was designed to assist in the evaluation of industry's capability t...

Ion Implantation with in-situ Patterning for IBC Solar Cells

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

Graff, John W.

2014-10-24

Interdigitated back-side Contact (IBC) solar cells are the highest efficiency silicon solar cells currently on the market. Unfortunately the cost to produce these solar cells is also very high, due to the large number of processing steps required. Varian believes that only the combination of high efficiency and low cost can meet the stated goal of $1/Wp. The core of this program has been to develop an in-situ patterning capability for an ion implantation system capable of producing patterned doped regions for IBC solar cells. Such a patterning capable ion implanter can reduce the number of process steps required tomore » manufacture IBC cells, and therefore significantly reduce the cost. The present program was organized into three phases. Phase I was to select a patterning approach and determine the patterning requirements for IBC cells. Phase II consists of construction of a Beta ion implantation system containing in-situ patterning capability. Phase III consists of shipping and installation of the ion implant system in a customer factory where it will be tested and proven in a pilot production line.« less

IN718 Additive Manufacturing Properties and Influences

NASA Technical Reports Server (NTRS)

Lambert, Dennis M.

2015-01-01

The results of tensile, fracture, and fatigue testing of IN718 coupons produced using the selective laser melting (SLM) additive manufacturing technique are presented. The data have been "sanitized" to remove the numerical values, although certain references to material standards are provided. This document provides some knowledge of the effect of variation of controlled build parameters used in the SLM process, a snapshot of the capabilities of SLM in industry at present, and shares some of the lessons learned along the way. For the build parameter characterization, the parameters were varied over a range that was centered about the machine manufacturer's recommended value, and in each case they were varied individually, although some co-variance of those parameters would be expected. Tensile, fracture, and high-cycle fatigue properties equivalent to wrought IN718 are achievable with SLM-produced IN718. Build and post-build processes need to be determined and then controlled to established limits to accomplish this. It is recommended that a multi-variable evaluation, e.g., design-of experiment (DOE), of the build parameters be performed to better evaluate the co-variance of the parameters.

IN718 Additive Manufacturing Properties and Influences

NASA Technical Reports Server (NTRS)

Lambert, Dennis M.

2015-01-01

The results of tensile, fracture, and fatigue testing of IN718 coupons produced using the selective laser melting (SLM) additive manufacturing technique are presented. The data has been "generalized" to remove the numerical values, although certain references to material standards are provided. This document provides some knowledge of the effect of variation of controlled build parameters used in the SLM process, a snapshot of the capabilities of SLM in industry at present, and shares some of the lessons learned along the way. For the build parameter characterization, the parameters were varied over a range about the machine manufacturer's recommended value, and in each case they were varied individually, although some co-variance of those parameters would be expected. SLM-produced IN718, tensile, fracture, and high-cycle fatigue properties equivalent to wrought IN718 are achievable. Build and post-build processes need to be determined and then controlled to established limits to accomplish this. It is recommended that a multi-variable evaluation, e.g., design-of-experiment (DOE), of the build parameters be performed to better evaluate the co-variance of the parameters.

Ni-H2 cell separator matrix engineering

NASA Technical Reports Server (NTRS)

Scott, W. E.

1992-01-01

This project was initiated to develop alternative separator materials to the previously used asbestos matrices which were removed from the market for health and environmental reasons. The objective of the research was to find a material or combination of materials that had the following characteristics: (1) resistant to the severe conditions encountered in Ni-H2 cells; (2) satisfactory electrical, electrolyte management, and thermal management properties to function properly; (3) environmentally benign; and (4) capable of being manufactured into a separator matrix. During the course of the research it was discovered that separators prepared from wettable polyethylene fibers along and in combination with potassium titanate pigment performed satisfactory in preliminary characterization tests. Further studies lead to the optimization of the separator composition and manufacturing process. Single ply separator sheets were manufactured with 100 percent polyethylene fibers and also with a combination of polyethylene fibers and potassium titanate pigment (PKT) in the ratio of 60 percent PKT and 40 percent fibers. A pilot paper machine was used to produce the experimental separator material by a continuous, wet laid process. Both types of matrices were produced at several different area densities (grams/sq m).

A taxonomy of green supply chain management capability among electronics-related manufacturing firms in Taiwan.

PubMed

Shang, Kuo-Chung; Lu, Chin-Shan; Li, Shaorui

2010-05-01

This study investigated crucial green supply chain management (GSCM) capability dimensions and firm performance based on electronics-related manufacturing firms in Taiwan. On the basis of a factor analysis, six green supply chain management dimensions were identified: green manufacturing and packaging, environmental participation, green marketing, green suppliers, green stock, and green eco-design. According to their factor scores in the GSCM dimensions, a cluster analysis subsequently assigned responding firms into four groups, namely, the weak GSCM oriented group, the green marketing oriented group, the green supplier oriented group, and the green stock oriented group. Differences in firm performance and GSCM dimensions among groups were examined. Results indicated that the green marketing oriented group performed best. Based on the resource-based view (RBV), the capability of the green marketing oriented group was considered to be the deployment of a collection of resources that enables it to successfully compete against rivals. The importance of green marketing as a GSCM capability and strategic asset/critical resources for electronics-related manufacturing firms to obtain a competitive edge is therefore highlighted in this study. Copyright 2010 Elsevier Ltd. All rights reserved.

Additive Manufacturing (AM) Activities and Non-Destructive Evaluation (NDE) at GSFC

NASA Technical Reports Server (NTRS)

Jones, Justin S.

2017-01-01

NASA personnel will be meeting with a delegation from the Japan Aerospace Exploration Agency (JAXA) Office of Safety and Mission Assurance (OSMA) at Langley Research Center on 2217 through 3217. The purpose of the meeting is a technical interchange between NASA and JAXA to discuss Non-Destructive Evaluation (NDE) of Additive Manufacturing (AM) parts and the HALT process (relates to accelerated life testing). The visitors will be a small group of Japanese citizens. Goddard Space Flight Center (GSFC) has been asked to participate in the meeting, either in person or via teleconference. This presentation covers NDE efforts at GSFC and provides a cursory overview of AM and lab capabilities.

Process for manufacture of thick film hydrogen sensors

DOEpatents

Perdieu, Louisa H.

2000-09-09

A thick film process for producing hydrogen sensors capable of sensing down to a one percent concentration of hydrogen in carrier gasses such as argon, nitrogen, and air. The sensor is also suitable to detect hydrogen gas while immersed in transformer oil. The sensor includes a palladium resistance network thick film printed on a substrate, a portion of which network is coated with a protective hydrogen barrier. The process utilizes a sequence of printing of the requisite materials on a non-conductive substrate with firing temperatures at each step which are less than or equal to the temperature at the previous step.

New electron beam facility for R&D and production at acsion industries

NASA Astrophysics Data System (ADS)

Lopata, V. J.; Barnard, J. W.; Saunders, C. B.; Stepanik, T. M.

2003-08-01

Since its incorporation in 1998, Acsion Industries Inc. has been working with clients to develop industrial uses of electron processing for improving products and manufacturing processes. Acsion has promoted this technology for sterilizing medical devices and pharmaceuticals, for treating wood pulp in the viscose/rayon process, for reducing pathogens in food and animal feed, and for curing advanced composites for the aerospace industry. As a result of significant developments in its composite curing programs, Acsion has recently made major modifications to its facility to increase its production and R&D capabilities. These modifications are described in this paper.

NASA's Preparations for ESA's L3 Gravitational Wave Mission

NASA Technical Reports Server (NTRS)

Stebbins, Robin

2016-01-01

Telescope Subsystem - Jeff Livas (GSFC): Demonstrate pathlength stability, straylight and manufacturability. Phase Measurement System - Bill Klipstein (JPL): Key measurement functions demonstrated. Incorporate full flight functionality. Laser Subsystem - Jordan Camp (GSFC): ECL master oscillator, phase noise of fiber power amplifier, demonstrate end-to-end performance in integrated system, lifetime. Micronewton Thrusters - John Ziemer (JPL): Propellant storage and distribution, system robustness, manufacturing yield, lifetime. Arm-locking Demonstration - Kirk McKenzie (JPL): Studying a demonstration of laser frequency stabilization with GRACE Follow-On. Torsion Pendulum - John Conklin (UF): Develop U.S. capability with GRS and torsion pendulum test bed. Multi-Axis Heterodyne Interferometry - Ira Thorpe (GSFC): Investigate test mass/optical bench interface. UV LEDs - John Conklin+ (UF): Flight qualify UV LEDs to replace mercury lamps in discharging system. Optical Bench - Guido Mueller (UF): Investigate alternate designs and fabrication processes to ease manufacturability. LISA researchers at JPL are leading the Laser Ranging Interferometer instrument on the GRACE Follow-On mission.

Statistical analysis and yield management in LED design through TCAD device simulation

NASA Astrophysics Data System (ADS)

Létay, Gergö; Ng, Wei-Choon; Schneider, Lutz; Bregy, Adrian; Pfeiffer, Michael

2007-02-01

This paper illustrates how technology computer-aided design (TCAD), which nowadays is an essential part of CMOS technology, can be applied to LED development and manufacturing. In the first part, the essential electrical and optical models inherent to LED modeling are reviewed. The second part of the work describes a methodology to improve the efficiency of the simulation procedure by using the concept of process compact models (PCMs). The last part demonstrates the capabilities of PCMs using an example of a blue InGaN LED. In particular, a parameter screening is performed to find the most important parameters, an optimization task incorporating the robustness of the design is carried out, and finally the impact of manufacturing tolerances on yield is investigated. It is indicated how the concept of PCMs can contribute to an efficient design for manufacturing DFM-aware development.

Laser penetration spike welding: a welding tool enabling novel process and design opportunities

NASA Astrophysics Data System (ADS)

Dijken, Durandus K.; Hoving, Willem; De Hosson, J. Th. M.

2002-06-01

A novel method for laser welding for sheet metal. is presented. This laser spike welding method is capable of bridging large gaps between sheet metal plates. Novel constructions can be designed and manufactured. Examples are light weight metal epoxy multi-layers and constructions having additional strength with respect to rigidity and impact resistance. Its capability to bridge large gaps allows higher dimensional tolerances in production. The required laser systems are commercially available and are easily implemented in existing production lines. The lasers are highly reliable, the resulting spike welds are quickly realized and the cost price per weld is very low.

Identified research directions for using manufacturing knowledge earlier in the product lifecycle

PubMed Central

Hedberg, Thomas D.; Hartman, Nathan W.; Rosche, Phil; Fischer, Kevin

2016-01-01

Design for Manufacturing (DFM), especially the use of manufacturing knowledge to support design decisions, has received attention in the academic domain. However, industry practice has not been studied enough to provide solutions that are mature for industry. The current state of the art for DFM is often rule-based functionality within Computer-Aided Design (CAD) systems that enforce specific design requirements. That rule-based functionality may or may not dynamically affect geometry definition. And, if rule-based functionality exists in the CAD system, it is typically a customization on a case-by-case basis. Manufacturing knowledge is a phrase with vast meanings, which may include knowledge on the effects of material properties decisions, machine and process capabilities, or understanding the unintended consequences of design decisions on manufacturing. One of the DFM questions to answer is how can manufacturing knowledge, depending on its definition, be used earlier in the product lifecycle to enable a more collaborative development environment? This paper will discuss the results of a workshop on manufacturing knowledge that highlights several research questions needing more study. This paper proposes recommendations for investigating the relationship of manufacturing knowledge with shape, behavior, and context characteristics of product to produce a better understanding of what knowledge is most important. In addition, the proposal includes recommendations for investigating the system-level barriers to reusing manufacturing knowledge and how model-based manufacturing may ease the burden of knowledge sharing. Lastly, the proposal addresses the direction of future research for holistic solutions of using manufacturing knowledge earlier in the product lifecycle. PMID:27990027

Identified research directions for using manufacturing knowledge earlier in the product lifecycle.

PubMed

Hedberg, Thomas D; Hartman, Nathan W; Rosche, Phil; Fischer, Kevin

2017-01-01

Design for Manufacturing (DFM), especially the use of manufacturing knowledge to support design decisions, has received attention in the academic domain. However, industry practice has not been studied enough to provide solutions that are mature for industry. The current state of the art for DFM is often rule-based functionality within Computer-Aided Design (CAD) systems that enforce specific design requirements. That rule-based functionality may or may not dynamically affect geometry definition. And, if rule-based functionality exists in the CAD system, it is typically a customization on a case-by-case basis. Manufacturing knowledge is a phrase with vast meanings, which may include knowledge on the effects of material properties decisions, machine and process capabilities, or understanding the unintended consequences of design decisions on manufacturing. One of the DFM questions to answer is how can manufacturing knowledge, depending on its definition, be used earlier in the product lifecycle to enable a more collaborative development environment? This paper will discuss the results of a workshop on manufacturing knowledge that highlights several research questions needing more study. This paper proposes recommendations for investigating the relationship of manufacturing knowledge with shape, behavior, and context characteristics of product to produce a better understanding of what knowledge is most important. In addition, the proposal includes recommendations for investigating the system-level barriers to reusing manufacturing knowledge and how model-based manufacturing may ease the burden of knowledge sharing. Lastly, the proposal addresses the direction of future research for holistic solutions of using manufacturing knowledge earlier in the product lifecycle.

Alternative Approach to Vehicle Element Processing

NASA Technical Reports Server (NTRS)

Huether, Jacob E.; Otto, Albert E.

1995-01-01

The National Space Transportation Policy (NSTP), describes the challenge facing today's aerospace industry. 'Assuring reliable and affordable access to space through U.S. space transportation capabilities is a fundamental goal of the U.S. space program'. Experience from the Space Shuttle Program (SSP) tells us that launch and mission operations are responsible for approximately 45 % of the cost of each shuttle mission. Reducing these costs is critical to NSTP goals in the next generation launch vehicle. Based on this, an innovative alternative approach to vehicle element processing was developed with an emphasis on reduced launch costs. State-of-the-art upgrades to the launch processing system (LPS) will enhance vehicle ground operations. To carry this one step further, these upgrade could be implemented at various vehicle element manufacturing sites to ensure system compatibility between the manufacturing facility and the launch site. Design center vehicle stand alone testing will ensure system integrity resulting in minimized checkout and testing at the launch site. This paper will addresses vehicle test requirements, timelines and ground checkout procedures which enable concept implementation.

Monitoring of Free Water and Particulate Contamination of F-24 Fuel

DTIC Science & Technology

2016-04-20

Reference herein to any specific commercial company, product , process, or service by trade name, trademark, manufacturer, or otherwise, does not...advertising or product endorsement purposes. Contracted Author As the author(s) is(are) not a Government employee(s), this document was only...14. ABSTRACT A study was conducted on the contaminant detection methods of fuel sensors which are capable of quantifying both free water (0

Materials and processing approaches for foundry-compatible transient electronics

PubMed Central

Chang, Jan-Kai; Fang, Hui; Bower, Christopher A.; Song, Enming; Yu, Xinge; Rogers, John A.

2017-01-01

Foundry-based routes to transient silicon electronic devices have the potential to serve as the manufacturing basis for “green” electronic devices, biodegradable implants, hardware secure data storage systems, and unrecoverable remote devices. This article introduces materials and processing approaches that enable state-of-the-art silicon complementary metal-oxide-semiconductor (CMOS) foundries to be leveraged for high-performance, water-soluble forms of electronics. The key elements are (i) collections of biodegradable electronic materials (e.g., silicon, tungsten, silicon nitride, silicon dioxide) and device architectures that are compatible with manufacturing procedures currently used in the integrated circuit industry, (ii) release schemes and transfer printing methods for integration of multiple ultrathin components formed in this way onto biodegradable polymer substrates, and (iii) planarization and metallization techniques to yield interconnected and fully functional systems. Various CMOS devices and circuit elements created in this fashion and detailed measurements of their electrical characteristics highlight the capabilities. Accelerated dissolution studies in aqueous environments reveal the chemical kinetics associated with the underlying transient behaviors. The results demonstrate the technical feasibility for using foundry-based routes to sophisticated forms of transient electronic devices, with functional capabilities and cost structures that could support diverse applications in the biomedical, military, industrial, and consumer industries. PMID:28652373

Automated imprint mask cleaning for step-and-flash imprint lithography

NASA Astrophysics Data System (ADS)

Singh, Sherjang; Chen, Ssuwei; Selinidis, Kosta; Fletcher, Brian; McMackin, Ian; Thompson, Ecron; Resnick, Douglas J.; Dress, Peter; Dietze, Uwe

2009-03-01

Step-and-Flash Imprint Lithography (S-FIL) is a promising lithography strategy for semiconductor manufacturing at device nodes below 32nm. The S-FIL 1:1 pattern transfer technology utilizes a field-by-field ink jet dispense of a low viscosity liquid resist to fill the relief pattern of the device layer etched into the glass mask. Compared to other sub 40nm CD lithography methods, the resulting high resolution, high throughput through clustering, 3D patterning capability, low process complexity, and low cost of ownership (CoO) of S-FIL makes it a widely accepted technology for patterned media as well as a promising mainstream option for future CMOS applications. Preservation of mask cleanliness is essential to avoid risk of repeated printing of defects. The development of mask cleaning processes capable of removing particles adhered to the mask surface without damaging the mask is critical to meet high volume manufacturing requirements. In this paper we have presented various methods of residual (cross-linked) resist removal and final imprint mask cleaning demonstrated on the HamaTech MaskTrack automated mask cleaning system. Conventional and non-conventional (acid free) methods of particle removal have been compared and the effect of mask cleaning on pattern damage and CD integrity is also studied.

Autonomous cloud based site monitoring through hydro geophysical data assimilation, processing and result delivery

NASA Astrophysics Data System (ADS)

Versteeg, R.; Johnson, D. V.; Rodzianko, A.; Zhou, H.; Dafflon, B.; Leger, E.; de Kleine, M.

2017-12-01

Understanding of processes in the shallow subsurface requires that geophysical, biogeochemical, hydrological and remote sensing datasets are assimilated, processed and interpreted. Multiple enabling software capabilities for process understanding have been developed by the science community. These include information models (ODM2), reactive transport modeling (PFLOTRAN, Modflow, CLM, Landlab), geophysical inversion (E4D, BERT), parameter estimation (PEST, DAKOTA), visualization (ViSiT, Paraview, D3, QGIS) as well as numerous tools written in python and R for petrophysical mapping, stochastic modeling, data analysis and so on. These capabilities use data collected using sensors and analytical tools developed by multiple manufacturers which produce many different measurements. While scientists obviously leverage tools, capabilities and lessons learned from one site at other sites, the current approach to site characterization and monitoring is very labor intensive and does not scale well. Our objective is to be able to monitor many (hundreds - thousands) of sites. This requires that monitoring can be done in a near time, affordable, auditable and essentially autonomous manner. For this we have developed a modular vertically integrated cloud based software framework which was designed from the ground up for effective site and process monitoring. This software framework (PAF - Predictive Assimilation Framework) is multitenant software and provides automation of data ingestion, processing and visualization of hydrological, geochemical and geophysical (ERT/DTS) data. The core organizational element of PAF is a project/user one in which capabilities available to users are controlled by a combination of available data and access permissions. All PAF capabilities are exposed through APIs, making it easy to quickly add new components. PAF is fully integrated with newly developed autonomous electrical geophysical hardware and thus allows for automation of electrical geophysical ingestion and processing and the ability for co analysis and visualization of the raw and processed data with other data of interest (e.g. soil temperature, soil moisture, precipitation). We will demonstrate current PAF capabilities and discuss future efforts.

Exotic Optical Fibers and Glasses: Innovative Material Processing Opportunities in Earth's Orbit.

