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At least 127 records · Page 7

All sources NASA NTRS DOE OSTI

DOE OSTI2026

TRIZ-Based Design Improvement for Facilitating Transmission Control Unit Remanufacturing

Design for Remanufacturing (DfRem) centers on enhancing product design and operations to facilitate remanufacturing while increasing both economic and environmental sustainability. DfRem requires a comprehensive understanding of product characteristics, production conditions, and operational constraints. Thus, DfRem requires a systematic methodology to identify and implement alternative designs. Among many critical steps in remanufacturing, disassembly is essential because it directly supports remanufacturing by separation of product components for cleaning, inspection, and other subsequent process steps. This study proposes a TRIZ-based framework to improve product design for disassembly in support of remanufacturing. The framework is applied to a transmission control unit (TCU) case study. The current TCU design prevents remanufacturing due to the sealant-based component joinery, which complicates disassembly and risks damaging the printed circuit board (PCB). After defining technical contradictions for the TCU product design and reviewing the suggested TRIZ principles to solve the conflicts, a cantilever snap-fit design alternative is developed. The economic feasibility of the snap-fit design is assessed by comparing the current and snap-fit design costs for three life cycles. The cost analysis demonstrates that the cost of the snap-fit design remains the same as the current design. Additionally, the snap-fit design offers substantial cost savings for three life cycles compared to the current design. We demonstrate how snap-fit design supports both environmental and economic sustainability.

42 ENGINEERING↗

DOE OSTI2025

Production, quality assurance and quality control of the SiPM Tiles for the DarkSide-20k Time Projection Chamber

The DarkSide-20k dark matter direct detection experiment will employ a 21 m 2 silicon photomultiplier (SiPM) array, instrumenting a dual-phase 50 tonnes liquid argon Time Projection Chamber (TPC). SiPMs are arranged into modular photosensors called Tiles, each integrating 24 SiPMs onto a printed circuit board (PCB) that provides signal amplification, power distribution, and a single-ended output for simplified readout. Tiles are further grouped into Photo-Detector Units (PDUs). This paper details the production of the Tiles and the Quality Assurance and Quality Control (QA-QC) protocol established to ensure their performance and uniformity. The production and QA-QC of the Tiles are carried out at Nuova Officina Assergi (NOA), an ISO-6 clean room facility at LNGS. This process includes wafer-level cryogenic characterisation, precision die attaching, wire bonding, and extensive electrical and optical validation of each Tile. The overall production yield exceeds 83.5%, matching the requirements of the DarkSide-20k production plan. These results validate the robustness of the Tile design and its suitability for operation in a cryogenic environment.

Acerbi, F. [Fondazione Bruno Kessler]↗

DOE OSTI2025

Combining Distributed Electrochemical Measurements with a Semi-Empirical Model to Identify Local Variations in Overpotentials for PEM Water Electrolyzers

Abstract A segmented cell and PCB approach was used to demonstrate an advanced technique for measuring and understanding the electrochemical behavior of PEM water electrolyzers. By employing a semi-empirical model, discrete modes of overpotential and their spatial distributions were identified in an operating cell. Distributed area-specific resistance (DASR measurements indicate that local dehydration of the polymer electrolyte membrane is the primary driver of increased polarization, behaving similarly to mass transport-limited currents at low flow rates due to ineffective gas-phase bubble removal. To improve quantification, the overall ohmic overpotential is divided into background (η Ohm,b ) and mass transport-coupled (η Ohm,mt ) components. Two types of anode diffusion media, a baseline PTL and a thin foil liquid/gas diffusion layer (LGDL), were examined. The results show significant variations in η Ohm,b and highlight that ineffective bubble removal leads to pronounced local dehydration. The effect of cell temperature on various overpotentials was also examined. Negligible differences in diffusion overpotential were observed when comparing PEWE performance using the PTL and LGDL, despite major differences in two-phase fluid transport within each diffusion media. This underscores the critical role of the catalyst layer's micro-porous structure in diffusion processes. The study highlights the complex nature and intricacies of mass transport limitations within PEWEs.

