The potential commercial applications as described by the awardee: The device’s potential for commercial success is enormous. The device’s greatest commercial application lies in its ability to respond to any user’s needs. Outside of the disability realm, the device can be reduced in size without losing any of its functionality. Portable computers could be made smaller, for example. Another useful application of the device, because of its self-containment, is in hostile environments. The device can be completely sealed and still be fully functional; it can even be used under water.

110. Interactive Telerobotic Video on the World Wide Web
Perceptual Robotics, Inc.
1840 Oak Ave.
Evanston, IL 60201
tel: 847-475-0512; fax: 847-866-1808
e-mail: pri-cooper@nwu.edu
Principal Investigator: Paul R. Cooper
President: Paul R. Cooper
NSF Grant No. 9661472; Amount: $75,000

This Small Business Innovation Research Phase I project will prototype InterCam, a system for providing interactive, telerobotically controlled, live video on the World Wide Web. The InterCam system will be based on an operational research system (LabCam; at http://vision.cs.uchicago.edu) developed earlier by the project principles.

To establish commercial viability, we must determine whether the system can be developed on a cost-effective hardware/software infrastructure, and we must develop important additional functionality. We plan to develop the new system on an Intel/Windows NT platform, and to re-engineer the timesharing functionality at the heart of the software as a multithreaded distributed operating system, exploiting the multiprocessing functionality and platform transparency of Java. We also plan to develop new shareable control methods, and explore the plausibility of incorporating basic computer vision capabilities into the system.

The potential commercial applications as described by the awardee: It is hard to overstate the potential impact of this technology. Inquiries from potential customers have helped us identify a number of different concrete application areas: teleconferencing ("look where you want to look"); security; remote process monitoring accessible from anywhere, affordably; Internet publishing; and product and real-estate marketing (the "virtual showroom or open-house").

111. Optoelectronic Label Verification System
Physical Optics Corp.
Engineering and Products Div.
20600 Gramercy Pl., Suite 103
Torrance, CA 90501
tel: 310-320-3088; fax: 310-320-4667
Principal Investigator: Andrew Kostrzewski, Ph.D.
President: Joanna Jannson, Ph.D.
NSF Grant No. 9661475; Amount: $74,995

This Small Business Innovation Research Phase I project will develop a unique anticounterfeiting method based on optical correlation techniques that will ensure extremely high confidence because of its large number of degrees of freedom. The key features of Physical Optics Corporation’s proposed system is its use of high-density phase encoded labels with 10³⁰ code possibilities. The research and development proposed here is an extension of existing optical correlation technology for label verification. This application is challenging because labels may be presented to the verification system with unpredictable scale, shift, and rotation. The key to the success of our project is in the development of scale, translation, and rotation invariant phase codes together with a flexible reading/processing head that will allow unrestricted placement of labels during the verification process. Scanning or replicating our phase label is impossible because of the high optical density of the phase information. An additional feature of the proposed phase-encoded labeling is its compatibility with a variety of substrates, including thin foil and plastic in both reflection and transmission modes of operation. The production cost of such labels will be in the range of a few cents per label.

The potential commercial applications as described by the awardee: The proposed development will be a new tool to fight counterfeit crime. It can be applied to many security applications, such as limited access security, ID cards, credit card verification, product label verification systems, and medical record cards.

112. High Performance Three-Dimensional Mouse and Head Tracker
Dynaflow, Inc.
7210 Pindell School Rd.
Fulton, MD 20759
tel: 301-604-3688; fax: 301-604-3689
e-mail: info@dynaflow-inc.com
Principal Investigator: Daniel F. DeMenthon
President: Georges L. Chahine
NSF Grant No. 9661576; Amount: $75,000

This Small Business Innovation Research Phase I program will test a novel instrument for tracking the hand and the head of a subject; it has particular application to user-system interfaces for interactive three-dimensional graphics and virtual reality.

Dynaflow, Inc., proposes a novel optical tracker using infrared light emitting diodes (LEDs) mounted on the hand and head of the user and a fixed camera equipped with a position-sensing diode (PSD). The system will modulate each LED at a distinct characteristic frequency from several kHz to several hundred kHz. The contributions from the LEDs to the PSD signal will all be measured simultaneously and separated by digital filters, each tuned to extract the contribution of a single LED. Sunlight and incandescent light sources do not produce components in the kHz range and will be rejected by high pass filters. This design will obtain accurate translation and rotation measurements at high rate, and with a low phase lag during rapid hand or head motion.