PubMed

Cozmuta, Ioana; Rasky, Daniel J

2017-09-01

Exotic optical fibers and glasses are the platform material for photonics applications, primarily due to their superior signal transmission (speed, low attenuation), with extending bandwidth deep into the infrared, exceeding that of silica fibers. Gravitational effects (convection sedimentation) have a direct impact on the phase diagram of these materials and influence melting properties, crystallization temperatures, and viscosity of the elemental mix during the manufacturing process. Such factors constitute limits to the yield, transmission quality, and strength and value of these fibers; they also constrain the range of applications. Manufacturing in a gravity-free environment such as the Earth's Orbit also helps with other aspects of the fabrication process (i.e., improved form factor of the manufacturing unit, sustainability). In this article, revolutionary developments in the field of photonics over the past decade merge with the paradigm shift in the privatization of government-owned capabilities supporting a more diverse infrastructure (parabolic, suborbital, orbital), reduced price, and increased frequency to access space and the microgravity environment. With the increased dependence on data (demand, bandwidth, efficiency), space and the microgravity environment provide opportunities for optimized performance of these exotic optical fibers and glasses underlying the development of enabling technologies to meet future data demand. Existing terrestrial markets (Internet, telecommunications, market transactions) and emerging space markets (on-orbit satellite servicing, space manufacturing, space resources, space communications, etc.) seem to converge, and this innovative material processing opportunity of exotic optical fibers and glasses might just be that "killer app": technologically competitive, economically viable, and with the ability to close the business case.

Exotic Optical Fibers and Glasses: Innovative Material Processing Opportunities in Earth's Orbit

PubMed Central

Rasky, Daniel J.

2017-01-01

Abstract Exotic optical fibers and glasses are the platform material for photonics applications, primarily due to their superior signal transmission (speed, low attenuation), with extending bandwidth deep into the infrared, exceeding that of silica fibers. Gravitational effects (convection sedimentation) have a direct impact on the phase diagram of these materials and influence melting properties, crystallization temperatures, and viscosity of the elemental mix during the manufacturing process. Such factors constitute limits to the yield, transmission quality, and strength and value of these fibers; they also constrain the range of applications. Manufacturing in a gravity-free environment such as the Earth's Orbit also helps with other aspects of the fabrication process (i.e., improved form factor of the manufacturing unit, sustainability). In this article, revolutionary developments in the field of photonics over the past decade merge with the paradigm shift in the privatization of government-owned capabilities supporting a more diverse infrastructure (parabolic, suborbital, orbital), reduced price, and increased frequency to access space and the microgravity environment. With the increased dependence on data (demand, bandwidth, efficiency), space and the microgravity environment provide opportunities for optimized performance of these exotic optical fibers and glasses underlying the development of enabling technologies to meet future data demand. Existing terrestrial markets (Internet, telecommunications, market transactions) and emerging space markets (on-orbit satellite servicing, space manufacturing, space resources, space communications, etc.) seem to converge, and this innovative material processing opportunity of exotic optical fibers and glasses might just be that “killer app”: technologically competitive, economically viable, and with the ability to close the business case. PMID:29375939

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 milling machine for computer-aided, in-office restorations.

PubMed

Kurbad, Andreas

Chairside computer-aided design/computer-aided manufacturing (CAD/CAM) technology requires an effective technical basis to obtain dental restorations with optimal marginal accuracy, esthetics, and longevity in as short a timeframe as possible. This article describes a compact, 5-axis milling machine based on an innovative milling technology (5XT - five-axis turn-milling technique), which is capable of achieving high-precision milling results within a very short processing time. Furthermore, the device's compact dimensioning and state-of-the-art mode of operation facilitate its use in the dental office. This model is also an option to be considered for use in smaller dental laboratories, especially as the open input format enables it to be quickly and simply integrated into digital processing systems already in use. The possibility of using ceramic and polymer materials with varying properties enables the manufacture of restorations covering all conceivable indications in the field of fixed dental prosthetics.

Setting new standards in MEMS

NASA Astrophysics Data System (ADS)

Rimskog, Magnus; O'Loughlin, Brian J.

2007-02-01

Silex Microsystems handles a wide range of customized MEMS components. This speech will be describing Silex's MEMS foundry work model for providing customized solutions based on MEMS in a cost effective and well controlled manner. Factors for success are the capabilities to reformulate a customer product concept to manufacturing processes in the wafer fab, using standard process modules and production equipment. A well-controlled system increases the likelihood of a first batch success and enables fast ramp-up into volume production. The following success factors can be listed: strong enduring relationships with the customers; highly qualified well-experienced specialists working close with the customer; process solutions and building blocks ready to use out of a library; addressing manufacturing issues in the early design phase; in-house know how to meet demands for volume manufacturing; access to a wafer fab with high capacity, good organization, high availability of equipment, and short lead times; process development done in the manufacturing environment using production equipment for easy ramp-up to volume production. The article covers a method of working to address these factors: to have a long and enduring relationships with customers utilizing MEMS expertise and working close with customers, to translate their product ideas to MEMS components; to have stable process solutions for features such as Low ohmic vias, Spiked electrodes, Cantilevers, Silicon optical mirrors, Micro needles, etc, which can be used and modified for the customer needs; to use a structured development and design methodology in order to handle hundreds of process modules, and setting up standard run sheets. It is also very important to do real time process development in the manufacturing line. It minimizes the lead-time for the ramp-up of production; to have access to a state of the art Wafer Fab which is well organized, controlled and flexible, with high capacity and short lead-time for prototypes. It is crucial to have intimate control of processes, equipment, organization, production flow control and WIP. This has been addressed by using a fully computerized control and reporting system.

A novel methodology for in-process monitoring of flow forming

NASA Astrophysics Data System (ADS)

Appleby, Andrew; Conway, Alastair; Ion, William

2017-10-01

Flow forming (FF) is an incremental cold working process with near-net-shape forming capability. Failures by fracture due to high deformation can be unexpected and sometimes catastrophic, causing tool damage. If process failures can be identified in real time, an automatic cut-out could prevent costly tool damage. Sound and vibration monitoring is well established and commercially viable in the machining sector to detect current and incipient process failures, but not for FF. A broad-frequency microphone was used to record the sound signature of the manufacturing cycle for a series of FF parts. Parts were flow formed using single and multiple passes, and flaws were introduced into some of the parts to simulate the presence of spontaneously initiated cracks. The results show that this methodology is capable of identifying both introduced defects and spontaneous failures during flow forming. Further investigation is needed to categorise and identify different modes of failure and identify further potential applications in rotary forming.

Computer aided manufacturing for complex freeform optics

NASA Astrophysics Data System (ADS)

Wolfs, Franciscus; Fess, Ed; Johns, Dustin; LePage, Gabriel; Matthews, Greg

2017-10-01

Recently, the desire to use freeform optics has been increasing. Freeform optics can be used to expand the capabilities of optical systems and reduce the number of optics needed in an assembly. The traits that increase optical performance also present challenges in manufacturing. As tolerances on freeform optics become more stringent, it is necessary to continue to improve methods for how the grinding and polishing processes interact with metrology. To create these complex shapes, OptiPro has developed a computer aided manufacturing package called PROSurf. PROSurf generates tool paths required for grinding and polishing freeform optics with multiple axes of motion. It also uses metrology feedback for deterministic corrections. ProSurf handles 2 key aspects of the manufacturing process that most other CAM systems struggle with. The first is having the ability to support several input types (equations, CAD models, point clouds) and still be able to create a uniform high-density surface map useable for generating a smooth tool path. The second is to improve the accuracy of mapping a metrology file to the part surface. To perform this OptiPro is using 3D error maps instead of traditional 2D maps. The metrology error map drives the tool path adjustment applied during processing. For grinding, the error map adjusts the tool position to compensate for repeatable system error. For polishing, the error map drives the relative dwell times of the tool across the part surface. This paper will present the challenges associated with these issues and solutions that we have created.

An improved method for characterizing photoresist lithographic and defectivity performance for sub-20nm node lithography

NASA Astrophysics Data System (ADS)

Amblard, Gilles; Purdy, Sara; Cooper, Ryan; Hockaday, Marjory

2016-03-01

The overall quality and processing capability of lithographic materials are critical for ensuring high device yield and performance at sub-20nm technology nodes in a high volume manufacturing environment. Insufficient process margin and high line width roughness (LWR) cause poor manufacturing control, while high defectivity causes product failures. In this paper, we focus on the most critical layer of a sub-20nm technology node LSI device, and present an improved method for characterizing both lithographic and post-patterning defectivity performance of state-of-the-art immersion photoresists. Multiple formulations from different suppliers were used and compared. Photoresists were tested under various process conditions, and multiple lithographic metrics were investigated (depth of focus, exposure dose latitude, line width roughness, etc.). Results were analyzed and combined using an innovative approach based on advanced software, providing clearer results than previously available. This increased detail enables more accurate performance comparisons among the different photoresists. Post-patterning defectivity was also quantified, with defects reviewed and classified using state-of-the-art inspection tools. Correlations were established between the lithographic and post-patterning defectivity performances for each material, and overall ranking was established among the photoresists, enabling the selection of the best performer for implementation in a high volume manufacturing environment.

Making vaccines “on demand”

PubMed Central

De Groot, Anne S; Einck, Leo; Moise, Leonard; Chambers, Michael; Ballantyne, John; Malone, Robert W; Ardito, Matthew; Martin, William

2013-01-01

The integrated US Public Health Emergency Medical Countermeasures Enterprise (PHEMCE) has made great strides in strategic preparedness and response capabilities. There have been numerous advances in planning, biothreat countermeasure development, licensure, manufacturing, stockpiling and deployment. Increased biodefense surveillance capability has dramatically improved, while new tools and increased awareness have fostered rapid identification of new potential public health pathogens. Unfortunately, structural delays in vaccine design, development, manufacture, clinical testing and licensure processes remain significant obstacles to an effective national biodefense rapid response capability. This is particularly true for the very real threat of “novel pathogens” such as the avian-origin influenzas H7N9 and H5N1, and new coronaviruses such as hCoV-EMC. Conventional approaches to vaccine development, production, clinical testing and licensure are incompatible with the prompt deployment needed for an effective public health response. An alternative approach, proposed here, is to apply computational vaccine design tools and rapid production technologies that now make it possible to engineer vaccines for novel emerging pathogen and WMD biowarfare agent countermeasures in record time. These new tools have the potential to significantly reduce the time needed to design string-of-epitope vaccines for previously unknown pathogens. The design process—from genome to gene sequence, ready to insert in a DNA plasmid—can now be accomplished in less than 24 h. While these vaccines are by no means “standard,” the need for innovation in the vaccine design and production process is great. Should such vaccines be developed, their 60-d start-to-finish timeline would represent a 2-fold faster response than the current standard. PMID:23877094

Residual stress evaluation of components produced via direct metal laser sintering

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

Kemerling, Brandon; Lippold, John C.; Fancher, Christopher M.

Direct metal laser sintering is an additive manufacturing process which is capable of fabricating three-dimensional components using a laser energy source and metal powder particles. Despite the numerous benefits offered by this technology, the process maturity is low with respect to traditional subtractive manufacturing methods. Relationships between key processing parameters and final part properties are generally lacking and require further development. In this study, residual stresses were evaluated as a function of key process variables. The variables evaluated included laser scan strategy and build plate preheat temperature. Residual stresses were measured experimentally via neutron diffraction and computationally via finite elementmore » analysis. Good agreement was shown between the experimental and computational results. Results showed variations in the residual stress profile as a function of laser scan strategy. Compressive stresses were dominant along the build height (z) direction, and tensile stresses were dominant in the x and y directions. Build plate preheating was shown to be an effective method for alleviating residual stress due to the reduction in thermal gradient.« less

Residual stress evaluation of components produced via direct metal laser sintering

DOE PAGES

Kemerling, Brandon; Lippold, John C.; Fancher, Christopher M.; ...

2018-03-22

Direct metal laser sintering is an additive manufacturing process which is capable of fabricating three-dimensional components using a laser energy source and metal powder particles. Despite the numerous benefits offered by this technology, the process maturity is low with respect to traditional subtractive manufacturing methods. Relationships between key processing parameters and final part properties are generally lacking and require further development. In this study, residual stresses were evaluated as a function of key process variables. The variables evaluated included laser scan strategy and build plate preheat temperature. Residual stresses were measured experimentally via neutron diffraction and computationally via finite elementmore » analysis. Good agreement was shown between the experimental and computational results. Results showed variations in the residual stress profile as a function of laser scan strategy. Compressive stresses were dominant along the build height (z) direction, and tensile stresses were dominant in the x and y directions. Build plate preheating was shown to be an effective method for alleviating residual stress due to the reduction in thermal gradient.« less

Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering

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

Yang, Nancy; Yee, J.; Zheng, B.

We investigate the process-structure-property relationships for 316L stainless steel prototyping utilizing 3-D laser engineered net shaping (LENS), a commercial direct energy deposition additive manufacturing process. Our study concluded that the resultant physical metallurgy of 3-D LENS 316L prototypes is dictated by the interactive metallurgical reactions, during instantaneous powder feeding/melting, molten metal flow and liquid metal solidification. This study also showed 3-D LENS manufacturing is capable of building high strength and ductile 316L prototypes due to its fine cellular spacing from fast solidification cooling, and the well-fused epitaxial interfaces at metal flow trails and interpass boundaries. However, without further LENS processmore » control and optimization, the deposits are vulnerable to localized hardness variation attributed to heterogeneous microstructure, i.e., the interpass heat-affected zone (HAZ) from repetitive thermal heating during successive layer depositions. Most significantly, the current deposits exhibit anisotropic tensile behavior, i.e., lower strain and/or premature interpass delamination parallel to build direction (axial). This anisotropic behavior is attributed to the presence of interpass HAZ, which coexists with flying feedstock inclusions and porosity from incomplete molten metal fusion. Our current observations and findings contribute to the scientific basis for future process control and optimization necessary for material property control and defect mitigation.« less

Process-Structure-Property Relationships for 316L Stainless Steel Fabricated by Additive Manufacturing and Its Implication for Component Engineering

DOE PAGES

Yang, Nancy; Yee, J.; Zheng, B.; ...

2016-12-08

We investigate the process-structure-property relationships for 316L stainless steel prototyping utilizing 3-D laser engineered net shaping (LENS), a commercial direct energy deposition additive manufacturing process. Our study concluded that the resultant physical metallurgy of 3-D LENS 316L prototypes is dictated by the interactive metallurgical reactions, during instantaneous powder feeding/melting, molten metal flow and liquid metal solidification. This study also showed 3-D LENS manufacturing is capable of building high strength and ductile 316L prototypes due to its fine cellular spacing from fast solidification cooling, and the well-fused epitaxial interfaces at metal flow trails and interpass boundaries. However, without further LENS processmore » control and optimization, the deposits are vulnerable to localized hardness variation attributed to heterogeneous microstructure, i.e., the interpass heat-affected zone (HAZ) from repetitive thermal heating during successive layer depositions. Most significantly, the current deposits exhibit anisotropic tensile behavior, i.e., lower strain and/or premature interpass delamination parallel to build direction (axial). This anisotropic behavior is attributed to the presence of interpass HAZ, which coexists with flying feedstock inclusions and porosity from incomplete molten metal fusion. Our current observations and findings contribute to the scientific basis for future process control and optimization necessary for material property control and defect mitigation.« less

Production of Energy Efficient Preform Structures (PEEPS)

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

Dr. John A. Baumann

2012-06-08

Due to its low density, good structural characteristics, excellent fabrication properties, and attractive appearance, aluminum metal and its alloys continue to be widely utilized. The transportation industry continues to be the largest consumer of aluminum products, with aerospace as the principal driver for this use. Boeing has long been the largest single company consumer of heat-treated aluminum in the U.S. The extensive use of aluminum to build aircraft and launch vehicles has been sustained, despite the growing reliance on more structurally efficient carbon fiber reinforced composite materials. The trend in the aerospace industry over the past several decades has beenmore » to rely extensively on large, complex, thin-walled, monolithic machined structural components, which are fabricated from heavy billets and thick plate using high speed machining. The use of these high buy-to-fly ratio starting product forms, while currently cost effective, is energy inefficient, with a high environmental impact. The widespread implementation of Solid State Joining (SSJ) technologies, to produce lower buy-to-fly ratio starting forms, tailored to each specific application, offers the potential for a more sustainable manufacturing strategy, which would consume less energy, require less material, and reduce material and manufacturing costs. One objective of this project was to project the energy benefits of using SSJ techniques to produce high-performance aluminum structures if implemented in the production of the world fleet of commercial aircraft. A further objective was to produce an energy consumption prediction model, capable of calculating the total energy consumption, solid waste burden, acidification potential, and CO2 burden in producing a starting product form - whether by conventional or SSJ processes - and machining that to a final part configuration. The model needed to be capable of computing and comparing, on an individual part/geometry basis, multiple possible manufacturing pathways, to identify the best balance of energy consumption and environmental impact. This model has been created and populated with energy consumption data for individual SSJ processes and process platforms. Technology feasibility cases studies were executed, to validate the model, and confirm the ability to create lower buy-to-fly ratio performs and machine these to final configuration aircraft components. This model can now be used as a tool to select manufacturing pathways that offer significant energy savings and, when coupled with a cost model, drive implementation of the SSJ processes.« less

Throughput Optimization of Continuous Biopharmaceutical Manufacturing Facilities.

PubMed

Garcia, Fernando A; Vandiver, Michael W

2017-01-01

In order to operate profitably under different product demand scenarios, biopharmaceutical companies must design their facilities with mass output flexibility in mind. Traditional biologics manufacturing technologies pose operational challenges in this regard due to their high costs and slow equipment turnaround times, restricting the types of products and mass quantities that can be processed. Modern plant design, however, has facilitated the development of lean and efficient bioprocessing facilities through footprint reduction and adoption of disposable and continuous manufacturing technologies. These development efforts have proven to be crucial in seeking to drastically reduce the high costs typically associated with the manufacturing of recombinant proteins. In this work, mathematical modeling is used to optimize annual production schedules for a single-product commercial facility operating with a continuous upstream and discrete batch downstream platform. Utilizing cell culture duration and volumetric productivity as process variables in the model, and annual plant throughput as the optimization objective, 3-D surface plots are created to understand the effect of process and facility design on expected mass output. The model shows that once a plant has been fully debottlenecked it is capable of processing well over a metric ton of product per year. Moreover, the analysis helped to uncover a major limiting constraint on plant performance, the stability of the neutralized viral inactivated pool, which may indicate that this should be a focus of attention during future process development efforts. LAY ABSTRACT: Biopharmaceutical process modeling can be used to design and optimize manufacturing facilities and help companies achieve a predetermined set of goals. One way to perform optimization is by making the most efficient use of process equipment in order to minimize the expenditure of capital, labor and plant resources. To that end, this paper introduces a novel mathematical algorithm used to determine the most optimal equipment scheduling configuration that maximizes the mass output for a facility producing a single product. The paper also illustrates how different scheduling arrangements can have a profound impact on the availability of plant resources, and identifies limiting constraints on the plant design. In addition, simulation data is presented using visualization techniques that aid in the interpretation of the scientific concepts discussed. © PDA, Inc. 2017.

Nonterrestrial utilization of materials: Automated space manufacturing facility

NASA Technical Reports Server (NTRS)

1982-01-01

Four areas related to the nonterrestrial use of materials are included: (1) material resources needed for feedstock in an orbital manufacturing facility, (2) required initial components of a nonterrestrial manufacturing facility, (3) growth and productive capability of such a facility, and (4) automation and robotics requirements of the facility.

24 CFR 3282.362 - Production Inspection Primary Inspection Agencies (IPIAs).

Code of Federal Regulations, 2013 CFR

2013-04-01

... a particular manufacturing plant shall be responsible for assuring: (i) That the plant is capable of... plant; (ii) That the plant continues to follow the quality assurance manual; (iii) That any part of any... standards, the failure to conform is corrected before the manufactured home leaves the manufacturing plant...

Rehabilitation Tool

NASA Technical Reports Server (NTRS)

1993-01-01

Biotran, or Fastex as named by Cybex, the company that manufactures it, is a force sensing system that helps physicians and physical therapists treat people with movement deficiencies. Based on NASA sensor technology, it also has applications in sports training and evaluation. Biotran provides a means of testing weight-bearing capabilities that may have been compromised by injury or disease. It also assists in the rehabilitation process by putting patients through a course of computer-directed exercises designed to improve strength and balance reaction time. The system tests and documents progress until maximum medical improvement is achieved. Lewis Research Center also assisted the company in the selection of the material used in the Biotran force sensing platforms. Biotran is currently manufactured by Cybex under the name Fastex.