Roy, Anirban (ORCID:0000000163803386)↗

DOE OSTI2026

Booster cavity damper redesign for PIP-II

A new Higher Order Mode (HOM) damper was designed and is undergoing testing for the Booster accelerator cavity at Fermilab. In anticipation of the PIP-II upgrade, it was discovered that the higher intensity of PIP-II may cause beam instability due to an excited mode at 106 MHz. This unfortunately corresponds with the cavity’s 2nd order harmonic mode, which will sweep from 86-105.7 MHz. The new damper is a modification of an existing damper that was designed to reduce an existing static HOM at 83 MHz, with the new design intending to cover the 2nd order HOM as well. The existing damper uses an inductive coupling loop to extract RF energy from the cavity which then goes through a filter in order to reflect the fundamental frequency back into the cavity while passing HOMs to a dump load. The new damper intends to replace the filter portion of the system with a wider band variant while also changing the topology from a coaxial cable loop filter to a componentized PCB-based design. Primary design challenges include bandwidth coverage, impedance matching of the various modes, long term thermal and mechanical stability, radiation hardness, and high voltage handling. Initial designs achieved the desired damping but were found to quickly succumb to destructive arcing due to the voltages present. More finalized designs intend to address this problem through circuit design modifications as well as the use of hardier components.

Pieper, Dustin [Fermilab]↗

DOE OSTI2024

Application of Flex-QA Arrays in HTS Magnet Testing

Flexible PCB quench antennas have been very useful in providing high-quality high-resolution data in low temperature superconducting magnet tests. Similar multi-sensor arrays have been employed recently to cover a high temperature superconductor magnet tested at FNAL. In the present work, data taking conditions and magnet features to support the analysis framework are discussed. Then observations made during complete magnet powering cycles are described and analysis of quench antenna data are presented. Based on results, improvements to instrumentation and data taking are debated. Views on the future of flexible quench antenna sensors for HTS magnet diagnostics and operational support are shared.

Stoynev, S.↗

DOE OSTI2025

Enhancements to Lab-on-a-Fish Technology: Final Report for I3T Project 81245

PNNL has engaged in discussions with several organizations regarding potential future collaborations. PNNL has developed the Lab-on-a-Fish prototypes and produced video instructions for an organization conducting research on shark eggs. Several organizations have expressed interest in using the Lab-on-a-Fish for their studies. We’ve also updated two versions of the Lab-on-a-Fish to expand its applications to a wider range of animal studies and accelerate its commercialization. The new design of the Lab-on-a-Fish, which incorporates PCB-based electrodes, has demonstrated the ability to capture clear ECG signals without the need for additional needle-shaped electrodes. This innovation eliminates the need for implanting electrodes beneath the fish's skin at specific locations, which is required with the current version of Lab-on-a-Fish. This change significantly simplifies the manufacturing and implantation process. For the Lab-on-a-Fish design that uses an optical pulse oximeter, the measurement results were primarily influenced by respiratory activity rather than heart rate. This occurred because the oximeter was placed beneath the operculum. Further research and development are needed to explore more suitable locations and methods for accurate pulse oximeter measurements.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2025

Broadband mm-Wave Substrate Integrated Waveguides [Poster]

At mm-wave frequencies, signals need to be supported by specialized, low-loss transmission lines such as waveguides. Substrate-integrated waveguides (SIWs) combine the good electrical properties of rectangular waveguides with the compactness of planar transmission lines. Additionally, SIWs can be fabricated using standard PCB manufacturing techniques and can be easily integrated with other mm-wave components. This study explores SIWs in the 50-75 GHz range, with designs optimized for simple fabrication.

42 ENGINEERING↗

DOE OSTI2025

Booster Cavity Damper Redesign for PIP-II

A new Higher Order Mode (HOM) damper was designed and tested for the Booster accelerator cavity at Fermilab. In anticipation of the PIP-II upgrade, it was discovered that the higher beam intensity of PIP-II may cause beam instability due to an excited mode at 106 MHz. This unfortunately corresponds with the cavity s 2nd order harmonic mode, which will sweep from 86-105.7 MHz. The new damper is a modification of an existing damper that was designed to reduce an existing static HOM at 83 MHz, with the new design intending to cover the 2nd order HOM as well. The existing damper uses an inductive coupling loop to extract RF energy from the cavity which then goes through a filter in order to reflect the fundamental frequency back into the cavity while passing HOMs to a dump load. The new damper intends to replace the filter portion of the system with a wider band variant while also changing the topology from a coaxial cable loop filter to a componentized PCB-based design. Primary design challenges include bandwidth coverage, impedance matching of the various modes, long term thermal and mechanical stability, radiation hardness, and high voltage handling. Initial designs achieved the desired damping but were found to quickly succumb to destructive arcing due to the voltages present. More finalized designs intend to address this problem through circuit design modifications as well as the use of hardier components.

