{"project":{"acronym":"","projectId":93332,"title":"Adaptive Laser Sintering System for In-Space Printed Electronics","primaryTaxonomyNodes":[{"taxonomyNodeId":10881,"taxonomyRootId":8816,"parentNodeId":10879,"level":3,"code":"TX12.4.2","title":"Intelligent Integrated Manufacturing","definition":"Intelligent integrated manufacturing technologies comprise the “digital thread” model-based manufacturing environment.","exampleTechnologies":"Integration of smart sensors, controls, and measurement, analysis, decision support, and communication software tools for process control; model-based, digital implementation that integrates design, manufacturing and product support processes","hasChildren":false,"hasInteriorContent":true}],"startTrl":1,"currentTrl":4,"endTrl":4,"benefits":"After the successful design, test and implementation of ALSS, the science and technology of laser sintering will be better understood for controllable adaptive operations. It provides a key solution to NASA's challenge of in-space, on-demand manufacturing capabilities to support the unique challenges of long-duration human spaceflight, which requires an automated adaptive in-line quality control system along with the manufacturing process. The reduction in both time and manpower with modularization of the process will allow better integration of a prototype instrument to be installed for demonstration on ISS. NASA can use this ALSS module at NASA research centers to compare and evaluate the advantages of printing electronics using different direct-write technologies, whether it is the Aerosol Jet or inkjet or other metal NP ink dispensing methods or plasma jet printing technology.
While the Aerosol Jet(R) technology is changing the way engineers and scientists design and develop electronic, biomedical, and mechanical systems, its applicability in printed electronics is mainly limited by the sintering process when the substrate materials must not be damaged by the elevated temperature, especially when the conventional thermal oven is used. The success of ALSS development will enable sintering printed metal NP inks on many low-temperature substrates that have been impossible with oven sintering, because the transient laser power is applied to a very small spot with a very short duration which minimizes the heat-affected zone. Thus, the Aerosol Jet system with the ALSS enhancement will tremendously increase its production capability and market share in printed electronics industry. On the other hand, the knowledge gained via ALSS development can be utilized in other in-line monitoring and control subsystem development for future system enhancement, which is also aimed at increasing the scopes of Aerosol Jet(R) potential commercial applications.","description":"The goal of this project is to enhance the Optomec Aerosol Jet(R) technology for additive manufacturing by introduction of an Adaptive Laser Sintering System (ALSS) module to enable a fully automated system for printed electronics. The Optomec-Harding team seeks to reduce the localized laser sintering concept to practice by developing ALSS with in-situ automated adjustment of laser power and processing time. ALSS will include a laser for sintering with sensors to monitor the process so that any flaws in the printed electronics circuitry can be repaired with minimal human intervention. The benefit will be two-fold: it will enable Optomec, Inc. to expand its commercial applications of the Aerosol Jet technology in printed electronics industry, and to pave the way for the use of this advanced technology in the next generation of human space exploration. The success of this endeavor will be of vital importance to the NASA's in-space, on-demand manufacturing capabilities to support the unique challenges of long-duration human spaceflight. The developed automated adaptive in-line quality control system with ALSS is also applicable to that required for long-duration human space missions with minimal need for astronaut intervention, when printing conformal electronics and sensors onto flexible substrates of various geometrical complexities using the Aerosol Jet technology. The liquid metal nanoparticle (NP) inks as printed are not conductive enough for required circuit functionality; they must be transformed to solid metal path by a sintering at an elevated temperature. To reduce sintering time and exposure of the substrate to damaging temperatures, localized laser sintering has been shown to be promising. The challenge to commercialization of laser sintering is controlling the laser power and processing time required for effective sintering of metal NP inks while avoiding thermal damage to substrate, which will be addressed by the ALSS.","startYear":2017,"startMonth":6,"endYear":2017,"endMonth":12,"statusDescription":"Completed","principalInvestigators":[{"contactId":3251398,"canUserEdit":false,"firstName":"Michael","lastName":"Renn","fullName":"Michael Renn","fullNameInverted":"Renn, Michael","primaryEmail":"mrenn@optomec.com","publicEmail":true,"nacontact":false},{"contactId":338358,"canUserEdit":false,"firstName":"Michael","lastName":"Renn","fullName":"Michael J Renn","fullNameInverted":"Renn, Michael J","middleInitial":"J","primaryEmail":"Mrenn@Optomec.Com","publicEmail":true,"nacontact":false}],"programDirectors":[{"contactId":206378,"canUserEdit":false,"firstName":"Jason","lastName":"Kessler","fullName":"Jason L Kessler","fullNameInverted":"Kessler, Jason L","middleInitial":"L","primaryEmail":"jason.l.kessler@nasa.gov","publicEmail":true,"nacontact":false}],"programExecutives":[{"contactId":215154,"canUserEdit":false,"firstName":"Jennifer","lastName":"Gustetic","fullName":"Jennifer L Gustetic","fullNameInverted":"Gustetic, Jennifer L","middleInitial":"L","primaryEmail":"jennifer.l.gustetic@nasa.gov","publicEmail":true,"nacontact":false}],"programManagers":[{"contactId":62051,"canUserEdit":false,"firstName":"Carlos","lastName":"Torrez","fullName":"Carlos Torrez","fullNameInverted":"Torrez, Carlos","primaryEmail":"carlos.torrez@nasa.gov","publicEmail":true,"nacontact":false}],"projectManagers":[{"contactId":156942,"canUserEdit":false,"firstName":"Furman","lastName":"Thompson","fullName":"Furman V Thompson","fullNameInverted":"Thompson, Furman 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The NASA SBIR and STTR programs fund the research, development, and demonstration of innovative technologies that fulfill NASA needs as described in the annual Solicitations and have significant potential for successful commercialization. If you are a small business concern (SBC) with 500 or fewer employees or a non-profit RI such as a university or a research laboratory with ties to an SBC, then NASA encourages you to learn more about the SBIR and STTR programs as a potential source of seed funding for the development of your innovations.
The SBIR and STTR programs have 3 phases:
The SBIR and STTR Phase I contracts last for 6 months with a maximum funding of $125,000, and Phase II contracts last for 24 months with a maximum funding of $750,000 - $1.5 million.
Opportunity for Continued Technology Development Post-Phase II:
The NASA SBIR/STTR Program currently has in place two initiatives for supporting its small business partners past the basic Phase I and Phase II elements of the program that emphasize opportunities for commercialization. Specifically, the NASA SBIR/STTR Program has the Phase II Enhancement (Phase II-E) and Phase II eXpanded (Phase II-X) contract options.
Please review the links below to obtain more information on the SBIR/STTR programs.
Provides an overview of the SBIR and STTR programs as implemented by NASA
Provides access to the annual SBIR/STTR Solicitations containing detailed information on the program eligibility requirements, proposal instructions and research topics and subtopics
Schedule and links for the SBIR/STTR solicitations and selection announcements
Federal and non-Federal sources of assistance for small business
Search our complete archive of awarded project abstracts to learn about what NASA has funded
Still have questions? Visit the program FAQs
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