Manufacturing the Horns of Dilemma: A Theory of Operational Initiative

DTIC Science & Technology

2015-05-21

Army began to understand CCF tactics by December, 1950. The Chinese preferred to infiltrate their infantry during darkness , utilized terrain to mask...most concerned with retaining its freedom of action against the CCF. The Third Chinese Counteroffensive began just after dark on December 31, 1950 and...IDF entered a process of soul -searching and reflection that questioned deeply held assumptions about the capabilities and utility of the IDF in the

Manufacturing Methods and Technology Program Plan, CY 1980.

DTIC Science & Technology

1980-09-01

AD-A092 2Ii3 &RMY INDUSTRIAL BASE ENGINEERING ACTIVITY ROCK ISLAND IL FIG 1346 ..ANIJPACTRItd METH4OS AND TECNOLOGY PROGRAM PLAN. CY 1960. (U) %EP 60... innovative solutions. For example, material handling, process tools and inspection systems must be computerized to achieve the desired operating economics and...to decrease expensive direct labor; however, the new systems must also be capable of economic layaway for periods of ten years or more, a situation

3D printing technologies for electrochemical energy storage

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

Zhang, Feng; Wei, Min; Viswanathan, Vilayanur V.

Fabrication of electrodes and electrolytes play an important role in promoting the performance of electrochemical energy storage (EES) devices such as batteries and supercapacitors. Traditional fabrication techniques have limited capability in controlling the geometry and architecture of the electrode and solid-state electrolytes, which would otherwise compromise the performance. 3D printing, a disruptive manufacturing technology, has emerged as an innovative approach to fabricating EES devices from nanoscale to macroscale and from nanowatt to megawatt, providing great opportunities to accurately control device geometry (e.g., dimension, porosity, morphology) and structure with enhanced specific energy and power densities. Moreover, the additive manufacturing nature ofmore » 3D printing provides excellent controllability of the electrode thickness with much simplified process in a cost effective manner. With the unique spatial and temporal material manipulation capability, 3D printing can integrate multiple nanomaterials in the same print, and multi-functional EES devices (including functional gradient devices) can be fabricated. Herein, we review recent advances in 3D printing of EES devices. We focused on two major 3D printing technologies including direct writing and inkjet printing. The direct material deposition characteristics of these two processes enable them to print on a variety of flat substrates, even a conformal one, well suiting them to applications such as wearable devices and on-chip integrations. Other potential 3D printing techniques such as freeze nano-printing, stereolithography, fused deposition modeling, binder jetting, laminated object manufacturing, and metal 3D printing are also introduced. The advantages and limitations of each 3D printing technology are extensively discussed. More importantly, we provide a perspective on how to integrate the emerging 3D printing with existing technologies to create structures over multiple length scale from macro to nano for EES applications.« less

Multilayer active shell mirrors for space telescopes

NASA Astrophysics Data System (ADS)

Steeves, John; Jackson, Kathryn; Pellegrino, Sergio; Redding, David; Wallace, J. Kent; Bradford, Samuel Case; Barbee, Troy

2016-07-01

A novel active mirror technology based on carbon fiber reinforced polymer (CFRP) substrates and replication techniques has been developed. Multiple additional layers are implemented into the design serving various functions. Nanolaminate metal films are used to provide a high quality reflective front surface. A backing layer of thin active material is implemented to provide the surface-parallel actuation scheme. Printed electronics are used to create a custom electrode pattern and flexible routing layer. Mirrors of this design are thin (< 1.0 mm), lightweight (2.7 kg/m2), and have large actuation capabilities. These capabilities, along with the associated manufacturing processes, represent a significant change in design compared to traditional optics. Such mirrors could be used as lightweight primaries for small CubeSat-based telescopes or as meter-class segments for future large aperture observatories. Multiple mirrors can be produced under identical conditions enabling a substantial reduction in manufacturing cost and complexity. An overview of the mirror design and manufacturing processes is presented. Predictions on the actuation performance have been made through finite element simulations demonstrating correctabilities on the order of 250-300× for astigmatic modes with only 41 independent actuators. A description of the custom metrology system used to characterize the active mirrors is also presented. The system is based on a Reverse Hartmann test and can accommodate extremely large deviations in mirror figure (> 100 μm PV) down to sub-micron precision. The system has been validated against several traditional techniques including photogrammetry and interferometry. The mirror performance has been characterized using this system, as well as closed-loop figure correction experiments on 150 mm dia. prototypes. The mirrors have demonstrated post-correction figure accuracies of 200 nm RMS (two dead actuators limiting performance).

Method for automatically evaluating a transition from a batch manufacturing technique to a lean manufacturing technique

DOEpatents

Ivezic, Nenad; Potok, Thomas E.

2003-09-30

A method for automatically evaluating a manufacturing technique comprises the steps of: receiving from a user manufacturing process step parameters characterizing a manufacturing process; accepting from the user a selection for an analysis of a particular lean manufacturing technique; automatically compiling process step data for each process step in the manufacturing process; automatically calculating process metrics from a summation of the compiled process step data for each process step; and, presenting the automatically calculated process metrics to the user. A method for evaluating a transition from a batch manufacturing technique to a lean manufacturing technique can comprise the steps of: collecting manufacturing process step characterization parameters; selecting a lean manufacturing technique for analysis; communicating the selected lean manufacturing technique and the manufacturing process step characterization parameters to an automatic manufacturing technique evaluation engine having a mathematical model for generating manufacturing technique evaluation data; and, using the lean manufacturing technique evaluation data to determine whether to transition from an existing manufacturing technique to the selected lean manufacturing technique.

Manufacture of a human mesenchymal stem cell population using an automated cell culture platform.

PubMed

Thomas, Robert James; Chandra, Amit; Liu, Yang; Hourd, Paul C; Conway, Paul P; Williams, David J

2007-09-01

Tissue engineering and regenerative medicine are rapidly developing fields that use cells or cell-based constructs as therapeutic products for a wide range of clinical applications. Efforts to commercialise these therapies are driving a need for capable, scaleable, manufacturing technologies to ensure therapies are able to meet regulatory requirements and are economically viable at industrial scale production. We report the first automated expansion of a human bone marrow derived mesenchymal stem cell population (hMSCs) using a fully automated cell culture platform. Differences in cell population growth profile, attributed to key methodological differences, were observed between the automated protocol and a benchmark manual protocol. However, qualitatively similar cell output, assessed by cell morphology and the expression of typical hMSC markers, was obtained from both systems. Furthermore, the critical importance of minor process variation, e.g. the effect of cell seeding density on characteristics such as population growth kinetics and cell phenotype, was observed irrespective of protocol type. This work highlights the importance of careful process design in therapeutic cell manufacture and demonstrates the potential of automated culture for future optimisation and scale up studies required for the translation of regenerative medicine products from the laboratory to the clinic.

Development of microtitre plates for electrokinetic assays

NASA Astrophysics Data System (ADS)

Burt, J. P. H.; Goater, A. D.; Menachery, A.; Pethig, R.; Rizvi, N. H.

2007-02-01

Electrokinetic processes have wide ranging applications in microsystems technology. Their optimum performance at micro and nano dimensions allows their use both as characterization and diagnostic tools and as a means of general particle manipulation. Within analytical studies, measurement of the electrokinesis of biological cells has the sensitivity and selectivity to distinguish subtle differences between cell types and cells undergoing changes and is gaining acceptance as a diagnostic tool in high throughput screening for drug discovery applications. In this work the development and manufacture of an electrokinetic-based microtitre plate is described. The plate is intended to be compatible with automated sample loading and handling systems. Manufacturing of the microtitre plate, which employs indium tin oxide microelectrodes, has been entirely undertaken using excimer and ultra-fast pulsed laser micromachining due to its flexibility in materials processing and accuracy in microstructuring. Laser micromachining has the ability to rapidly realize iterations in device prototype design while also having the capability to be scaled up for large scale manufacture. Device verification is achieved by the measurement of the electrorotation and dielectrophoretic properties of yeast cells while the flexibility of the developed microtitre plate is demonstrated by the selective separation of live yeast from polystyrene microbeads.

High volume fabrication of laser targets using MEMS techniques

NASA Astrophysics Data System (ADS)

Spindloe, C.; Arthur, G.; Hall, F.; Tomlinson, S.; Potter, R.; Kar, S.; Green, J.; Higginbotham, A.; Booth, N.; Tolley, M. K.

2016-04-01

The latest techniques for the fabrication of high power laser targets, using processes developed for the manufacture of Micro-Electro-Mechanical System (MEMS) devices are discussed. These laser targets are designed to meet the needs of the increased shot numbers that are available in the latest design of laser facilities. Traditionally laser targets have been fabricated using conventional machining or coarse etching processes and have been produced in quantities of 10s to low 100s. Such targets can be used for high complexity experiments such as Inertial Fusion Energy (IFE) studies and can have many complex components that need assembling and characterisation with high precision. Using the techniques that are common to MEMS devices and integrating these with an existing target fabrication capability we are able to manufacture and deliver targets to these systems. It also enables us to manufacture novel targets that have not been possible using other techniques. In addition, developments in the positioning systems that are required to deliver these targets to the laser focus are also required and a system to deliver the target to a focus of an F2 beam at 0.1Hz is discussed.

Manufacturability: from design to SPC limits through "corner-lot" characterization

NASA Astrophysics Data System (ADS)

Hogan, Timothy J.; Baker, James C.; Wesneski, Lisa; Black, Robert S.; Rothenbury, Dave

2004-12-01

Texas Instruments" Digital Micro-mirror Device, is used in a wide variety of optical display applications ranging from fixed and portable projectors to high-definition television (HDTV) to digital cinema projection systems. A new DMD pixel architecture, called "FTP", was designed and qualified by Texas Instruments DLPTMTM Group in 2003 to meet increased performance objectives for brightness and contrast ratio. Coordination between design, test and fabrication groups was required to balance pixel performance requirements and manufacturing capability. "Corner Lot" designed experiments (DOE) were used to verify "fabrication space" available for the pixel design. The corner lot technique allows confirmation of manufacturability projections early in the design/qualification cycle. Through careful design and analysis of the corner-lot DOE, a balance of critical dimension (cd) "budgets" is possible so that specification and process control limits can be established that meet both customer and factory requirements. The application of corner-lot DOE is illustrated in a case history of the DMD "FTP" pixel. The process for balancing test parameter requirements with multiple critical dimension budgets is shown. MEMS/MOEMS device design and fabrication can use similar techniques to achieve agressive design-to-qualification goals.

Manufacturability: from design to SPC limits through "corner-lot" characterization

NASA Astrophysics Data System (ADS)

Hogan, Timothy J.; Baker, James C.; Wesneski, Lisa; Black, Robert S.; Rothenbury, Dave

2005-01-01

Texas Instruments" Digital Micro-mirror Device, is used in a wide variety of optical display applications ranging from fixed and portable projectors to high-definition television (HDTV) to digital cinema projection systems. A new DMD pixel architecture, called "FTP", was designed and qualified by Texas Instruments DLPTMTM Group in 2003 to meet increased performance objectives for brightness and contrast ratio. Coordination between design, test and fabrication groups was required to balance pixel performance requirements and manufacturing capability. "Corner Lot" designed experiments (DOE) were used to verify "fabrication space" available for the pixel design. The corner lot technique allows confirmation of manufacturability projections early in the design/qualification cycle. Through careful design and analysis of the corner-lot DOE, a balance of critical dimension (cd) "budgets" is possible so that specification and process control limits can be established that meet both customer and factory requirements. The application of corner-lot DOE is illustrated in a case history of the DMD "FTP" pixel. The process for balancing test parameter requirements with multiple critical dimension budgets is shown. MEMS/MOEMS device design and fabrication can use similar techniques to achieve agressive design-to-qualification goals.

Additive Manufacturing for Affordable Rocket Engines

NASA Technical Reports Server (NTRS)

West, Brian; Robertson, Elizabeth; Osborne, Robin; Calvert, Marty

2016-01-01

Additive manufacturing (also known as 3D printing) technology has the potential to drastically reduce costs and lead times associated with the development of complex liquid rocket engine systems. NASA is using 3D printing to manufacture rocket engine components including augmented spark igniters, injectors, turbopumps, and valves. NASA is advancing the process to certify these components for flight. Success Story: MSFC has been developing rocket 3D-printing technology using the Selective Laser Melting (SLM) process. Over the last several years, NASA has built and tested several injectors and combustion chambers. Recently, MSFC has 3D printed an augmented spark igniter for potential use the RS-25 engines that will be used on the Space Launch System. The new design is expected to reduce the cost of the igniter by a factor of four. MSFC has also 3D printed and tested a liquid hydrogen turbopump for potential use on an Upper Stage Engine. Additive manufacturing of the turbopump resulted in a 45% part count reduction. To understanding how the 3D printed parts perform and to certify them for flight, MSFC built a breadboard liquid rocket engine using additive manufactured components including injectors, turbomachinery, and valves. The liquid rocket engine was tested seven times in 2016 using liquid oxygen and liquid hydrogen. In addition to exposing the hardware to harsh environments, engineers learned to design for the new manufacturing technique, taking advantage of its capabilities and gaining awareness of its limitations. Benefit: The 3D-printing technology promises reduced cost and schedule for rocket engines. Cost is a function of complexity, and the most complicated features provide the largest opportunities for cost reductions. This is especially true where brazes or welds can be eliminated. The drastic reduction in part count achievable with 3D printing creates a waterfall effect that reduces the number of processes and drawings, decreases the amount of touch labor required, and increases reliability. When certification is achieved, NASA missions will be able to realize these benefits.

Additive Manufacturing of SiC Based Ceramics and Ceramic Matrix Composites

NASA Technical Reports Server (NTRS)

Halbig, Michael Charles; Singh, Mrityunjay

2015-01-01

Silicon carbide (SiC) ceramics and SiC fiber reinforcedSiC ceramic matrix composites (SiCSiC CMCs) offer high payoff as replacements for metals in turbine engine applications due to their lighter weight, higher temperature capability, and lower cooling requirements. Additive manufacturing approaches can offer game changing technologies for the quick and low cost fabrication of parts with much greater design freedom and geometric complexity. Four approaches for developing these materials are presented. The first two utilize low cost 3D printers. The first uses pre-ceramic pastes developed as feed materials which are converted to SiC after firing. The second uses wood containing filament to print a carbonaceous preform which is infiltrated with a pre-ceramic polymer and converted to SiC. The other two approaches pursue the AM of CMCs. The first is binder jet SiC powder processing in collaboration with rp+m (Rapid Prototyping+Manufacturing). Processing optimization was pursued through SiC powder blending, infiltration with and without SiC nano powder loading, and integration of nanofibers into the powder bed. The second approach was laminated object manufacturing (LOM) in which fiber prepregs and laminates are cut to shape by a laser and stacked to form the desired part. Scanning electron microscopy was conducted on materials from all approaches with select approaches also characterized with XRD, TGA, and bend testing.

Additive technology of soluble mold tooling for embedded devices in composite structures: A study on manufactured tolerances

NASA Astrophysics Data System (ADS)

Roy, Madhuparna

Composite textiles have found widespread use and advantages in various industries and applications. The constant demand for high quality products and services requires companies to minimize their manufacturing costs, and delivery time in order to compete in general and niche marketplaces. Advanced manufacturing methods aim to provide economical methods of mold production. Creation of molding and tooling options for advanced composites encompasses a large portion of the fabrication time, making it a costly process and restraining factor. This research discusses a preliminary investigation into the use of soluble polymer compounds and additive manufacturing to fabricate soluble molds. These molds suffer from dimensional errors due to several factors, which have also been characterized. The basic soluble mold of a composite is 3D printed to meet the desired dimensions and geometry of holistic structures or spliced components. The time taken to dissolve the mold depends on the rate of agitation of the solvent. This process is steered towards enabling the implantation of optoelectronic devices within the composite to provide sensing capability for structural health monitoring. The shape deviation of the 3D printed mold is also studied and compared to its original dimensions to optimize the dimensional quality to produce dimensionally accurate parts. Mechanical tests were performed on compact tension (CT) resin samples prepared from these 3D printed molds and revealed crack propagation towards an embedded intact optical fiber.

Photovoltaic Materials

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

Duty, C.; Angelini, J.; Armstrong, B.

The goal of the current project was to help make the US solar industry a world leader in the manufacture of thin film photovoltaics. The overall approach was to leverage ORNL’s unique characterization and processing technologies to gain a better understanding of the fundamental challenges for solar cell processing and apply that knowledge to targeted projects with industry members. ORNL has the capabilities in place and the expertise required to understand how basic material properties including defects, impurities, and grain boundaries affect the solar cell performance. ORNL also has unique processing capabilities to optimize the manufacturing process for fabrication ofmore » high efficiency and low cost solar cells. ORNL recently established the Center for Advanced Thin-film Systems (CATS), which contains a suite of optical and electrical characterization equipment specifically focused on solar cell research. Under this project, ORNL made these facilities available to industrial partners who were interested in pursuing collaborative research toward the improvement of their product or manufacturing process. Four specific projects were pursued with industrial partners: Global Solar Energy is a solar industry leader in full scale production manufacturing highly-efficient Copper Indium Gallium diSelenide (CIGS) thin film solar material, cells and products. ORNL worked with GSE to develop a scalable, non-vacuum, solution technique to deposit amorphous or nanocrystalline conducting barrier layers on untextured stainless steel substrates for fabricating high efficiency flexible CIGS PV. Ferro Corporation’s Electronic, Color and Glass Materials (“ECGM”) business unit is currently the world’s largest supplier of metallic contact materials in the crystalline solar cell marketplace. Ferro’s ECGM business unit has been the world's leading supplier of thick film metal pastes to the crystalline silicon PV industry for more than 30 years, and has had operational cells and modules in the field for 25 years. Under this project, Ferro leveraged world leading analytical capabilities at ORNL to characterize the paste-to-silicon interface microstructure and develop high efficiency next generation contact pastes. Ampulse Corporation is developing a revolutionary crystalline-silicon (c-Si) thin-film solar photovoltaic (PV) technology. Utilizing uniquely-textured substrates and buffer materials from the Oak Ridge National Laboratory (ORNL), and breakthroughs in Hot-Wire Chemical Vapor Deposition (HW-CVD) techniques in epitaxial silicon developed at the National Renewable Energy Laboratory (NREL), Ampulse is creating a solar technology that is tunable in silicon thickness, and hence in efficiency and economics, to meet the specific requirements of multiple solar PV applications. This project focused on the development of a high rate deposition process to deposit Si, Ge, and Si1-xGex films as an alternate to hot-wire CVD. Mossey Creek Solar is a start-up company with great expertise in the solar field. The primary interest is to create and preserve jobs in the solar sector by developing high-yield, low-cost, high-efficiency solar cells using MSC-patented and -proprietary technologies. The specific goal of this project was to produce large grain formation in thin, net-shape-thickness mc-Si wafers processed with high-purity silicon powder and ORNL's plasma arc lamp melting without introducing impurities that compromise absorption coefficient and carrier lifetime. As part of this project, ORNL also added specific pieces of equipment to enhance our ability to provide unique insight for the solar industry. These capabilities include a moisture barrier measurement system, a combined physical vapor deposition and sputtering system dedicated to cadmium-containing deposits, adeep level transient spectroscopy system useful for identifying defects, an integrating sphere photoluminescence system, and a high-speed ink jet printing system. These tools were combined with others to study the effect of defects on the performance of crystalline silicon and thin film solar cells, to explore non-vacuum ink-based approaches to solar cell production, as well as large-scale and low-cost deposition and processing of thin film CdTe material.« less

Film Delivery Module For Fiber Placement Fabrication of Hybridized Composite Structures

NASA Technical Reports Server (NTRS)

Hulcher, Anthony Bruce; Young, Greg

2005-01-01

A new fabrication technology has been developed at the NASA Marshall Space Flight Center that will allow for the fabrication of hybridized composite structures using fiber placement processing. This technology was originally developed in response to a need to address the issue of hydrogen permeation and microcracking in cryogenic propellant tanks. Numerous thin polymeric and metallized films were investigated under low temperatures conditions for use as barrier films in a composite tank. Manufacturing studies conducted at that time did not address the processing issues related to fabrication of a hybridized tank wall. A film processing head was developed that will allow for the processing of thin polymeric and metallized films, metallic foils, and adhesives using fiber placement processing machinery. The film head is designed to enable the simultaneous processing of film materials and composite tape/tow during the composite part layup process and is also capable of processing the film during an independent operation. Several initial demonstrations were conducted to assess the performance of the film module device. Such assessments included film strip lay-up accuracy, capability to fabricate panels having internal film liners, and fabrication of laminates with embedded film layers.