Pieper, Dustin [Fermilab]↗

DOE OSTI2026

Quench Propagation On Rare-Earth Barium Copper Oxide (REBCO) Tape

Rare-earth barium copper oxide (REBCO) high-temperature superconductors can carry high currents with zero electrical resistance, enabling applications in high-field magnets, energy systems, and fusion devices. However, localized losses of superconductivity, known as quenches, pose a severe risk due to REBCO’s mechanical brittleness and slow quench propagation, complicating early detection. This work investigates quench propagation and thermal response through controlled experiments. A segmented REBCO tape soldered onto a printed circuit board (PCB) with multiple voltage taps and temperature sensors was submerged in liquid nitrogen at 77 K. In the first test, current ramping produced a quench near 360 A, consistent with theoretical current limits, but resulted in local burnout. In the second test, a heater-induced quench at 300 A propagated bidirectionally with velocities ranging from 164–226 mm/s. These results provide critical parameters for improving REBCO quench detection and protection system design while accounting for REBCO’s limited bendability.

Ju, Han [Northern Illinois U.]↗

DOE OSTI2026

IMPACT 2025-2026 Internship Poster

At Sandia National Laboratories, I developed a C++ program that converts printed circuit boards(PCB) and integrated circuits(IC) design files to be compatible for computed tomography (CT) simulations through Monte Carlo methods.

97 MATHEMATICS AND COMPUTING↗

DOE OSTI2026

Quench Propagation on Rare-Earth Barium Copper Oxide (REBCO) Tape

Rare-earth barium copper oxide (REBCO) high-temperature superconductors can carry high currents with zero electrical resistance, enabling applications in high-field magnets, energy systems, and fusion devices. However, the localized losses of superconductivity called a quench pose a severe risk due to REBCO’s mechanical brittleness and slow quench propagation, hence complicating early detection. This work investigates quench propagation and thermal response through controlled experiments. A segmented REBCO tape soldered on a PCB with multiple voltage taps and temperature sensors was submerged in liquid nitrogen at 77 K. In the first test, current ramping produced a quench near 360 A, consistent with theoretical current limits but resulted in a local burn. In the second test, a heater-induced quench at 300 A propagated bidirectionally with measured velocities ranging from 164–226 mm/s. These measurements provide critical parameters for improving REBCO quench detection and protection system design with accounts for REBCO's limited bendability.

Ju, Han [NIU, DeKalb]↗

DOE OSTI2026

Adiabatic Propagation Fixture

Previous simulations have tested HTS magnets with dissipative flux flow regimens for thermal runaway. My goal was to make a system that would be able to take real world data on this for Quench Detection. My poster will show the design for a PCB I made and the test setup for conducting said experiment.

Mercado, E. [NIU, DeKalb]↗

DOE OSTI2024

Understanding the temperature and humidity dependence of the SiPM characteristics

A miniature version of the ICAL experiment at the India-based Neutrino Observatory, the mini-ICALis in operation at the IICHEP, Madurai. The commissioning work of a Cosmic Muon Veto detector (CMVD)on top of the mini-ICAL is continued using extruded plastic scintillators with embeddedWLS fibers and the SiPM as a photo-transducer. The CMVD is being built to study thefeasibility of a cosmic muon veto for a shallow-depth neutrino experiment. The SiPM is calibratedusing an ultrafast LED driver andthe same calibration techniques will be used during the data taking period with a simplified LED in thesame readout PCB. An experimental setup wasdesigned to characterise the SiPMs in a temperature controlled environment. The readout electronicsinvolves trans-impedance amplifiers and a voltage followers of combined gain 1.24 mV/$\mu$A and adigital storage oscilloscope for the data collection with a minimal distortion of SiPM signal.Various characteristics of the Hamamatsu SiPM (S13360-2050VE), e.g. signal shape, optically correlatedand uncorrelated noise, recovery time etc were studied as a function of $V_{ov}$, number of photoelectrons,the ambient temperature and the humidity. This paper will cover the details of those results.