In-Line Detection and Measurement of Molecular Contamination in Semiconductor Process Solutions

NASA Astrophysics Data System (ADS)

Wang, Jason; West, Michael; Han, Ye; McDonald, Robert C.; Yang, Wenjing; Ormond, Bob; Saini, Harmesh

2005-09-01

This paper discusses a fully automated metrology tool for detection and quantitative measurement of contamination, including cationic, anionic, metallic, organic, and molecular species present in semiconductor process solutions. The instrument is based on an electrospray ionization time-of-flight mass spectrometer (ESI-TOF/MS) platform. The tool can be used in diagnostic or analytical modes to understand process problems in addition to enabling routine metrology functions. Metrology functions include in-line contamination measurement with near real-time trend analysis. This paper discusses representative organic and molecular contamination measurement results in production process problem solving efforts. The examples include the analysis and identification of organic compounds in SC-1 pre-gate clean solution; urea, NMP (N-Methyl-2-pyrrolidone) and phosphoric acid contamination in UPW; and plasticizer and an organic sulfur-containing compound found in isopropyl alcohol (IPA). It is expected that these unique analytical and metrology capabilities will improve the understanding of the effect of organic and molecular contamination on device performance and yield. This will permit the development of quantitative correlations between contamination levels and process degradation. It is also expected that the ability to perform routine process chemistry metrology will lead to corresponding improvements in manufacturing process control and yield, the ability to avoid excursions and will improve the overall cost effectiveness of the semiconductor manufacturing process.

Direct analysis in real time mass spectrometry, a process analytical technology tool for real-time process monitoring in botanical drug manufacturing.

PubMed

Wang, Lu; Zeng, Shanshan; Chen, Teng; Qu, Haibin

2014-03-01

A promising process analytical technology (PAT) tool has been introduced for batch processes monitoring. Direct analysis in real time mass spectrometry (DART-MS), a means of rapid fingerprint analysis, was applied to a percolation process with multi-constituent substances for an anti-cancer botanical preparation. Fifteen batches were carried out, including ten normal operations and five abnormal batches with artificial variations. The obtained multivariate data were analyzed by a multi-way partial least squares (MPLS) model. Control trajectories were derived from eight normal batches, and the qualification was tested by R(2) and Q(2). Accuracy and diagnosis capability of the batch model were then validated by the remaining batches. Assisted with high performance liquid chromatography (HPLC) determination, process faults were explained by corresponding variable contributions. Furthermore, a batch level model was developed to compare and assess the model performance. The present study has demonstrated that DART-MS is very promising in process monitoring in botanical manufacturing. Compared with general PAT tools, DART-MS offers a particular account on effective compositions and can be potentially used to improve batch quality and process consistency of samples in complex matrices. Copyright © 2014 Elsevier B.V. All rights reserved.

Current Good Manufacturing Practice Production of an Oncolytic Recombinant Vesicular Stomatitis Viral Vector for Cancer Treatment

PubMed Central

Meseck, M.; Derecho, I.; Lopez, P.; Knoblauch, C.; McMahon, R.; Anderson, J.; Dunphy, N.; Quezada, V.; Khan, R.; Huang, P.; Dang, W.; Luo, M.; Hsu, D.; Woo, S.L.C.; Couture, L.

2011-01-01

Abstract Vesicular stomatitis virus (VSV) is an oncolytic virus currently being investigated as a promising tool to treat cancer because of its ability to selectively replicate in cancer cells. To enhance the oncolytic property of the nonpathologic laboratory strain of VSV, we generated a recombinant vector [rVSV(MΔ51)-M3] expressing murine gammaherpesvirus M3, a secreted viral chemokine-binding protein that binds to a broad range of mammalian chemokines with high affinity. As previously reported, when rVSV(MΔ51)-M3 was used in an orthotopic model of hepatocellular carcinoma (HCC) in rats, it suppressed inflammatory cell migration to the virus-infected tumor site, which allowed for enhanced intratumoral virus replication leading to increased tumor necrosis and substantially prolonged survival. These encouraging results led to the development of this vector for clinical translation in patients with HCC. However, a scalable current Good Manufacturing Practice (cGMP)-compliant manufacturing process has not been described for this vector. To produce the quantities of high-titer virus required for clinical trials, a process that is amenable to GMP manufacturing and scale-up was developed. We describe here a large-scale (50-liter) vector production process capable of achieving crude titers on the order of 109 plaque-forming units (PFU)/ml under cGMP. This process was used to generate a master virus seed stock and a clinical lot of the clinical trial agent under cGMP with an infectious viral titer of approximately 2 × 1010 PFU/ml (total yield, 1 × 1013 PFU). The lot has passed all U.S. Food and Drug Administration-mandated release testing and will be used in a phase 1 clinical translational trial in patients with advanced HCC. PMID:21083425

Current good manufacturing practice production of an oncolytic recombinant vesicular stomatitis viral vector for cancer treatment.

PubMed

Ausubel, L J; Meseck, M; Derecho, I; Lopez, P; Knoblauch, C; McMahon, R; Anderson, J; Dunphy, N; Quezada, V; Khan, R; Huang, P; Dang, W; Luo, M; Hsu, D; Woo, S L C; Couture, L

2011-04-01

Vesicular stomatitis virus (VSV) is an oncolytic virus currently being investigated as a promising tool to treat cancer because of its ability to selectively replicate in cancer cells. To enhance the oncolytic property of the nonpathologic laboratory strain of VSV, we generated a recombinant vector [rVSV(MΔ51)-M3] expressing murine gammaherpesvirus M3, a secreted viral chemokine-binding protein that binds to a broad range of mammalian chemokines with high affinity. As previously reported, when rVSV(MΔ51)-M3 was used in an orthotopic model of hepatocellular carcinoma (HCC) in rats, it suppressed inflammatory cell migration to the virus-infected tumor site, which allowed for enhanced intratumoral virus replication leading to increased tumor necrosis and substantially prolonged survival. These encouraging results led to the development of this vector for clinical translation in patients with HCC. However, a scalable current Good Manufacturing Practice (cGMP)-compliant manufacturing process has not been described for this vector. To produce the quantities of high-titer virus required for clinical trials, a process that is amenable to GMP manufacturing and scale-up was developed. We describe here a large-scale (50-liter) vector production process capable of achieving crude titers on the order of 10(9) plaque-forming units (PFU)/ml under cGMP. This process was used to generate a master virus seed stock and a clinical lot of the clinical trial agent under cGMP with an infectious viral titer of approximately 2 × 10(10) PFU/ml (total yield, 1 × 10(13) PFU). The lot has passed all U.S. Food and Drug Administration-mandated release testing and will be used in a phase 1 clinical translational trial in patients with advanced HCC.

Extension of the Vane Pump-Grinder Technology to Manufacture Finely Dispersed Meat Batters.

PubMed

Irmscher, Stefan B; Gibis, Monika; Herrmann, Kurt; Oechsle, Anja Maria; Kohlus, Reinhard; Weiss, Jochen

2016-03-01

A vane pump-grinder system was extended to enable the manufacture of finely dispersed emulsion-type sausages by constructing and attaching a high-shear homogenizer at the outlet. We hypothesized that the dispersing capabilities of the extended system may be improved to the point of facilitating meat-fat emulsification due to an overall increased volumetric energy input EV . Coarsely ground raw material mixtures were processed to yield meat batters at varying volume flow rates (10 to 60 L/min) and rotational rotor speeds of the homogenizer nrotor (1000 to 3400 rpm). The normalized torques acting on pump, grinder, and homogenizer motors were recorded and unit power consumptions were calculated. The structure of the manufactured meat batters and sausages were analyzed via image analysis. Key physicochemical properties of unheated and heated batters, that is, texture, water-binding, color, and solubilized protein were determined. The mean diameter d10 of the visible lean meat particles varied between 352 and 406 μm whereas the mean volume-surface diameter d32 varied between 603 and 796 μm. The lightness L* ranged from 66.2 to 70.7 and correlated with the volumetric energy input and product structure. By contrast, varying process parameters did not impact color values a* (approximately 11) and b* (approximately 8). Interestingly, water-binding and protein solubilization were not affected. An exponential process-structure relationship was identified allowing manufacturers to predict product properties as a function of applied process parameters. Raw material mixtures can be continuously comminuted, emulsified, and subsequently filled into casings using an extended vane pump-grinder. © 2016 Institute of Food Technologists®

Electron Beam Freeform Fabrication for Cost Effective Near-Net Shape Manufacturing

NASA Technical Reports Server (NTRS)

Taminger, Karen M.; Hafley, Robert A.

2006-01-01

Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley Research Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF3), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. EBF3 deposits of 2219 aluminium and Ti-6Al-4V have exhibited a range of grain morphologies depending upon the deposition parameters. These materials have exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF3 process is capable of bulk metal deposition at deposition rates in excess of 2500 cm3/hr (150 in3/hr) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

Electron Beam Freeform Fabrication (EBF3) for Cost Effective Near-Net Shape Manufacturing

NASA Technical Reports Server (NTRS)

Taminger, Karen M.; Hafley, Robert A.

2006-01-01

Manufacturing of structural metal parts directly from computer aided design (CAD) data has been investigated by numerous researchers over the past decade. Researchers at NASA Langley Research Center are developing a new solid freeform fabrication process, electron beam freeform fabrication (EBF3), as a rapid metal deposition process that works efficiently with a variety of weldable alloys. EBF3 deposits of 2219 aluminium and Ti-6Al-4V have exhibited a range of grain morphologies depending upon the deposition parameters. These materials have exhibited excellent tensile properties comparable to typical handbook data for wrought plate product after post-processing heat treatments. The EBF3 process is capable of bulk metal deposition at deposition rates in excess of 2500 cubic centimeters per hour (150 in3/hr) or finer detail at lower deposition rates, depending upon the desired application. This process offers the potential for rapidly adding structural details to simpler cast or forged structures rather than the conventional approach of machining large volumes of chips to produce a monolithic metallic structure. Selective addition of metal onto simpler blanks of material can have a significant effect on lead time reduction and lower material and machining costs.

A Low Temperature Co-fired Ceramics Manufactured Power Inductor Based on A Ternary Hybrid Material System

NASA Astrophysics Data System (ADS)

Xie, Yunsong; Chen, Ru

Low temperature co-fired ceramics (LTCC) is one of the most important techniques to produce circuits with high working frequency, multi-functionality and high integration. We have developed a methodology to enable a ternary hybrid material system being implemented into the LTCC manufacturing process. The co-firing sintering process can be divided into a densification and cooling process. In this method, a successful ternary hybrid material densification process is achieved by tuning the sintering profile of each material to match each other. The system integrity is maintained in the cooling process is obtained by develop a strong bonding at the interfaces of each materials. As a demonstration, we have construct a power inductor device made of the ternary material system including Ag, NiCuZn ferrite and non-magnetic ceramic. The power inductors well maintains its physical integrity after sintering. The microscopic images show no obvious sign of cracks or structural deformation. More importantly, despite the bonding between the ferrite and ceramic is enhanced by non-magnetic element diffusion, the undesired magnetic elements diffusion is effectively suppressed. The electric performance shows that the power handling capability is comparable to the current state of art device.

To repair or not to repair: with FAVOR there is no question

NASA Astrophysics Data System (ADS)

Garetto, Anthony; Schulz, Kristian; Tabbone, Gilles; Himmelhaus, Michael; Scheruebl, Thomas

2016-10-01

In the mask shop the challenges associated with today's advanced technology nodes, both technical and economic, are becoming increasingly difficult. The constant drive to continue shrinking features means more masks per device, smaller manufacturing tolerances and more complexity along the manufacturing line with respect to the number of manufacturing steps required. Furthermore, the extremely competitive nature of the industry makes it critical for mask shops to optimize asset utilization and processes in order to maximize their competitive advantage and, in the end, profitability. Full maximization of profitability in such a complex and technologically sophisticated environment simply cannot be achieved without the use of smart automation. Smart automation allows productivity to be maximized through better asset utilization and process optimization. Reliability is improved through the minimization of manual interactions leading to fewer human error contributions and a more efficient manufacturing line. In addition to these improvements in productivity and reliability, extra value can be added through the collection and cross-verification of data from multiple sources which provides more information about our products and processes. When it comes to handling mask defects, for instance, the process consists largely of time consuming manual interactions that are error prone and often require quick decisions from operators and engineers who are under pressure. The handling of defects itself is a multiple step process consisting of several iterations of inspection, disposition, repair, review and cleaning steps. Smaller manufacturing tolerances and features with higher complexity contribute to a higher number of defects which must be handled as well as a higher level of complexity. In this paper the recent efforts undertaken by ZEISS to provide solutions which address these challenges, particularly those associated with defectivity, will be presented. From automation of aerial image analysis to the use of data driven decision making to predict and propose the optimized back end of line process flow, productivity and reliability improvements are targeted by smart automation. Additionally the generation of the ideal aerial image from the design and several repair enhancement features offer additional capabilities to improve the efficiency and yield associated with defect handling.

Connecting American Manufacturers (CAM) Virtual Manufacturing Marketplace (VMM)

DTIC Science & Technology

2013-11-01

88ABW-2013-5037 1.0 SUMMARY The Connecting American Manufacturing (CAM) initiative was designed to improve the sourcing capability for Department...addition, CAM was designed to increase the number of US companies bidding on DoD business. The team’s overall approach was based on three major...is to designate a North American Industry Classification System (NAICS) code for each opportunity. Every manufacturing opportunity is posted to

EUV mask defect inspection and defect review strategies for EUV pilot line and high volume manufacturing

NASA Astrophysics Data System (ADS)

Chan, Y. David; Rastegar, Abbas; Yun, Henry; Putna, E. Steve; Wurm, Stefan

2010-04-01

Reducing mask blank and patterned mask defects is the number one challenge for extreme ultraviolet lithography. If the industry succeeds in reducing mask blank defects at the required rate of 10X every year for the next 2-3 years to meet high volume manufacturing defect requirements, new inspection and review tool capabilities will soon be needed to support this goal. This paper outlines the defect inspection and review tool technical requirements and suggests development plans to achieve pilot line readiness in 2011/12 and high volume manufacturing readiness in 2013. The technical specifications, tooling scenarios, and development plans were produced by a SEMATECH-led technical working group with broad industry participation from material suppliers, tool suppliers, mask houses, integrated device manufacturers, and consortia. The paper summarizes this technical working group's assessment of existing blank and mask inspection/review infrastructure capabilities to support pilot line introduction and outlines infrastructure development requirements and tooling strategies to support high volume manufacturing.

Development of advanced materials composites for use as insulations for LH2 tanks

NASA Technical Reports Server (NTRS)

Lemons, C. R.; Watts, C. R.; Salmassy, O. K.

1972-01-01

A study of internal insulation materials and fabrication processes for space shuttle LH2 tanks is reported. Emphasis was placed on an insulation system capable of reentry and multiple reuse in the Shuttle environment. Results are given on the optimization and manufacturing process scale-up of a 3D fiberreinforced foam insulation, BX-251-3D, derived from the Saturn S-4B internal insulation. It is shown that BX-251-3D can be satisfactorily installed in large-scale tanks under conditions that will permit a significant cost saving over the existing S-4B technology.

Advanced helmet vision system (AHVS) integrated night vision helmet mounted display (HMD)

NASA Astrophysics Data System (ADS)

Ashcraft, Todd W.; Atac, Robert

2012-06-01

Gentex Corporation, under contract to Naval Air Systems Command (AIR 4.0T), designed the Advanced Helmet Vision System to provide aircrew with 24-hour, visor-projected binocular night vision and HMD capability. AHVS integrates numerous key technologies, including high brightness Light Emitting Diode (LED)-based digital light engines, advanced lightweight optical materials and manufacturing processes, and innovations in graphics processing software. This paper reviews the current status of miniaturization and integration with the latest two-part Gentex modular helmet, highlights the lessons learned from previous AHVS phases, and discusses plans for qualification and flight testing.

Advanced manufacturing—A transformative enabling capability for fusion

DOE PAGES

Nygren, Richard E.; Dehoff, Ryan R.; Youchison, Dennis L.; ...

2018-05-24

Additive Manufacturing (AM) can create novel and complex engineered material structures. Features such as controlled porosity, micro-fibers and/or nano-particles, transitions in materials and integral robust coatings can be important in developing solutions for fusion subcomponents. A realistic understanding of this capability would be particularly valuable in identifying development paths. Major concerns for using AM processes with lasers or electron beams that melt powder to make refractory parts are the power required and residual stresses arising in fabrication. A related issue is the required combination of lasers or e-beams to continue heating of deposited material (to reduce stresses) and to depositmore » new material at a reasonable built rate while providing adequate surface finish and resolution for meso-scale features. In conclusion, Some Direct Write processes that can make suitable preforms and be cured to an acceptable density may offer another approach for PFCs.« less

Advanced manufacturing—A transformative enabling capability for fusion

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

Nygren, Richard E.; Dehoff, Ryan R.; Youchison, Dennis L.

Additive Manufacturing (AM) can create novel and complex engineered material structures. Features such as controlled porosity, micro-fibers and/or nano-particles, transitions in materials and integral robust coatings can be important in developing solutions for fusion subcomponents. A realistic understanding of this capability would be particularly valuable in identifying development paths. Major concerns for using AM processes with lasers or electron beams that melt powder to make refractory parts are the power required and residual stresses arising in fabrication. A related issue is the required combination of lasers or e-beams to continue heating of deposited material (to reduce stresses) and to depositmore » new material at a reasonable built rate while providing adequate surface finish and resolution for meso-scale features. In conclusion, Some Direct Write processes that can make suitable preforms and be cured to an acceptable density may offer another approach for PFCs.« less

Investigation into the use of smartphone as a machine vision device for engineering metrology and flaw detection, with focus on drilling

NASA Astrophysics Data System (ADS)

Razdan, Vikram; Bateman, Richard

2015-05-01

This study investigates the use of a Smartphone and its camera vision capabilities in Engineering metrology and flaw detection, with a view to develop a low cost alternative to Machine vision systems which are out of range for small scale manufacturers. A Smartphone has to provide a similar level of accuracy as Machine Vision devices like Smart cameras. The objective set out was to develop an App on an Android Smartphone, incorporating advanced Computer vision algorithms written in java code. The App could then be used for recording measurements of Twist Drill bits and hole geometry, and analysing the results for accuracy. A detailed literature review was carried out for in-depth study of Machine vision systems and their capabilities, including a comparison between the HTC One X Android Smartphone and the Teledyne Dalsa BOA Smart camera. A review of the existing metrology Apps in the market was also undertaken. In addition, the drilling operation was evaluated to establish key measurement parameters of a twist Drill bit, especially flank wear and diameter. The methodology covers software development of the Android App, including the use of image processing algorithms like Gaussian Blur, Sobel and Canny available from OpenCV software library, as well as designing and developing the experimental set-up for carrying out the measurements. The results obtained from the experimental set-up were analysed for geometry of Twist Drill bits and holes, including diametrical measurements and flaw detection. The results show that Smartphones like the HTC One X have the processing power and the camera capability to carry out metrological tasks, although dimensional accuracy achievable from the Smartphone App is below the level provided by Machine vision devices like Smart cameras. A Smartphone with mechanical attachments, capable of image processing and having a reasonable level of accuracy in dimensional measurement, has the potential to become a handy low-cost Machine vision system for small scale manufacturers, especially in field metrology and flaw detection.

An evolutionary sensor approach for self-organizing production chains

NASA Astrophysics Data System (ADS)

Mocan, M.; Gillich, E. V.; Mituletu, I. C.; Korka, Z. I.

2018-01-01

Industry 4.0 is the actual great step in industrial progress. Convergence of industrial equipment with the power of advanced computing and analysis, low-cost sensing, and new connecting technologies are presumed to bring unexpected advancements in automation, flexibility, and efficiency. In this context, sensors ensure information regarding three essential areas: the number of processed elements, the quality of production and the condition of tools and equipment. To obtain this valuable information, the data resulted from a sensor has to be firstly processed and afterward used by the different stakeholders. If machines are linked together, this information can be employed to organize the production chain with few or without human intervention. We describe here the implementation of a sensor in a milling machine that is part of a simple production chain, capable of providing information regarding the number of manufactured pieces. It is used by the other machines in the production chain, in order to define the type and number of pieces to be manufactured by them and/or to set optimal parameters for their working regime. Secondly, the information achieved by monitoring the machine and manufactured piece dynamic behavior is used to evaluate the product quality. This information is used to warn about the need of maintenance, being transmitted to the specialized department. It is also transmitted to the central unit, in order to reorganize the production by involving other machines or by reconsidering the manufacturing regime of the existing machines. A special attention is drawn on analyzing and classifying the signals acquired via optical sensor from simulated processes.

The Manufacture of W-UO2 Fuel Elements for NTP Using the Hot Isostatic Pressing Consolidation Process

NASA Technical Reports Server (NTRS)

Broadway, Jeramie; Hickman, Robert; Mireles, Omar

2012-01-01

NTP is attractive for space exploration because: (1) Higher Isp than traditional chemical rockets (2)Shorter trip times (3) Reduced propellant mass (4) Increased payload. Lack of qualified fuel material is a key risk (cost, schedule, and performance). Development of stable fuel form is a critical path, long lead activity. Goals of this project are: Mature CERMET and Graphite based fuel materials and Develop and demonstrate critical technologies and capabilities.

Development of autonomous multirotor platform for exploration missions

NASA Astrophysics Data System (ADS)

Czyba, Roman; Janik, Marcin; Kurgan, Oliver; Niezabitowski, Michał; Nocoń, Marek

2016-06-01

This paper outlines development process of unmanned multirotor aerial vehicle HF-4X, which consists of design and manufacturing semi-autonomous UAV dedicated for indoor flight, which would be capable of stable and controllable mission flight. A micro air vehicle was designed to participate in the International Micro Air Vehicle Conference and Flight Competition. In this paper much attention was paid to the structure of flight control system, stabilization algorithms, analysis of IMU sensors, fusion algorithms.

Development of autonomous multirotor platform for exploration missions

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

Czyba, Roman; Janik, Marcin; Kurgan, Oliver

This paper outlines development process of unmanned multirotor aerial vehicle HF-4X, which consists of design and manufacturing semi-autonomous UAV dedicated for indoor flight, which would be capable of stable and controllable mission flight. A micro air vehicle was designed to participate in the International Micro Air Vehicle Conference and Flight Competition. In this paper much attention was paid to the structure of flight control system, stabilization algorithms, analysis of IMU sensors, fusion algorithms.

Advanced manufacturing rules check (MRC) for fully automated assessment of complex reticle designs

NASA Astrophysics Data System (ADS)

Gladhill, R.; Aguilar, D.; Buck, P. D.; Dawkins, D.; Nolke, S.; Riddick, J.; Straub, J. A.

2005-11-01

Advanced electronic design automation (EDA) tools, with their simulation, modeling, design rule checking, and optical proximity correction capabilities, have facilitated the improvement of first pass wafer yields. While the data produced by these tools may have been processed for optimal wafer manufacturing, it is possible for the same data to be far from ideal for photomask manufacturing, particularly at lithography and inspection stages, resulting in production delays and increased costs. The same EDA tools used to produce the data can be used to detect potential problems for photomask manufacturing in the data. A production implementation of automated photomask manufacturing rule checking (MRC) is presented and discussed for various photomask lithography and inspection lines. This paper will focus on identifying data which may cause production delays at the mask inspection stage. It will be shown how photomask MRC can be used to discover data related problems prior to inspection, separating jobs which are likely to have problems at inspection from those which are not. Photomask MRC can also be used to identify geometries requiring adjustment of inspection parameters for optimal inspection, and to assist with any special handling or change of routing requirements. With this foreknowledge, steps can be taken to avoid production delays that increase manufacturing costs. Finally, the data flow implemented for MRC can be used as a platform for other photomask data preparation tasks.

Targeted Structural Optimization with Additive Manufacturing of Metals

NASA Technical Reports Server (NTRS)

Burt, Adam; Hull, Patrick

2015-01-01

The recent advances in additive manufacturing (AM) of metals have now improved the state-of-the-art such that traditionally non-producible parts can be readily produced in a cost-effective way. Because of these advances in manufacturing technology, structural optimization techniques are well positioned to supplement and advance this new technology. The goal of this project is to develop a structural design, analysis, and optimization framework combined with AM to significantly light-weight the interior of metallic structures while maintaining the selected structural properties of the original solid. This is a new state-of-the-art capability to significantly reduce mass, while maintaining the structural integrity of the original design, something that can only be done with AM. In addition, this framework will couple the design, analysis, and fabrication process, meaning that what has been designed directly represents the produced part, thus closing the loop on the design cycle and removing human iteration between design and fabrication. This fundamental concept has applications from light-weighting launch vehicle components to in situ resource fabrication.

Rapid prototyping for biomedical engineering: current capabilities and challenges.

PubMed

Lantada, Andrés Díaz; Morgado, Pilar Lafont

2012-01-01

A new set of manufacturing technologies has emerged in the past decades to address market requirements in a customized way and to provide support for research tasks that require prototypes. These new techniques and technologies are usually referred to as rapid prototyping and manufacturing technologies, and they allow prototypes to be produced in a wide range of materials with remarkable precision in a couple of hours. Although they have been rapidly incorporated into product development methodologies, they are still under development, and their applications in bioengineering are continuously evolving. Rapid prototyping and manufacturing technologies can be of assistance in every stage of the development process of novel biodevices, to address various problems that can arise in the devices' interactions with biological systems and the fact that the design decisions must be tested carefully. This review focuses on the main fields of application for rapid prototyping in biomedical engineering and health sciences, as well as on the most remarkable challenges and research trends.

Future directions for the development of virtual reality within an automotive manufacturer.

PubMed

Lawson, Glyn; Salanitri, Davide; Waterfield, Brian

2016-03-01

Virtual Reality (VR) can reduce time and costs, and lead to increases in quality, in the development of a product. Given the pressure on car companies to reduce time-to-market and to continually improve quality, the automotive industry has championed the use of VR across a number of applications, including design, manufacturing, and training. This paper describes interviews with 11 engineers and employees of allied disciplines from an automotive manufacturer about their current physical and virtual properties and processes. The results guided a review of research findings and scientific advances from the academic literature, which formed the basis of recommendations for future developments of VR technologies and applications. These include: develop a greater range of virtual contexts; use multi-sensory simulation; address perceived differences between virtual and real cars; improve motion capture capabilities; implement networked 3D technology; and use VR for market research. Copyright © 2015 Elsevier Ltd and The Ergonomics Society. All rights reserved.

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.

Regulatory Considerations in the Design and Manufacturing of Implantable 3D‐Printed Medical Devices

PubMed Central

Morrison, Robert J.; Kashlan, Khaled N.; Flanangan, Colleen L.; Wright, Jeanne K.; Green, Glenn E.; Hollister, Scott J.

2015-01-01

Abstract Three‐dimensional (3D) printing, or additive manufacturing, technology has rapidly penetrated the medical device industry over the past several years, and innovative groups have harnessed it to create devices with unique composition, structure, and customizability. These distinctive capabilities afforded by 3D printing have introduced new regulatory challenges. The customizability of 3D‐printed devices introduces new complexities when drafting a design control model for FDA consideration of market approval. The customizability and unique build processes of 3D‐printed medical devices pose unique challenges in meeting regulatory standards related to the manufacturing quality assurance. Consistent material powder properties and optimal printing parameters such as build orientation and laser power must be addressed and communicated to the FDA to ensure a quality build. Postprinting considerations unique to 3D‐printed devices, such as cleaning, finishing and sterilization are also discussed. In this manuscript we illustrate how such regulatory hurdles can be navigated by discussing our experience with our group's 3D‐printed bioresorbable implantable device. PMID:26243449

SLI Complex Curvature Friction Stir Weld Risk Reduction Program

NASA Technical Reports Server (NTRS)

Hartley, Paula J.; Schneider, Jules; Jones, Chip; Lawless, Kirby; Russell, Carolyn

2003-01-01

The Space Launch Initiative Program (SLI) in conjunction with the National Center for Advanced Manufacturing (NCAM) will demonstrate the ability to produce large-scale complex curvature hardware using the self-reacting friction stir welding process. This multi-phased risk reduction program includes friction stir welding process development and manufacture of a 22-ft diameter quarter dome using a conventional tooling approach; it culminates in a 27.5-ft diameter quarter dome demonstration performed on a 5-axis Universal Weld System. The design, fabrication, and installation of the Universal Weld System is made possible through a collaboration between the State of Louisiana, NASA, and the University of New Orleans. The Universal Weld System, manufactured by MTS Systems Corporation, will be installed at the Michoud Assembly Facility in New Orleans, Louisiana, and will be capable of manufacturing domes up to 30 ft in diameter. All welding will be accomplished using the Adaptable Adjustable Pin Tool (AdAPT) weld head and controller manufactured by MTS. Weld parameters will be developed for an aluminum alloy in gauges ranging from 0.320 to 0.400 in. thick. Weld quality will be verified through radiography, mechanical property testing at ambient and LN2 temperatures, and metallurgical analysis. The AdAPT weld head will then be mounted on a 22-ft diameter dome tool, which will be modified to include a welding track and drive system for moving the AdAPT weld head along the weld joint. This tool will then be used to manufacture a 22-ft diameter dome of an aluminum alloy, with 0.320-in. constant thickness joints, consisting of three individual gore panels. Finally, the 27.5-ft diameter quarter dome will be welded on the Universal Weld System. The quarter dome will consist of three individual gore panels with weld lands tapering from 0.320 to 0.360 in. in thickness. With the demonstration of these welds, the ability to manufacture large diameter domes using the friction stir weld process in conjunction with a universal weld system provides a low risk approach to the fabrication of aluminum tanks for future launch vehicle applications.

Institute for Defense Analysis. Annual Report 1994

DTIC Science & Technology

1994-01-01

activities with engineering and rines in submarine-unique roles. However, we manufacturing development into a single identified a number of other...development efforts. In addition, and mine-laying capabilities, with roughly 25 the panel proposed increasing both the number nations manufacturing ...the engineering concepts and design, and for implementing Synthetic Aperture Radar flexible manufacturing procedures for focal Reconnaissance

Method of manufacturing large dish reflectors for a solar concentrator apparatus

DOEpatents

Angel, Roger P [Tucson, AZ; Olbert, Blain H [Tucson, AZ

2011-12-27

A method of manufacturing monolithic glass reflectors for concentrating sunlight in a solar energy system is disclosed. The method of manufacturing allows large monolithic glass reflectors to be made from float glass in order to realize significant cost savings on the total system cost for a solar energy system. The method of manufacture includes steps of heating a sheet of float glass positioned over a concave mold until the sheet of glass sags and stretches to conform to the shape of the mold. The edges of the dish-shaped glass are rolled for structural stiffening around the periphery. The dish-shaped glass is then silvered to create a dish-shaped mirror that reflects solar radiation to a focus. The surface of the mold that contacts the float glass preferably has a grooved surface profile comprising a plurality of cusps and concave valleys. This grooved profile minimizes the contact area and marring of the specular glass surface, reduces parasitic heat transfer into the mold and increases mold lifetime. The disclosed method of manufacture is capable of high production rates sufficiently fast to accommodate the output of a conventional float glass production line so that monolithic glass reflectors can be produced as quickly as a float glass production can make sheets of float glass to be used in the process.

The effect of adopting new storage methods for extending product validity periods on manufacturers expected inventory costs.

PubMed

Chen, Po-Yu

2014-01-01

The validness of the expiration dates (validity period) that manufacturers provide on food product labels is a crucial food safety problem. Governments must study how to use their authority by implementing fair awards and punishments to prompt manufacturers into adopting rigorous considerations, such as the effect of adopting new storage methods for extending product validity periods on expected costs. Assuming that a manufacturer sells fresh food or drugs, this manufacturer must respond to current stochastic demands at each unit of time to determine the purchase amount of products for sale. If this decision maker is capable and an opportunity arises, new packaging methods (e.g., aluminum foil packaging, vacuum packaging, high-temperature sterilization after glass packaging, or packaging with various degrees of dryness) or storage methods (i.e., adding desiccants or various antioxidants) can be chosen to extend the validity periods of products. To minimize expected costs, this decision maker must be aware of the processing costs of new storage methods, inventory standards, inventory cycle lengths, and changes in relationships between factors such as stochastic demand functions in a cycle. Based on these changes in relationships, this study established a mathematical model as a basis for discussing the aforementioned topics.

A modelling framework for the transport, transformation and biouptake of manufactured nanoparticles in the aquatic environment

NASA Astrophysics Data System (ADS)

Lofts, Stephen; Keller, Virginie; Dumont, Egon; Williams, Richard; Praetorius, Antonia; von der Kammer, Frank

2016-04-01

The development of innovative new chemical products is a key aspect of the modern economy, yet society demands that such development is environmentally sustainable. Developing knowledge of how new classes of chemicals behave following release to the environment is key to understanding the hazards that will potentially result. Nanoparticles are a key example of a class of chemicals that have undergone a significant expansion in production and use in recent years and so there is a need to develop tools to predict their potential hazard following their deliberate or incidental release to the environment. Generalising the understanding of the environmental behaviour of manufactured nanoparticles in general is challenging, as they are chemically and physically diverse (e.g. metals, metal oxides, carbon nanotubes, cellulose, quantum dots). Furthermore, nanoparticles may be manufactured with capping agents to modify their desired behaviour in industrial applications; such agents may also influence their environmental behaviour. Also, nanoparticles may become significantly modified from their as-manufactured forms both prior to and after the point of environmental release. Tools for predicting nanoparticle behaviour and hazard need to be able to consider a wide range of release scenarios and aspects of nanoparticle behaviour in the environment (e.g. dissolution, transformation of capping agents, agglomeration and aggregation behaviour), where such behaviours are not shared by all types of nanoparticle. This implies the need for flexible, futureproofed tools capable of being updated to take new understanding of behavioural processes into account as such knowledge emerges. This presentation will introduce the NanoFASE model system, a multimedia modelling framework for the transport, transformation and biouptake of manufactured nanoparticles. The complete system will comprise atmospheric, terrestrial and aquatic compartments to allow holistic simulation of nanoparticles; this presentation will focus on the aquatic compartment but will demonstrate the linkages with the other compartments. The system is intended for application at scales up to a large European river catchment at a resolution suitable for assessing spatially-resolved fate and biouptake. The model will be built around a transport framework which will deal with the bulk movement of water, sediments and nanoparticles through the system. Transformation processes such as dissolution, capping agent transformation, sorption of environmental molecules to particle surfaces, heteroaggregation with sediments, will be dealt with within 'reactors' with each grid cell. The reactor concept is intended to provide a separation between transport and transformation process, to allow alternative formulations of transformation processes for different classes of nanoparticles, and to allow new and updated formulations to be readily incorporated. Using this structure we aim to develop a flexible system capable of simulating the environmental transformation and fate of diverse nanoparticle classes under varying release scenarios. We will show conceptual model structures for release scenarios most relevant to the aquatic environment.

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

Lindsey, Nicholas C.

The growth of additive manufacturing as a disruptive technology poses nuclear proliferation concerns worthy of serious consideration. Additive manufacturing began in the early 1980s with technological advances in polymer manipulation, computer capabilities, and computer-aided design (CAD) modeling. It was originally limited to rapid prototyping; however, it eventually developed into a complete means of production that has slowly penetrated the consumer market. Today, additive manufacturing machines can produce complex and unique items in a vast array of materials including plastics, metals, and ceramics. These capabilities have democratized the manufacturing industry, allowing almost anyone to produce items as simple as cup holdersmore » or as complex as jet fuel nozzles. Additive manufacturing, or three-dimensional (3D) printing as it is commonly called, relies on CAD files created or shared by individuals with additive manufacturing machines to produce a 3D object from a digital model. This sharing of files means that a 3D object can be scanned or rendered as a CAD model in one country, and then downloaded and printed in another country, allowing items to be shared globally without physically crossing borders. The sharing of CAD files online has been a challenging task for the export controls regime to manage over the years, and additive manufacturing could make these transfers more common. In this sense, additive manufacturing is a disruptive technology not only within the manufacturing industry but also within the nuclear nonproliferation world. This paper provides an overview of additive manufacturing concerns of proliferation.« less

Stent manufacturing using cobalt chromium molybdenum (CoCrMo) by selective laser melting technology

NASA Astrophysics Data System (ADS)

Omar, Mohd Asnawi; Baharudin, BT-HT; Sulaiman, S.

2017-12-01

This paper reviews the capabilities of additive manufacturing (AM) technology and the use of Cobalt super alloy stent fabrication by looking at the dimensional accuracy and mechanical properties of the stent. Current conventional process exhibit many processes which affect the supply chain, costing, and post processing. By alternatively switching to AM, the step of production can be minimized and thus customization of stent can be carried out according to patients need. The proposed methodology is a perfect choice as surgeons need to have an accurate size during stent implantation. It also is able to reduce time-to-market delivery in a matter of hours and from days. The suggested stent model was taken from the third party vendor and flow optimization was carried out using Materialise Magics TM software. By using SLM125TM printer, the printing parameters such as Energy Density (DE), Laser Power (PL), Scanning Speed (SS) and Hatching Distance (DH) was used to print the stent. The properties of the finished product, such as strength, surface finish and orientation was investigated.

Process in manufacturing high efficiency AlGaAs/GaAs solar cells by MO-CVD

NASA Technical Reports Server (NTRS)

Yeh, Y. C. M.; Chang, K. I.; Tandon, J.

1984-01-01

Manufacturing technology for mass producing high efficiency GaAs solar cells is discussed. A progress using a high throughput MO-CVD reactor to produce high efficiency GaAs solar cells is discussed. Thickness and doping concentration uniformity of metal oxide chemical vapor deposition (MO-CVD) GaAs and AlGaAs layer growth are discussed. In addition, new tooling designs are given which increase the throughput of solar cell processing. To date, 2cm x 2cm AlGaAs/GaAs solar cells with efficiency up to 16.5% were produced. In order to meet throughput goals for mass producing GaAs solar cells, a large MO-CVD system (Cambridge Instrument Model MR-200) with a susceptor which was initially capable of processing 20 wafers (up to 75 mm diameter) during a single growth run was installed. In the MR-200, the sequencing of the gases and the heating power are controlled by a microprocessor-based programmable control console. Hence, operator errors can be reduced, leading to a more reproducible production sequence.

Allogeneic Cell Therapy Bioprocess Economics and Optimization: Single-Use Cell Expansion Technologies

PubMed Central

Simaria, Ana S; Hassan, Sally; Varadaraju, Hemanthram; Rowley, Jon; Warren, Kim; Vanek, Philip; Farid, Suzanne S

2014-01-01

For allogeneic cell therapies to reach their therapeutic potential, challenges related to achieving scalable and robust manufacturing processes will need to be addressed. A particular challenge is producing lot-sizes capable of meeting commercial demands of up to 109 cells/dose for large patient numbers due to the current limitations of expansion technologies. This article describes the application of a decisional tool to identify the most cost-effective expansion technologies for different scales of production as well as current gaps in the technology capabilities for allogeneic cell therapy manufacture. The tool integrates bioprocess economics with optimization to assess the economic competitiveness of planar and microcarrier-based cell expansion technologies. Visualization methods were used to identify the production scales where planar technologies will cease to be cost-effective and where microcarrier-based bioreactors become the only option. The tool outputs also predict that for the industry to be sustainable for high demand scenarios, significant increases will likely be needed in the performance capabilities of microcarrier-based systems. These data are presented using a technology S-curve as well as windows of operation to identify the combination of cell productivities and scale of single-use bioreactors required to meet future lot sizes. The modeling insights can be used to identify where future R&D investment should be focused to improve the performance of the most promising technologies so that they become a robust and scalable option that enables the cell therapy industry reach commercially relevant lot sizes. The tool outputs can facilitate decision-making very early on in development and be used to predict, and better manage, the risk of process changes needed as products proceed through the development pathway. Biotechnol. Bioeng. 2014;111: 69–83. © 2013 Wiley Periodicals, Inc. PMID:23893544

Allogeneic cell therapy bioprocess economics and optimization: single-use cell expansion technologies.