46 INSTRUMENTATION RELATED TO NUCLEAR SCIENCE AND ↗

DOE OSTI2025

High-Throughput Microfluidic Electroporation (HTME): A Scalable, 384-Well Platform for Multiplexed Cell Engineering

Electroporation-mediated gene delivery is a cornerstone of synthetic biology, offering several advantages over other methods: higher efficiencies, broader applicability, and simpler sample preparation. Yet, electroporation protocols are often challenging to integrate into highly multiplexed workflows, owing to limitations in their scalability and tunability. These challenges ultimately increase the time and cost per transformation. As a result, rapidly screening genetic libraries, exploring combinatorial designs, or optimizing electroporation parameters requires extensive iterations, consuming large quantities of expensive custom-made DNA and cell lines or primary cells. To address these limitations, we have developed a High-Throughput Microfluidic Electroporation (HTME) platform that includes a 384-well electroporation plate (E-Plate) and control electronics capable of rapidly electroporating all wells in under a minute with individual control of each well. Fabricated using scalable and cost-effective printed-circuit-board (PCB) technology, the E-Plate significantly reduces consumable costs and reagent consumption by operating on nano to microliter volumes. Furthermore, individually addressable wells facilitate rapid exploration of large sets of experimental conditions to optimize electroporation for different cell types and plasmid concentrations/types. Use of the standard 384-well footprint makes the platform easily integrable into automated workflows, thereby enabling end-to-end automation. We demonstrate transformation of E. coli with pUC19 to validate the HTME's core functionality, achieving at least a single colony forming unit in more than 99% of wells and confirming the platform's ability to rapidly perform hundreds of electroporations with customizable conditions. This work highlights the HTME's potential to significantly accelerate synthetic biology Design-Build-Test-Learn (DBTL) cycles by mitigating the transformation/transfection bottleneck.

Gaillard, William R↗

NASA NTRS1991

The M68HC11 gripper controller electronics

This document describes the instrumentation, operational theory, circuit implementation, calibration procedures, and general notes for the CIRSSE general purpose pneumatic hand. The mechanical design and the control software are discussed. The circuit design, PCB layout, hand instrumentation, and controller construction described in detail in this document are the result of a senior project.

Kelley, Robert B.↗

NASA NTRS1993

An application protocol for CAD to CAD transfer of electronic information

The exchange of Computer Aided Design (CAD) information between dissimilar CAD systems is a problem. This is especially true for transferring electronics CAD information such as multi-chip module (MCM), hybrid microcircuit assembly (HMA), and printed circuit board (PCB) designs. Currently, there exists several neutral data formats for transferring electronics CAD information. These include IGES, EDIF, and DXF formats. All these formats have limitations for use in exchanging electronic data. In an attempt to overcome these limitations, the Navy's MicroCIM program implemented a project to transfer hybrid microcircuit design information between dissimilar CAD systems. The IGES (Initial Graphics Exchange Specification) format is used since it is well established within the CAD industry. The goal of the project is to have a complete transfer of microelectronic CAD information, using IGES, without any data loss. An Application Protocol (AP) is being developed to specify how hybrid microcircuit CAD information will be represented by IGES entity constructs. The AP defines which IGES data items are appropriate for describing HMA geometry, connectivity, and processing as well as HMA material characteristics.

Azu, Charles C., Jr.↗

NASA NTRS1992

Response of a piezoelectric pressure transducer to IR laser beam impingement

The non-pressure response of a PCB Model 113A transducer to a far infrared radiation impulse from a carbon dioxide laser was investigated. Incident radiation was applied both to the bare transducer diaphragm and to coated diaphragms. Coatings included two common ablative materials and a reflective gold coating. High-flux radiation impulses induced an immediate brief negative output followed by a longer-duration positive output. Both timing and amplitude of the responses will be discussed, and the effects of coatings will be compared. Bursts of blackbody radiation from a 1500 K source produced qualitatively similar responses.

Smith, William C.↗

NASA NTRS1995

Direct analysis of organic priority pollutants by IMS

Many routine methods for monitoring of trace amounts of atmospheric organic pollutants consist of several steps. Typical steps are: (1) collection of the air sample; (2) trapping of organics from the sample; (3) extraction of the trapped organics; and (4) identification of the organics in the extract by GC (gas chromatography), HPLC (High Performance Liquid Chromatography), or MS (Mass Spectrometry). These methods are often cumbersome and time consuming. A simple and fast method for monitoring atmospheric organics using an IMS (Ion Mobility Spectrometer) is proposed. This method has a short sampling time and does not require extraction of the organics since the sample is placed directly in the IMS. The purpose of this study was to determine the responses in the IMS to organic 'priority pollutants'. Priority pollutants including representative polycyclic aromatic hydrocarbons (PAHs), phthalates, phenols, chlorinated pesticides, and polychlorinated biphenyls (PCB's) were analyzed in both the positive and negative detection mode at ambient atmospheric pressure. Detection mode and amount detected are presented.

Giam, C. S.↗