PubMed

Simaria, Ana S; Hassan, Sally; Varadaraju, Hemanthram; Rowley, Jon; Warren, Kim; Vanek, Philip; Farid, Suzanne S

2014-01-01

For allogeneic cell therapies to reach their therapeutic potential, challenges related to achieving scalable and robust manufacturing processes will need to be addressed. A particular challenge is producing lot-sizes capable of meeting commercial demands of up to 10(9) cells/dose for large patient numbers due to the current limitations of expansion technologies. This article describes the application of a decisional tool to identify the most cost-effective expansion technologies for different scales of production as well as current gaps in the technology capabilities for allogeneic cell therapy manufacture. The tool integrates bioprocess economics with optimization to assess the economic competitiveness of planar and microcarrier-based cell expansion technologies. Visualization methods were used to identify the production scales where planar technologies will cease to be cost-effective and where microcarrier-based bioreactors become the only option. The tool outputs also predict that for the industry to be sustainable for high demand scenarios, significant increases will likely be needed in the performance capabilities of microcarrier-based systems. These data are presented using a technology S-curve as well as windows of operation to identify the combination of cell productivities and scale of single-use bioreactors required to meet future lot sizes. The modeling insights can be used to identify where future R&D investment should be focused to improve the performance of the most promising technologies so that they become a robust and scalable option that enables the cell therapy industry reach commercially relevant lot sizes. The tool outputs can facilitate decision-making very early on in development and be used to predict, and better manage, the risk of process changes needed as products proceed through the development pathway. © 2013 Wiley Periodicals, Inc.

In-Space Recycler Technology Demonstration

NASA Technical Reports Server (NTRS)

Hoyt, Rob; Werkheiser, NIKI; Kim, Tony

2016-01-01

In 2014, a 3D printer was installed and used successfully on the International Space Station (ISS), creating the first additively manufactured part in space. While additive manufacturing is a game changing technology for exploration missions, the process still requires raw feedstock material to fabricate parts. Without a recycling capability, a large supply of feedstock would need to be stored onboard, which negates the logistical benefits of these capabilities. Tethers Unlimited, Inc. (TUI), received a Small Business Innovation Research (SBIR) award to design and build the first In-space Recycler for demonstration aboard the ISS in 2017. To fully test this technology in microgravity, parts will be 3D printed, recycled into reusable filament, and then reprinted into new parts. Recycling scrap into printer filament is quite challenging in that a recycler must be able to handle a large variety of possible scrap configurations and densities. New challenges include: dealing with inevitable contamination of the scrap material, minimizing damage to the molecular structure of the plastic during reprocessing, managing a larger volume of hot liquid plastic, and exercising greater control over the cooling/resolidification of the material. TUI has developed an architecture that addresses these challenges by combining standard, proven technologies with novel, patented processes developed through this effort. Results show that the filament diameter achieved is more consistent than commercial filament, with only minimal degradation of material properties over recycling steps. In May 2016, TUI completed fabrication of a flight prototype, which will ultimately progress to the demonstration unit for the ISS as a testbed for future exploration missions. This capability will provide significant cost savings by reducing the launch mass and volume required for printer feedstock as well as reduce waste that must be stored or disposed.

On the monitoring and implications of growing damages caused by manufacturing defects in composite structures

NASA Astrophysics Data System (ADS)

Schagerl, M.; Viechtbauer, C.; Hörrmann, S.

2015-07-01

Damage tolerance is a classical safety concept for the design of aircraft structures. Basically, this approach considers possible damages in the structure, predicts the damage growth under applied loading conditions and predicts the following decrease of the structural strength. As a fundamental result the damage tolerance approach yields the maximum inspection interval, which is the time a damage grows from a detectable to a critical level. The above formulation of the damage tolerance safety concept targets on metallic structures where the damage is typically a simple fatigue crack. Fiber-reinforced polymers show a much more complex damage behavior, such as delaminationsin laminated composites. Moreover, progressive damage in composites is often initiated by manufacturing defects. The complex manufacturing processes for composite structures almost certainly yield parts with defects, e.g. pores in the matrix or undulations of fibers. From such defects growing damages may start after a certain time of operation. The demand to simplify or even avoid the inspection of composite structures has therefore led to a comeback of the traditional safe-life safety concept. The aim of the so-called safe-life flaw tolerance concept is a structure that is capable of carrying the static loads during operation, despite significant damages and after a representative fatigue load spectrum. A structure with this property does not need to be inspected, respectively monitored at all during its service life. However, its load carrying capability is thereby not fully utilized. This article presents the possible refinement of the state-of-the-art safe-life flaw tolerance concept for composite structures towards a damage tolerance approach considering also the influence of manufacturing defects on damage initiation and growth. Based on fundamental physical relations and experimental observations the challenges when developing damage growth and residual strength curves are discussed.

Metal injection molding as enabling technology for the production of metal prosthesis components: electrochemical and in vitro characterization.

PubMed

Melli, Virginia; Rondelli, Gianni; Sandrini, Enrico; Altomare, Lina; Bolelli, Giovanni; Bonferroni, Benedetta; Lusvarghi, Luca; Cigada, Alberto; De Nardo, Luigi

2013-10-01

Industrial manufacturing of prosthesis components could take significant advantage by the introduction of new, cost-effective manufacturing technologies with near net-shape capabilities, which have been developed during the last years to fulfill the needs of different technological sectors. Among them, metal injection molding (MIM) appears particularly promising for the production of orthopedic arthroplasty components with significant cost saving. These new manufacturing technologies, which have been developed, however, strongly affect the chemicophysical structure of processed materials and their resulting properties. In order to investigate this relationship, here we evaluated the effects on electrochemical properties, ion release, and in vitro response of medical grade CoCrMo alloy processed via MIM compared to conventional processes. MIM of the CoCrMo alloy resulted in coarser polygonal grains, with largely varying sizes; however, these microstructural differences between MIM and forged/cast CoCrMo alloys showed a negligible effect on electrochemical properties. Passive current densities values observed were 0.49 µA cm(-2) for MIM specimens and 0.51 µA cm(-2) for forged CoCrMo specimens, with slightly lower transpassive potential in the MIM case; open circuit potential and Rp stationary values showed no significant differences. Moreover, in vitro biocompatibility tests resulted in cell viability levels not significantly different for MIM and conventionally processed alloys. Although preliminary, these results support the potential of MIM technology for the production of CoCrMo components of implantable devices. Copyright © 2013 Wiley Periodicals, Inc.

2015 Summer Series - Kevin Reynolds - Affordable Airplanes: Modular Design and Additive Manufacturing

NASA Image and Video Library

2015-07-02

At NASA Ames, a project called FrankenEye combines salvaged, unmanned air systems parts with 3D printed materials to resurrect old aircraft. In the field of unmanned aerial vehicles for science, researchers are looking for longer flight times and increased payload capability. Benefits of the additive manufacturing approach include a decrease in development time and project costs and an increase in survivability, efficiency, capability, and endurance. Kevin Reynolds describes a technology hybrid that serves as a unique approach for optimizing flight parameters.

Design and fabrication of conductive polyaniline transducers via computer controlled direct ink writing

NASA Astrophysics Data System (ADS)

Holness, F. Benjamin; Price, Aaron D.

2017-04-01

The intractable nature of the conjugated polymer (CP) polyaniline (PANI) has largely limited PANI-based transducers to monolithic geometries derived from thin-film deposition techniques. To address this limitation, we have previously reported additive manufacturing processes for the direct ink writing of three-dimensional electroactive PANI structures. This technology incorporates a modified delta robot having an integrated polymer paste extrusion system in conjunction with a counter-ion induced thermal doping process to achieve these 3D structures. In this study, we employ an improved embodiment of this methodology for the fabrication of functional PANI devices with increasingly complex geometries and enhanced electroactive functionality. Advances in manufacturing capabilities achieved through the integration of a precision pneumatic fluid dispenser and redesigned high-pressure end-effector enable extrusion of viscous polymer formulations, improving the realizable resolutions of features and deposition layers. The integration of a multi-material dual-extrusion end-effector has further aided the fabrication of these devices, enabling the concurrent assembly of passive and active structures, which reduces the limitations on device geometry. Subsequent characterization of these devices elucidates the relationships between polymer formulation, process parameters, and device design such that electromechanical properties can be tuned according to application requirements. This methodology ultimately leads to the improved manufacturing of electroactive polymer-enabled devices with high-resolution 3D features and enhanced electroactive performance.

Automated visual inspection system based on HAVNET architecture

NASA Astrophysics Data System (ADS)

Burkett, K.; Ozbayoglu, Murat A.; Dagli, Cihan H.

1994-10-01

In this study, the HAusdorff-Voronoi NETwork (HAVNET) developed at the UMR Smart Engineering Systems Lab is tested in the recognition of mounted circuit components commonly used in printed circuit board assembly systems. The automated visual inspection system used consists of a CCD camera, a neural network based image processing software and a data acquisition card connected to a PC. The experiments are run in the Smart Engineering Systems Lab in the Engineering Management Dept. of the University of Missouri-Rolla. The performance analysis shows that the vision system is capable of recognizing different components under uncontrolled lighting conditions without being effected by rotation or scale differences. The results obtained are promising and the system can be used in real manufacturing environments. Currently the system is being customized for a specific manufacturing application.

Development of advanced structural analysis methodologies for predicting widespread fatigue damage in aircraft structures

NASA Technical Reports Server (NTRS)

Harris, Charles E.; Starnes, James H., Jr.; Newman, James C., Jr.

1995-01-01

NASA is developing a 'tool box' that includes a number of advanced structural analysis computer codes which, taken together, represent the comprehensive fracture mechanics capability required to predict the onset of widespread fatigue damage. These structural analysis tools have complementary and specialized capabilities ranging from a finite-element-based stress-analysis code for two- and three-dimensional built-up structures with cracks to a fatigue and fracture analysis code that uses stress-intensity factors and material-property data found in 'look-up' tables or from equations. NASA is conducting critical experiments necessary to verify the predictive capabilities of the codes, and these tests represent a first step in the technology-validation and industry-acceptance processes. NASA has established cooperative programs with aircraft manufacturers to facilitate the comprehensive transfer of this technology by making these advanced structural analysis codes available to industry.

Scale up of large ALON® and spinel windows

NASA Astrophysics Data System (ADS)

Goldman, Lee M.; Kashalikar, Uday; Ramisetty, Mohan; Jha, Santosh; Sastri, Suri

2017-05-01

Aluminum Oxynitride (ALON® Transparent Ceramic) and Magnesia Aluminate Spinel (Spinel) combine broadband transparency with excellent mechanical properties. Their cubic structure means that they are transparent in their polycrystalline form, allowing them to be manufactured by conventional powder processing techniques. Surmet has scaled up its ALON® production capability to produce and deliver windows as large as 4.4 sq ft. We have also produced our first 6 sq ft window. We are in the process of producing 7 sq ft ALON® window blanks for armor applications; and scale up to even larger, high optical quality blanks for Recce window applications is underway. Surmet also produces spinel for customers that require superior transmission at the longer wavelengths in the mid wave infra-red (MWIR). Spinel windows have been limited to smaller sizes than have been achieved with ALON. To date the largest spinel window produced is 11x18-in, and windows 14x20-in size are currently in process. Surmet is now scaling up its spinel processing capability to produce high quality window blanks as large as 19x27-in for sensor applications.

Mass-manufacturable polymer microfluidic device for dual fiber optical trapping.

PubMed

De Coster, Diane; Ottevaere, Heidi; Vervaeke, Michael; Van Erps, Jürgen; Callewaert, Manly; Wuytens, Pieter; Simpson, Stephen H; Hanna, Simon; De Malsche, Wim; Thienpont, Hugo

2015-11-30

We present a microfluidic chip in Polymethyl methacrylate (PMMA) for optical trapping of particles in an 80µm wide microchannel using two counterpropagating single-mode beams. The trapping fibers are separated from the sample fluid by 70µm thick polymer walls. We calculate the optical forces that act on particles flowing in the microchannel using wave optics in combination with non-sequential ray-tracing and further mathematical processing. Our results are compared with a theoretical model and the Mie theory. We use a novel fabrication process that consists of a premilling step and ultraprecision diamond tooling for the manufacturing of the molds and double-sided hot embossing for replication, resulting in a robust microfluidic chip for optical trapping. In a proof-of-concept demonstration, we show the trapping capabilities of the hot embossed chip by trapping spherical beads with a diameter of 6µm, 8µm and 10µm and use the power spectrum analysis of the trapped particle displacements to characterize the trap strength.

On-Demand Production of Flow-Reactor Cartridges by 3D Printing of Thermostable Enzymes.

PubMed

Maier, Manfred; Radtke, Carsten P; Hubbuch, Jürgen; Niemeyer, Christof M; Rabe, Kersten S

2018-05-04

The compartmentalization of chemical reactions is an essential principle of life that provides a major source of innovation for the development of novel approaches in biocatalysis. To implement spatially controlled biotransformations, rapid manufacturing methods are needed for the production of biocatalysts that can be applied in flow systems. Whereas three-dimensional (3D) printing techniques offer high-throughput manufacturing capability, they are usually not compatible with the delicate nature of enzymes, which call for physiological processing parameters. We herein demonstrate the utility of thermostable enzymes in the generation of biocatalytic agarose-based inks for a simple temperature-controlled 3D printing process. As examples we utilized an esterase and an alcohol dehydrogenase from thermophilic organisms as well as a decarboxylase that was thermostabilized by directed protein evolution. We used the resulting 3D-printed parts for a continuous, two-step sequential biotransformation in a fluidic setup. © 2018 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim.

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

Getting the Gold Treatment

NASA Technical Reports Server (NTRS)

2002-01-01

Epner Technology, Inc., worked with Goddard Space Center to apply gold coating to the Vegetation Canopy Lidar (VCL) mirror. This partnership resulted in new commercial applications for Epner's LaserGold(R) process in the automotive industry. Previously, the company did not have equipment large enough to handle the plating of the stainless steel panels cost effectively. Seeing a chance to renew this effort, Epner Technology and Goddard entered into an agreement by which NASA would fund the facility needed to do the gold-plating, and Epner Technology would cover all other costs as part of their internal research and development. The VCL mirror project proceeded successfully, fulfilling Goddard's needs and leaving Epner Technology with a new facility to provide LaserGold for the automotive industry. The new capability means increased power savings and improvements in both quality and production time for BMW Manufacturing Corporation of Spartanburg, South Carolina, and Cadillac of Detroit, Michigan, as well as other manufacturers who have implemented Epner Technology's LaserGold process. LaserGold(R) is a registered trademark of Epner Technology, Inc.

Implementing QML for radiation hardness assurance

NASA Astrophysics Data System (ADS)

Winokur, P. S.; Sexton, F. W.; Fleetwood, D. M.; Terry, M. D.; Shaneyfelt, M. R.

1990-12-01

The US government has proposed a qualified manufacturers list (QML) methodology to qualify integrated circuits for high reliability and radiation hardness. An approach to implementing QML for single-event upset (SEU) immunity on 16k SRAMs that involves relating values of feedback resistance to system error rates is demonstrated. It is seen that the process capability indices, Cp and Cpk, for the manufacture of 400-k-ohm feedback resistors required to provide SEU tolerance do not conform to 6 sigma quality standards. For total-dose, interface trap charge, Delta Vit, shifts measured on transistors are correlated with circuit response in the space environment. Statistical process control (SPC) is illustrated for Delta Vit, and violations of SPC rules are interpreted in terms of continuous improvement. Design validation for SEU and quality conformance inspections for total-dose are identified as major obstacles to cost-effective QML implementation. Techniques and tools that will help QML provide real cost savings are identified as physical models, 3-D device-plus-circuit codes, and improved design simulators.

EUV mask pilot line at Intel Corporation

NASA Astrophysics Data System (ADS)

Stivers, Alan R.; Yan, Pei-Yang; Zhang, Guojing; Liang, Ted; Shu, Emily Y.; Tejnil, Edita; Lieberman, Barry; Nagpal, Rajesh; Hsia, Kangmin; Penn, Michael; Lo, Fu-Chang

2004-12-01

The introduction of extreme ultraviolet (EUV) lithography into high volume manufacturing requires the development of a new mask technology. In support of this, Intel Corporation has established a pilot line devoted to encountering and eliminating barriers to manufacturability of EUV masks. It concentrates on EUV-specific process modules and makes use of the captive standard photomask fabrication capability of Intel Corporation. The goal of the pilot line is to accelerate EUV mask development to intersect the 32nm technology node. This requires EUV mask technology to be comparable to standard photomask technology by the beginning of the silicon wafer process development phase for that technology node. The pilot line embodies Intel's strategy to lead EUV mask development in the areas of the mask patterning process, mask fabrication tools, the starting material (blanks) and the understanding of process interdependencies. The patterning process includes all steps from blank defect inspection through final pattern inspection and repair. We have specified and ordered the EUV-specific tools and most will be installed in 2004. We have worked with International Sematech and others to provide for the next generation of EUV-specific mask tools. Our process of record is run repeatedly to ensure its robustness. This primes the supply chain and collects information needed for blank improvement.

Using the surface charge profiler for in-line monitoring of doping concentration in silicon epitaxial wafer manufacturing

NASA Astrophysics Data System (ADS)

Tower, Joshua P.; Kamieniecki, Emil; Nguyen, M. C.; Danel, Adrien

1999-08-01

The Surface Charge Profiler (SCP) has been introduced for monitoring and development of silicon epitaxial processes. The SCP measures the near-surface doping concentration and offers advantages that lead to yield enhancement in several ways. First, non-destructive measurement technology enables in-line process monitoring, eliminating the need to sacrifice production wafers for resistivity measurements. Additionally, the full-wafer mapping capability helps in development of improved epitaxial growth processes and early detection of reactor problems. As examples, we present the use of SCP to study the effects of susceptor degradation in barrel reactors and to study autodoping for development of improved dopant uniformity.

Finding the right way: DFM versus area efficiency for 65 nm gate layer lithography

NASA Astrophysics Data System (ADS)

Sarma, Chandra S.; Scheer, Steven; Herold, Klaus; Fonseca, Carlos; Thomas, Alan; Schroeder, Uwe P.

2006-03-01

DFM (Design for Manufacturing) has become a buzzword for lithography since the 90nm node. Implementing DFM intelligently can boost yield rates and reliability in semiconductor manufacturing significantly. However, any restriction on the design space will always result in an area loss, thus diminishing the effective shrink factor for a given technology. For a lithographer, the key task is to develop a manufacturable process, while not sacrificing too much area. We have developed a high performing lithography process for attenuated gate level lithography that is based on aggressive illumination and a newly optimized SRAF placement schemes. In this paper we present our methodology and results for this optimization, using an anchored simulation model. The wafer results largely confirm the predictions of the simulations. The use of aggressive SRAF (Sub Resolution Assist Features) strategy leads to reduction of forbidden pitch regions without any SRAF printing. The data show that our OPC is capable of correcting the PC tip to tip distance without bridging between the tips in dense SRAM cells. SRAF strategy for various 2D cases has also been verified on wafer. We have shown that aggressive illumination schemes yielding a high performing lithography process can be employed without sacrificing area. By carefully choosing processing conditions, we were able develop a process that has very little restrictions for design. In our approach, the remaining issues can be addressed by DFM, partly in data prep procedures, which are largely area neutral and transparent to the designers. Hence, we have shown successfully, that DFM and effective technology shrinks are not mutually exclusive.

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;

NASA's In Space Manufacturing Initiatives: Conquering the Challenges of In-Space Manufacturing

NASA Technical Reports Server (NTRS)

Clinton, R. G., Jr.

2017-01-01

Current maintenance logistics strategy will not be effective for deep space exploration missions. ISM (In Space Manufacturing) offers the potential to: Significantly reduce maintenance logistics mass requirements; Enable the use of recycled materials and in-situ resources for more dramatic reductions in mass requirements; Enable flexibility, giving systems a broad capability to adapt to unanticipated circumstances; Mitigate risks that are not covered by current approaches to maintainability. Multiple projects are underway currently to develop and validate these capabilities for infusion into ISM exploration systems. ISS is a critical testbed for demonstrating ISM technologies, proving out these capabilities, and performing operational validation of deep space ISM applications. Developing and testing FabLab is a major milestone for springboard to DSG/Cis-lunar Space applications. ISM is a necessary paradigm shift in space operations – design for repair culture must be embraced. ISM team needs to be working with exploration system designers now to identify high-value application areas and influence design.

Techniques and potential capabilities of multi-resolutional information (knowledge) processing

NASA Technical Reports Server (NTRS)

Meystel, A.

1989-01-01

A concept of nested hierarchical (multi-resolutional, pyramidal) information (knowledge) processing is introduced for a variety of systems including data and/or knowledge bases, vision, control, and manufacturing systems, industrial automated robots, and (self-programmed) autonomous intelligent machines. A set of practical recommendations is presented using a case study of a multiresolutional object representation. It is demonstrated here that any intelligent module transforms (sometimes, irreversibly) the knowledge it deals with, and this tranformation affects the subsequent computation processes, e.g., those of decision and control. Several types of knowledge transformation are reviewed. Definite conditions are analyzed, satisfaction of which is required for organization and processing of redundant information (knowledge) in the multi-resolutional systems. Providing a definite degree of redundancy is one of these conditions.

Low-cost small scale parabolic trough collector design for manufacturing and deployment in Africa

NASA Astrophysics Data System (ADS)

Orosz, Matthew; Mathaha, Paul; Tsiu, Anadola; Taele, B. M.; Mabea, Lengeta; Ntee, Marcel; Khakanyo, Makoanyane; Teker, Tamer; Stephens, Jordan; Mueller, Amy

2016-05-01

Concentrating Solar Power is expanding its deployment on the African subcontinent, highlighting the importance of efforts to indigenize manufacturing of this technology to increase local content and therefore local economic benefits of these projects. In this study a design for manufacturing (DFM) exercise was conducted to create a locally produced parabolic trough collector (the G4 PTC). All parts were sourced or fabricated at a production facility in Lesotho, and several examples of the design were prototyped and tested with collaborators in the Government of Lesotho's Appropriate Technology Services division and the National University of Lesotho. Optical and thermal performance was simulated and experimentally validated, and pedagogical pre-commercial versions of the PTC have been distributed to higher education partners in Lesotho and Europe. The cost to produce the PTC is 180 USD/m2 for a locally manufactured heat collection element (HCE) capable of sustaining 250C operation at ~65% efficiency. A version with an imported evacuated HCE can operate at 300°C with 70% efficiency. Economically relevant applications for this locally produced PTC include industrial process heat and distributed generation scenarios where cogeneration is required.

MSFC Optical Metrology: A National Resource

NASA Technical Reports Server (NTRS)

Burdine, Robert

1998-01-01

A national need exists for Large Diameter Optical Metrology Services. These services include the manufacture, testing, and assurance of precision and control necessary to assure the success of large optical projects. "Best Practices" are often relied on for manufacture and quality controls while optical projects are increasingly more demanding and complex. Marshall Space Flight Center (MSFC) has acquired unique optical measurement, testing and metrology capabilities through active participation in a wide variety of NASA optical programs. An overview of existing optical facilities and metrology capabilities is given with emphasis on use by other optical projects. Cost avoidance and project success is stressed through use of existing MSFC facilities and capabilities for measurement and metrology controls. Current issues in large diameter optical metrology are briefly reviewed. The need for a consistent and long duration Large Diameter Optical Metrology Service Group is presented with emphasis on the establishment of a National Large Diameter Optical Standards Laboratory. Proposals are made to develop MSFC optical standards and metrology capabilities as the primary national standards resource, providing access to MSFC Optical Core Competencies for manufacturers and researchers. Plans are presented for the development of a national lending library of precision optical standards with emphasis on cost avoidance while improving measurement assurance.

The Future of Additive Manufacturing in Air Force Acquisition

DTIC Science & Technology

2017-03-22

manufacturing data - Designing and deploying a virtual aircraft fleet for future conflict - Space-based satellite production for defense capabilities via...changing system design via lower production costs, enhanced performance possibilities, and rapid replenishment. In the Technology Maturation and Risk... manufacturing as well as major cost savings via reduction of required materials, unique tooling, specialized production plans, and segments of the

Copiers and Duplicators for Audio Tape Cassettes: Criteria for Selection, Laboratory Test Findings, Manufacturers' Data Reports. EPIE Report: Number 84e.

ERIC Educational Resources Information Center

Educational Products Information Exchange Inst., Stony Brook, NY.

Because needs for cassette duplication equipment differ, the user must match his requirements to the capabilities of manufactured products, and the essential product characteristics. To help educators in choosing cassette duplicators, EPIE has gathered data from manufacturers and tested 11 units. The first section of the report explains the…

Collection, Measurement and Treatment of Microorganism Using Dielectrophoretic Micro Devices

NASA Astrophysics Data System (ADS)

Uchida, Satoshi

Constant monitoring of manufacturing processes has been essential in food industry because of global expansion of microbial infection. Micro-scale dielectrophoretic method is an attractive technique for direct operation and quantitative detection of bioparticles. The electrical system is capable of rapid and simple treatments corresponding to severe legal control for food safety. In this paper, newly developed techniques are reviewed for bacterial concentration, detection and sterilization using dielectrophoresis in a micro reactor. The perspective to an integrated micro device of those components is also discussed.

Nondestructive Evaluation (NDE) Capabilities Data Book (3rd Edition)

DTIC Science & Technology

1997-11-01

include: 4340 Steel Flat Plate Panels Bolt Holes in i85 Scvcnth Stage Compressor Disks Visual Inspection of Fatigue Cracks in Inconel 718 and HaynEs 188...safety engineer * The maintenance engineer * Thc manufacturing / production process engineer • The liaison (rework and repair) engineer a ’[ lhc life...TC03: Through crnck from an offset hole in a plate TC04: Through crack from hole in a lug TC05: Through crack from hole in plate with a row of holcs

SKYLAB (SL) PRIME CREW - BLDG. 5 - JSC

NASA Image and Video Library

1973-03-20

S73-20759 (1 March 1973) --- Astronaut Charles Conrad Jr., commander of the first manned Skylab mission, takes items from the M512 materials processing equipment storage assembly during Skylab training at Johnson Space Center. Conrad is standing in the Multiple Docking Adapter (MDA) trainer in the JSC Mission Simulation and Training Facility. The assembly holds equipment designed to explore space manufacturing capability in a weightless state. Conrad is holding one of the experiment parts in his left hand. Photo credit: NASA

Subaperture metrology technologies extend capabilities in optics manufacturing

NASA Astrophysics Data System (ADS)

Tricard, Marc; Forbes, Greg; Murphy, Paul

2005-10-01

Subaperture polishing technologies have radically changed the landscape of precision optics manufacturing and enabled the production of higher precision optics with increasingly difficult figure requirements. However, metrology is a critical piece of the optics fabrication process, and the dependence on interferometry is especially acute for computer-controlled, deterministic finishing. Without accurate full-aperture metrology, figure correction using subaperture polishing technologies would not be possible. QED Technologies has developed the Subaperture Stitching Interferometer (SSI) that extends the effective aperture and dynamic range of a phase measuring interferometer. The SSI's novel developments in software and hardware improve the capacity and accuracy of traditional interferometers, overcoming many of the limitations previously faced. The SSI performs high-accuracy automated measurements of spheres, flats, and mild aspheres up to 200 mm in diameter by stitching subaperture data. The system combines a six-axis precision workstation, a commercial Fizeau interferometer of 4" or 6" aperture, and dedicated software. QED's software automates the measurement design, data acquisition, and mathematical reconstruction of the full-aperture phase map. The stitching algorithm incorporates a general framework for compensating several types of errors introduced by the interferometer and stage mechanics. These include positioning errors, viewing system distortion, the system reference wave error, etc. The SSI has been proven to deliver the accurate and flexible metrology that is vital to precision optics fabrication. This paper will briefly review the capabilities of the SSI as a production-ready, metrology system that enables costeffective manufacturing of precision optical surfaces.

High-power ultrasonic processing: Recent developments and prospective advances

NASA Astrophysics Data System (ADS)

Gallego-Juarez, Juan A.

2010-01-01

Although the application of ultrasonic energy to produce or to enhance a wide variety of processes have been explored since about the middle of the 20th century, only a reduced number of ultrasonic processes have been established at industrial level. However, during the last ten years the interest in ultrasonic processing has revived particularly in industrial sectors where the ultrasonic technology may represent a clean and efficient tool to improve classical existing processes or an innovation alternative for the development of new processes. Such seems to be the case of relevant sectors such as food industry, environment, pharmaceuticals and chemicals manufacture, machinery, mining, etc where power ultrasound is becoming an emerging technology for process development. The possible major problem in the application of high-intensity ultrasound on industrial processing is the design and development of efficient power ultrasonic systems (generators and reactors) capable of large scale successful operation specifically adapted to each individual process. In the area of ultrasonic processing in fluid media and more specifically in gases, the development of the steppedplate transducers and other power ge with extensive radiating surface has strongly contributed to the implementation at semi-industrial and industrial stage of several commercial applications, in sectors such as food and beverage industry (defoaming, drying, extraction, etc), environment (air cleaning, sludge filtration, etc...), machinery and process for manufacturing (textile washing, paint manufacture, etc). The development of different cavitational reactors for liquid treatment in continuous flow is helping to introduce into industry the wide potential of the area of sonochemistry. Processes such as water and effluent treatment, crystallization, soil remediation, etc have been already implemented at semi-industrial and/or industrial stage. Other single advances in sectors like mining or energy have also to be mentioned. The objective of this paper is to review some recent developments in ultrasonic processing to show the present situation and the prospective progresses of high-power ultrasonics as an innovative technology in many industrial sectors.

Applicability of near-infrared spectroscopy in the monitoring of film coating and curing process of the prolonged release coated pellets.

PubMed

Korasa, Klemen; Hudovornik, Grega; Vrečer, Franc

2016-10-10

Although process analytical technology (PAT) guidance has been introduced to the pharmaceutical industry just a decade ago, this innovative approach has already become an important part of efficient pharmaceutical development, manufacturing, and quality assurance. PAT tools are especially important in technologically complex operations which require strict control of critical process parameters and have significant effect on final product quality. Manufacturing of prolonged release film coated pellets is definitely one of such processes. The aim of the present work was to study the applicability of the at-line near-infrared spectroscopy (NIR) approach in the monitoring of pellet film coating and curing steps. Film coated pellets were manufactured by coating the active ingredient containing pellets with film coating based on polymethacrylate polymers (Eudragit® RS/RL). The NIR proved as a useful tool for the monitoring of the curing process since it was able to determine the extent of the curing and hence predict drug release rate by using partial least square (PLS) model. However, such approach also showed a number of limitations, such as low reliability and high susceptibility to pellet moisture content, and was thus not able to predict drug release from pellets with high moisture content. On the other hand, the at-line NIR was capable to predict the thickness of Eudragit® RS/RL film coating in a wide range (up to 40μm) with good accuracy even in the pellets with high moisture content. To sum up, high applicability of the at-line NIR in the monitoring of the prolonged release pellets production was demonstrated in the present study. The present findings may contribute to more efficient and reliable PAT solutions in the manufacturing of prolonged release dosage forms. Copyright © 2016 Elsevier B.V. All rights reserved.

Benchmarking the expected stack manufacturing cost of next generation, intermediate-temperature protonic ceramic fuel cells with solid oxide fuel cell technology

NASA Astrophysics Data System (ADS)

Dubois, Alexis; Ricote, Sandrine; Braun, Robert J.

2017-11-01

Recent progress in the performance of intermediate temperature (500-600 °C) protonic ceramic fuel cells (PCFCs) has demonstrated both fuel flexibility and increasing power density that approach commercial application requirements. These developments may eventually position the technology as a viable alternative to solid oxide fuel cells (SOFCs) and molten carbonate fuel cells (MCFCs). The PCFCs investigated in this work are based on a BaZr0.8Y0.2O3-δ (BZY20) thin electrolyte supported by BZY20/Ni porous anodes, and a triple conducting cathode material comprised of BaCo0.4Fe0.4Zr0.1Y0.1O3-δ (BCFZY0.1). These cells are prepared using a low-cost solid-state reactive sintering (SSRS) process, and are capable of power densities of 0.156 W cm-2 at 500 °C operating directly from methane fuel. We develop a manufacturing cost model to estimate the Nth generation production costs of PCFC stack technology using high volume manufacturing processes and compare them to the state-of-the-art in SOFC technology. The low-cost cell manufacturing enabled by the SSRS technique compensates for the lower PCFC power density and the trade-off between operating temperature and efficiency enables the use of lower-cost stainless steel materials. PCFC stack production cost estimates are found to be as much as 27-37% lower at 550 °C than SOFCs operating at 800 °C.

Laser-Assisted Wire Additive Manufacturing System for the Deep Space Gateway

NASA Astrophysics Data System (ADS)

Foster, B. D.; Matthews, B.

2018-02-01

Investigation on the Deep Space Gateway will involve experiments/operations inside pressurized modules. Support for those experiments may necessitate a means to fabricate and repair required articles. This capability can be provided through an additive manufacturing (AM) system.

Additively Manufactured Low Cost Upper Stage Combustion Chamber

NASA Technical Reports Server (NTRS)

Protz, Christopher; Cooper, Ken; Ellis, David; Fikes, John; Jones, Zachary; Kim, Tony; Medina, Cory; Taminger, Karen; Willingham, Derek

2016-01-01

Over the past two years NASA's Low Cost Upper Stage Propulsion (LCUSP) project has developed Additive Manufacturing (AM) technologies and design tools aimed at reducing the costs and manufacturing time of regeneratively cooled rocket engine components. High pressure/high temperature combustion chambers and nozzles must be regeneratively cooled to survive their operating environment, causing their design fabrication to be costly and time consuming due to the number of individual steps and different processes required. Under LCUSP, AM technologies in Sintered Laser Melting (SLM) GRCop-84 and Electron Beam Freeform Fabrication (EBF3) Inconel 625 have been significantly advanced, allowing the team to successfully fabricate a 25k-class regenerative chamber. Estimates of the costs and schedule of future builds indicate cost reductions and significant schedule reductions will be enabled by this technology. Characterization of the microstructural and mechanical properties of the SLM-produced GRCop-84, EBF3 Inconel 625 and the interface layer between the two has been performed and indicates the properties will meet the design requirements. The LCUSP chamber is to be tested with a previously demonstrated SLM injector in order to advance the Technology Readiness Level (TRL) and demonstrate the capability of the application of these processes. NASA is advancing these technologies to reduce cost and schedule for future engine applications and commercial needs.

3-D laser patterning process utilizing horizontal and vertical patterning

DOEpatents

Malba, Vincent; Bernhardt, Anthony F.

2000-01-01

A process which vastly improves the 3-D patterning capability of laser pantography (computer controlled laser direct-write patterning). The process uses commercially available electrodeposited photoresist (EDPR) to pattern 3-D surfaces. The EDPR covers the surface of a metal layer conformally, coating the vertical as well as horizontal surfaces. A laser pantograph then patterns the EDPR, which is subsequently developed in a standard, commercially available developer, leaving patterned trench areas in the EDPR. The metal layer thereunder is now exposed in the trench areas and masked in others, and thereafter can be etched to form the desired pattern (subtractive process), or can be plated with metal (additive process), followed by a resist stripping, and removal of the remaining field metal (additive process). This improved laser pantograph process is simpler, faster, move manufacturable, and requires no micro-machining.

Autonomous Agents for Dynamic Process Planning in the Flexible Manufacturing System

NASA Astrophysics Data System (ADS)

Nik Nejad, Hossein Tehrani; Sugimura, Nobuhiro; Iwamura, Koji; Tanimizu, Yoshitaka

Rapid changes of market demands and pressures of competition require manufacturers to maintain highly flexible manufacturing systems to cope with a complex manufacturing environment. This paper deals with development of an agent-based architecture of dynamic systems for incremental process planning in the manufacturing systems. In consideration of alternative manufacturing processes and machine tools, the process plans and the schedules of the manufacturing resources are generated incrementally and dynamically. A negotiation protocol is discussed, in this paper, to generate suitable process plans for the target products real-timely and dynamically, based on the alternative manufacturing processes. The alternative manufacturing processes are presented by the process plan networks discussed in the previous paper, and the suitable process plans are searched and generated to cope with both the dynamic changes of the product specifications and the disturbances of the manufacturing resources. We initiatively combine the heuristic search algorithms of the process plan networks with the negotiation protocols, in order to generate suitable process plans in the dynamic manufacturing environment.

Advanced plasma etch technologies for nanopatterning

NASA Astrophysics Data System (ADS)

Wise, Rich

2013-10-01

Advances in patterning techniques have enabled the extension of immersion lithography from 65/45 nm through 14/10 nm device technologies. A key to this increase in patterning capability has been innovation in the subsequent dry plasma etch processing steps. Multiple exposure techniques, such as litho-etch-litho-etch, sidewall image transfer, line/cut mask, and self-aligned structures, have been implemented to solution required device scaling. Advances in dry plasma etch process control across wafer uniformity and etch selectivity to both masking materials have enabled adoption of vertical devices and thin film scaling for increased device performance at a given pitch. Plasma etch processes, such as trilayer etches, aggressive critical dimension shrink techniques, and the extension of resist trim processes, have increased the attainable device dimensions at a given imaging capability. Precise control of the plasma etch parameters affecting across-design variation, defectivity, profile stability within wafer, within lot, and across tools has been successfully implemented to provide manufacturable patterning technology solutions. IBM has addressed these patterning challenges through an integrated total patterning solutions team to provide seamless and synergistic patterning processes to device and integration internal customers. We will discuss these challenges and the innovative plasma etch solutions pioneered by IBM and our alliance partners.

Advanced plasma etch technologies for nanopatterning

NASA Astrophysics Data System (ADS)

Wise, Rich

2012-03-01

Advances in patterning techniques have enabled the extension of immersion lithography from 65/45nm through 14/10nm device technologies. A key to this increase in patterning capability has been innovation in the subsequent dry plasma etch processing steps. Multiple exposure techniques such as litho-etch-litho-etch, sidewall image transfer, line/cut mask and self-aligned structures have been implemented to solution required device scaling. Advances in dry plasma etch process control, across wafer uniformity and etch selectivity to both masking materials and have enabled adoption of vertical devices and thin film scaling for increased device performance at a given pitch. Plasma etch processes such as trilayer etches, aggressive CD shrink techniques, and the extension of resist trim processes have increased the attainable device dimensions at a given imaging capability. Precise control of the plasma etch parameters affecting across design variation, defectivity, profile stability within wafer, within lot, and across tools have been successfully implemented to provide manufacturable patterning technology solutions. IBM has addressed these patterning challenges through an integrated Total Patterning Solutions team to provide seamless and synergistic patterning processes to device and integration internal customers. This paper will discuss these challenges and the innovative plasma etch solutions pioneered by IBM and our alliance partners.

Capable Copper Electrodeposition Process for Integrated Circuit - substrate Packaging Manufacturing

NASA Astrophysics Data System (ADS)

Ghanbari, Nasrin

This work demonstrates a capable reverse pulse deposition methodology to influence gap fill behavior inside microvia along with a uniform deposit in the fine line patterned regions for substrate packaging applications. Interconnect circuitry in IC substrate packages comprises of stacked microvia that varies in depth from 20microm to 100microm with an aspect ratio of 0.5 to 1.5 and fine line patterns defined by photolithography. Photolithography defined pattern regions incorporate a wide variety of feature sizes including large circular pad structures with diameter of 20microm - 200microm, fine traces with varying widths of 3microm - 30microm and additional planar regions to define a IC substrate package. Electrodeposition of copper is performed to establish the desired circuit. Electrodeposition of copper in IC substrate applications holds certain unique challenges in that they require a low cost manufacturing process that enables a void-free gap fill inside the microvia along with uniform deposition of copper on exposed patterned regions. Deposition time scales to establish the desired metal thickness for such packages could range from several minutes to few hours. This work showcases a reverse pulse electrodeposition methodology that achieves void-free gap fill inside the microvia and uniform plating in FLS (Fine Lines and Spaces) regions with significantly higher deposition rates than traditional approaches. In order to achieve this capability, systematic experimental and simulation studies were performed. A strong correlation of independent parameters that govern the electrodeposition process such as bath temperature, reverse pulse plating parameters and the ratio of electrolyte concentrations is shown to the deposition kinetics and deposition uniformity in fine patterned regions and gap fill rate inside the microvia. Additionally, insight into the physics of via fill process is presented with secondary and tertiary current simulation efforts. Such efforts lead to show "smart" control of deposition rate at the top and bottom of via to avoid void formation. Finally, a parametric effect on grain size and the ensuing copper metallurgical characteristics of bulk copper is also shown to enable high reliability substrate packages for the IC packaging industry.

Manufacturability study of masks created by inverse lithography technology (ILT)

NASA Astrophysics Data System (ADS)

Martin, Patrick M.; Progler, C. J.; Xiao, G.; Gray, R.; Pang, L.; Liu, Y.

2005-11-01

As photolithography is pushed to fabricate deep-sub wavelength devices for 90nm, 65nm and smaller technology nodes using available exposure tools (i.e., 248nm, 193nm steppers), photomask capability is becoming extremely critical. For example, PSM masks require more complicated processing; aggressive OPC makes the writing time longer and sometimes unpredictable; and, high MEEF imposes much more stringent demands on mask quality. Therefore, in order for any new lithography technology to be adopted into production, mask manufacturability must be studied thoroughly and carefully. In this paper we will present the mask manufacturability study on mask patterns created using Inverse Lithography Technology (ILT). Unlike conventional OPC methodologies, ILT uses a unique outcome-based technology to mathematically determine the mask features that produce the desired on-wafer results. ILT solves the most critical litho challenges of the deep sub-wavelength era. Potential benefits include: higher yield; expanded litho process windows; superb pattern fidelity at 90, 65 & 45-nm nodes; and reduced time-to-silicon - all without changing the existing lithography infrastructure and design-to-silicon flow. In this study a number of cell structures were selected and used as test patterns. "Luminized patterns" were generated for binary mask and attenuated phase-shift mask. Both conventional OPC patterns and "luminized patterns" were put on a test reticle side by side, and they all have a number of variations in term of correction aggressivity level and mask complexity. Mask manufacturability, including data fracturing, writing time, mask inspection, and metrology were studied. The results demonstrate that, by optimizing the inspection recipe, masks created using ILT technology can be made and qualified using current processes with a reasonable turn-around time.

Electrostatic Levitation for Studies of Additive Manufactured Materials

NASA Technical Reports Server (NTRS)

SanSoucie, Michael P.; Rogers, Jan R.; Tramel, Terri

2014-01-01

The electrostatic levitation (ESL) laboratory at NASA's Marshall Space Flight Center is a unique facility for investigators studying high temperature materials. The laboratory boasts two levitators in which samples can be levitated, heated, melted, undercooled, and resolidified. Electrostatic levitation minimizes gravitational effects and allows materials to be studied without contact with a container or instrumentation. The lab also has a high temperature emissivity measurement system, which provides normal spectral and normal total emissivity measurements at use temperature. The ESL lab has been instrumental in many pioneering materials investigations of thermophysical properties, e.g., creep measurements, solidification, triggered nucleation, and emissivity at high temperatures. Research in the ESL lab has already led to the development of advanced high temperature materials for aerospace applications, coatings for rocket nozzles, improved medical and industrial optics, metallic glasses, ablatives for reentry vehicles, and materials with memory. Modeling of additive manufacturing materials processing is necessary for the study of their resulting materials properties. In addition, the modeling of the selective laser melting processes and its materials property predictions are also underway. Unfortunately, there is very little data for the properties of these materials, especially of the materials in the liquid state. Some method to measure thermophysical properties of additive manufacturing materials is necessary. The ESL lab is ideal for these studies. The lab can provide surface tension and viscosity of molten materials, density measurements, emissivity measurements, and even creep strength measurements. The ESL lab can also determine melting temperature, surface temperatures, and phase transition temperatures of additive manufactured materials. This presentation will provide background on the ESL lab and its capabilities, provide an approach to using the ESL in supporting the development and modeling of the selective laser melting process for metals, and provide an overview of the results to date.

20 years of KVH fiber optic gyro technology: the evolution from large, low performance FOGs to compact, precise FOGs and FOG-based inertial systems

NASA Astrophysics Data System (ADS)

Napoli, Jay

2016-05-01

Precision fiber optic gyroscopes (FOGs) are critical components for an array of platforms and applications ranging from stabilization and pointing orientation of payloads and platforms to navigation and control for unmanned and autonomous systems. In addition, FOG-based inertial systems provide extremely accurate data for geo-referencing systems. Significant improvements in the performance of FOGs and FOG-based inertial systems at KVH are due, in large part, to advancements in the design and manufacture of optical fiber, as well as in manufacturing operations and signal processing. Open loop FOGs, such as those developed and manufactured by KVH Industries, offer tactical-grade performance in a robust, small package. The success of KVH FOGs and FOG-based inertial systems is due to innovations in key fields, including the development of proprietary D-shaped fiber with an elliptical core, and KVH's unique ThinFiber. KVH continually improves its FOG manufacturing processes and signal processing, which result in improved accuracies across its entire FOG product line. KVH acquired its FOG capabilities, including its patented E•Core fiber, when the company purchased Andrew Corporation's Fiber Optic Group in 1997. E•Core fiber is unique in that the light-guiding core - critical to the FOG's performance - is elliptically shaped. The elliptical core produces a fiber that has low loss and high polarization-maintaining ability. In 2010, KVH developed its ThinFiber, a 170-micron diameter fiber that retains the full performance characteristics of E•Core fiber. ThinFiber has enabled the development of very compact, high-performance open-loop FOGs, which are also used in a line of FOG-based inertial measurement units and inertial navigation systems.

NASA's Space Launch System: Momentum Builds Toward First Launch

NASA Technical Reports Server (NTRS)

May, Todd A.; Lyles, Garry M.

2014-01-01

NASA's Space Launch System (SLS) is gaining momentum toward the first launch of a new exploration-class heavy lift launch vehicle for international exploration and science initiatives. The SLS comprises an architecture that begins with a vehicle capable of launching 70 metric tons (t) into low Earth orbit. It will launch the Orion Multi-Purpose Crew Vehicle (MPCV) on its first autonomous flight beyond the Moon and back in December 2017. Its first crewed flight follows in 2021. SLS can evolve to a130-t lift capability and serve as a baseline for numerous robotic and human missions ranging from a Mars sample return to delivering the first astronauts to explore another planet. The SLS Program formally transitioned from the formulation phase to implementation with the successful completion of the rigorous Key Decision Point C review in 2014. As a result, the Agency authorized the Program to move forward to Critical Design Review, scheduled for 2015. In the NASA project life cycle process, SLS has completed 50 percent of its major milestones toward first flight. Every SLS element manufactured development hardware for testing over the past year. Accomplishments during 2013/2014 included manufacture of core stage test articles, preparations for qualification testing the solid rocket boosters and the RS-25 main engines, and shipment of the first flight hardware in preparation for the Exploration Flight Test-1 (EFT-1) in 2014. SLS was conceived with the goals of safety, affordability, and sustainability, while also providing unprecedented capability for human exploration and scientific discovery beyond Earth orbit. In an environment of economic challenges, the SLS team continues to meet ambitious budget and schedule targets through the studied use of hardware, infrastructure, and workforce investments the United States made in the last half century, while selectively using new technologies for design, manufacturing, and testing, as well as streamlined management approaches that have increased decision velocity and reduced associated costs. This paper will summarize recent SLS Program accomplishments, as well as the challenges and opportunities ahead for the most powerful and capable launch vehicle in history.

Workplace Literacy in a Total Quality Management Environment for the Manufacturing Industry in Chicago and Northern Illinois. Final Performance Report.

ERIC Educational Resources Information Center

Mrowicki, Linda; And Others

A project was conducted to improve the productivity and efficiency of 10 manufacturers by providing workplace literacy instruction to workers lacking basic skills required for their jobs, and to improve the capability of educational programs to meet the basic skill needs of the manufacturing industry by developing an evaluation manual for basic…

Additive manufacturing of three-dimensional (3D) microfluidic-based microelectromechanical systems (MEMS) for acoustofluidic applications.

PubMed

Cesewski, Ellen; Haring, Alexander P; Tong, Yuxin; Singh, Manjot; Thakur, Rajan; Laheri, Sahil; Read, Kaitlin A; Powell, Michael D; Oestreich, Kenneth J; Johnson, Blake N

2018-06-13

Three-dimensional (3D) printing now enables the fabrication of 3D structural electronics and microfluidics. Further, conventional subtractive manufacturing processes for microelectromechanical systems (MEMS) relatively limit device structure to two dimensions and require post-processing steps for interface with microfluidics. Thus, the objective of this work is to create an additive manufacturing approach for fabrication of 3D microfluidic-based MEMS devices that enables 3D configurations of electromechanical systems and simultaneous integration of microfluidics. Here, we demonstrate the ability to fabricate microfluidic-based acoustofluidic devices that contain orthogonal out-of-plane piezoelectric sensors and actuators using additive manufacturing. The devices were fabricated using a microextrusion 3D printing system that contained integrated pick-and-place functionality. Additively assembled materials and components included 3D printed epoxy, polydimethylsiloxane (PDMS), silver nanoparticles, and eutectic gallium-indium as well as robotically embedded piezoelectric chips (lead zirconate titanate (PZT)). Electrical impedance spectroscopy and finite element modeling studies showed the embedded PZT chips exhibited multiple resonant modes of varying mode shape over the 0-20 MHz frequency range. Flow visualization studies using neutrally buoyant particles (diameter = 0.8-70 μm) confirmed the 3D printed devices generated bulk acoustic waves (BAWs) capable of size-selective manipulation, trapping, and separation of suspended particles in droplets and microchannels. Flow visualization studies in a continuous flow format showed suspended particles could be moved toward or away from the walls of microfluidic channels based on selective actuation of in-plane or out-of-plane PZT chips. This work suggests additive manufacturing potentially provides new opportunities for the design and fabrication of acoustofluidic and microfluidic devices.

SAMIS- STANDARD ASSEMBLY-LINE MANUFACTURING INDUSTRY SIMULATION

NASA Technical Reports Server (NTRS)

Chamberlain, R. G.

1994-01-01

The Standard Assembly-Line Manufacturing Industry Simulation (SAMIS) program was originally developed to model a hypothetical U. S. industry which manufactures silicon solar modules for use in electricity generation. The SAMIS program has now been generalized to the extent that it should be useful for simulating many different production-line manufacturing industries and companies. The most important capability of SAMIS is its ability to "simulate" an industry based on a model developed by the user with the aid of the SAMIS program. The results of the simulation are a set of financial reports which detail the requirements, including quantities and cost, of the companies and processes which comprise the industry. SAMIS provides a fair, consistent, and reliable means of comparing manufacturing processes being developed by numerous independent efforts. It can also be used to assess the industry-wide impact of changes in financial parameters, such as cost of resources and services, inflation rates, interest rates, tax policies, and required return on equity. Because of the large amount of data needed to describe an industry, a major portion of SAMIS is dedicated to data entry and maintenance. This activity in SAMIS is referred to as model management. Model management requires a significant amount of interaction through a system of "prompts" which make it possible for persons not familiar with computers, or the SAMIS program, to provide all of the data necessary to perform a simulation. SAMIS is written in TURBO PASCAL (version 2.0 required for compilation) and requires 10 meg of hard disk space, an 8087 coprocessor, and an IBM color graphics monitor. Executables and source code are provided. SAMIS was originally developed in 1978; the IBM PC version was developed in 1985. Release 6.1 was made available in 1986, and includes the PC-IPEG program.

Remineralization potential of nano-hydroxyapatite on enamel and cementum surrounding margin of computer-aided design and computer-aided manufacturing ceramic restoration

PubMed Central

Juntavee, Niwut; Juntavee, Apa; Plongniras, Preeyarat

2018-01-01

Objective This study investigates the effects of nano-hydroxyapatite (NHA) gel and Clinpro (CP) on remineralization potential of enamel and cementum at the cavosurface area of computer-aided design and computer-aided manufacturing ceramic restoration. Materials and methods Thirty extracted human mandibular third molars were sectioned at 1 mm above and below the cemento–enamel junction to remove the cemento–enamel junction portions and replaced them with zirconia ceramic disks by bonding them to the crown and root portions with resin cement. The enamel and cementum with an area of 4×4 mm2 surrounding the ceramic disk was demineralized with carbopol. The demineralized surfaces were treated with either NHA or CP, while 1 group was left with no treatment. Vickers microhardness of enamel and cementum were determined before demineralization, after demineralization, and after remineralization. Analysis of variance and Tukey multiple comparisons were used to determine statistically significant differences at 95% level of confidence. Scanning electron microscopy and X-ray diffraction were used to evaluate for surface alterations. Results The mean ± SD of Vickers microhardness for before demineralization, after demineralization, and after remineralization for enamel and cementum were 377.37±22.99, 161.95±10.54, 161.70±5.92 and 60.37±3.81, 17.65±0.91, 17.04±1.00 for the no treatment group; 378.20±18.76, 160.72±8.38, 200.08±8.29 and 62.58±3.37, 18.38±1.33, 27.99±2.68 for the NHA groups; and 380.53±25.14, 161.94±5.66, 193.16±7.54 and 62.78±4.75, 19.07±1.30, 24.46±2.02 for the CP groups. Analysis of variance indicated significant increase in microhardness of demineralized enamel and cementum upon the application of either NHA or CP (p<0.05). Post hoc multiple comparisons indicated significantly higher remineralization capability of NHA for both enamel and cementum than CP (p<0.05), as evidenced by scanning electron microscopy, indicating NHA particle deposition in the area of remineralization, and crystallinity accumulation, as indicated by X-ray diffraction. Conclusion NHA gel and CP were capable of remineralization of the enamel and cementum. NHA was more capable in the remineralization process than CP. NHA was extremely capable in the remineralization process for enamel and cementum surrounding the margin of the computer-aided design and computer-aided manufacturing ceramic. PMID:29780246

Tunable smart digital structure (SDS) to modularly assemble soft actuators with layered adhesive bonding

NASA Astrophysics Data System (ADS)

Jin, Hu; Dong, Erbao; Xu, Min; Xia, Qirong; Liu, Shuai; Li, Weihua; Yang, Jie

2018-01-01

Many shape memory alloy (SMA)-based soft actuators have specific composite structures and manufacture processes, and are therefore unique. However, these exclusive characteristics limit their capabilities and applications, so in this article a soft and smart digital structure (SDS) is proposed that acts like a modular unit to assemble soft actuators by a layered adhesive bonding process. The SDS is a fully soft structure that encapsulates a digital skeleton consisting of four groups of parallel and independently actuated SMA wires capable of outputting a four-channel tunable force. The layered adhesive bonding process modularly bonds several SDSs with an elastic backbone to fabricate a layered soft actuator where the elastic backbone is used to recover the SDSs in a cooling process using the SMA wires. Two kinds of SDS-based soft actuators were modularly assembled, an actuator, SDS-I, with a two-dimensional reciprocal motion, and an actuator, SDS-II, capable of bi-directional reciprocal motion. The thermodynamics and phase transformation modeling of the SDS-based actuator were analyzed. Several extensional soft actuators were also assembled by bonding the SDS with an anomalous elastic backbone or modularly assembling the SDS-Is and SDS-IIs. These modularly assembled soft actuators delivered more output channels and a complicated motion, e.g., an actinomorphic soft actuator with four SDS-Is jumps in a series of hierarchical heights and directional movement by tuning the input channels of the SDSs. This result showed that the SDS can modularly assemble multifarious soft actuators with diverse capabilities, steerability and tunable outputs.

Laser-based additive manufacturing: where it has been, where it needs to go

NASA Astrophysics Data System (ADS)

Cooper, Khershed P.

2014-03-01

It is no secret that the laser was the driver for additive manufacturing (AM) of 3D objects since such objects were first demonstrated in the mid-1980s. A myriad of techniques utilizing the directed energy of lasers were invented. Lasers are used to selectively sinter or fuse incremental layers in powder-beds, melt streaming powder following a programmed path, and polymerize photopolymers in a liquid vat layer-by-layer. The laser is an energy source of choice for repair of damaged components, for manufacture of new or replacement parts, and for rapid prototyping of concept designs. Lasers enable microstructure gradients and heterogeneous structures designed to exhibit unique properties and behavior. Laserbased additive manufacturing has been successful in producing relatively simple near net-shape metallic parts saving material and cost, but requiring finish-machining and in repair and refurbishment of worn components. It has been routinely used to produce polymer parts. These capabilities have been widely recognized as evidenced by the explosion in interest in AM technology, nationally. These successes are, however, tempered by challenges facing practitioners such as process and part qualification and verification, which are needed to bring AM as a true manufacturing technology. The ONR manufacturing science program, in collaboration with other agencies, invested in basic R&D in AM since its beginnings. It continues to invest, currently focusing on developing cyber-enabled manufacturing systems for AM. It is believed that such computation, communication and control approaches will help in validating AM and moving it to the factory floor along side CNC machines.

3D Printing in Zero-G ISS Technology Demonstration

NASA Technical Reports Server (NTRS)

Johnston, Mallory M.; Werkheiser, Mary J.; Cooper, Kenneth G.; Snyder, Michael P.; Edmunson, Jennifer E.

2014-01-01

The National Aeronautics and Space Administration (NASA) has a long term strategy to fabricate components and equipment on-demand for manned missions to the Moon, Mars, and beyond. To support this strategy, NASA and Made in Space, Inc. are developing the 3D Printing In Zero-G payload as a Technology Demonstration for the International Space Station. The 3D Printing In Zero-G experiment will be the first machine to perform 3D printing in space. The greater the distance from Earth and the longer the mission duration, the more difficult resupply becomes; this requires a change from the current spares, maintenance, repair, and hardware design model that has been used on the International Space Station up until now. Given the extension of the ISS Program, which will inevitably result in replacement parts being required, the ISS is an ideal platform to begin changing the current model for resupply and repair to one that is more suitable for all exploration missions. 3D Printing, more formally known as Additive Manufacturing, is the method of building parts/ objects/tools layer-by-layer. The 3D Print experiment will use extrusion-based additive manufacturing, which involves building an object out of plastic deposited by a wire-feed via an extruder head. Parts can be printed from data files loaded on the device at launch, as well as additional files uplinked to the device while on-orbit. The plastic extrusion additive manufacturing process is a low-energy, low-mass solution to many common needs on board the ISS. The 3D Print payload will serve as the ideal first step to proving that process in space. It is unreasonable to expect NASA to launch large blocks of material from which parts or tools can be traditionally machined, and even more unreasonable to fly up specialized manufacturing hardware to perform the entire range of function traditionally machining requires. The technology to produce parts on demand, in space, offers unique design options that are not possible through traditional manufacturing methods while offering cost-effective, high-precision, low-unit on-demand manufacturing. Thus, Additive Manufacturing capabilities are the foundation of an advanced manufacturing in space roadmap.

XRCF Testing Capabilities

NASA Technical Reports Server (NTRS)

Reily, Cary; Kegely, Jeff; Burdine, Robert (Technical Monitor)

2001-01-01

The Space Optics Manufacturing Technology Center's X-ray Calibration Facility has been recently modified to test Next Generation Space Telescope (NGST) developmental mirrors at cryogenic temperatures (35 degrees Kelvin) while maintaining capability for performance testing of x-ray optics and detectors. The facility's current cryo-optical testing capability and potential modifications for future support of NGST will be presented.