The potential commercial applications as described by the awardee: The proposed technology will result in the development of optical tracking systems that perform reliably in unconstrained lighting environments, while providing high update rates and high responsiveness. Potential commercial applications include three-dimensional mouse systems and head mounted display trackers for the interactive three-dimensional graphics market, the simulator market, and the entertainment market.

113. Power Electronic Interface to Connect a Micro-SMES System to Inverters for the Power Quality Market
Superconductivity, Inc.
(now American Superconductor Corp.)
2114 Eagle Dr.
Middleton, WI 53562
tel: 608-828-9109; fax: 608-831-4609
e-mail: ekostecki@amsuper.com
Principal Investigator: Eric L. Kostecki
President: Greg Yurek
NSF Grant No. 9660113; Amount: $75,000

This Small Business Innovation Research Phase I project’s technical objective is to develop a power electronic interface module to connect an energy source to an inverter system parallel connected to the utility system. Specifically, this design effort will focus on such an interface module for connecting a superconducting energy storage (Micro-SMES) system to an inverter system.

Higher magnet currents are needed to increase the power output level of Micro-SMES systems. Design objectives include the evaluation of different topologies and determination of the optimal solution. The ultimate power rating shall be in the 5 to 10 MW range.

The potential commercial applications as described by the awardee: One of the largest growing national and global areas for Micro-SMES systems is the power quality market. Power quality problems can be addressed in a range of customer locations or on the electric utility system. A Micro-SMES system with a new interface module offers a unique solution to these problems because (1) it has the ability to connect to a variety of inverters, (2) paralleling devices increases the power rating, and (3) this higher power rating combined with the parallel-connected inverters permits the development of applications at the utility distribution system voltage level.

114. Automated Optimal Robot Trajectory Planner
Analytical Mechanics Associates, Inc.
17 Research Dr.
Hampton, VA 23666
tel: 757-865-0944; fax: 757-865-1881
e-mail: renji@ama-inc.com
Principal Investigator: Renjith R. Kumar
President: Renjith R. Kumar
NSF Grant No. 9660214; Amount: $74,995

This Small Business Innovation Research Phase I project evaluates feasibility of creating a generic, user-friendly optimal robotic trajectory planning software, which is robust, fully automated, and capable of multi-degree-of-freedom optimization with path constraints. Currently, no commercial software exists that can solve generic robot optimization problems in a turnkey fashion. A differential inclusions technique recently developed at AMA is ideally suited to solve the robot trajectory optimization problem because the controls appear linearly. Proving concept feasibility implies:
(1) Construction of a generalized symbolic algorithm that creates the equations of motion of multi-degree-of-freedom manipulators from user-provided mass and geometry data; (2) Representation of above equations in the differential inclusion format; (3) Evaluation of analytical partial derivatives of the resulting hodograph, boundary, and path constraints with respect to the generalized states; (4) Evaluation of convergence robustness of the differential inclusion approach for the entire class of open-chain manipulators and comparison to classical variational and collocation techniques; and (5) Obtaining optimal solutions for high-DOF manipulators via a special dense-sparse discretization approach developed at AMA.

The potential commercial applications as described by the awardee: Commercial applications include performance enhancement of manufacturing processes such as spot welding, painting, and assembly, where minimizing time and energy requirements map into millions of dollars saved in direct manufacturing costs.

115. Ultra-Miniature Transformer and Inductor Design and Manufacture
BH Electronics, Inc.
12219 Wood Lake Dr.
Burnsville, MN 55337
tel: 612-894-9590; fax: 612-894-9380
e-mail: jdecramer@bhelectronics.com
Principal Investigator: John E. DeCramer
President: Richard H. Jackson
NSF Grant No. 9660219; Amount: $74,954

This Small Business Innovation Research Phase I project addresses the development of automated manufacturing for high frequency (5 MHz to 1 GHz) transformers and inductors. Current manufacturing processes are labor intensive. Magnetic core and wire diameters are very small (2.5 mm and 0.075 mm), making machine assembly impractical. The proposed approach uses automated techniques similar to semiconductor manufacturing to deposit, etch, and coat patterned layers of magnetic, conductive, and insulating materials. This automation will significantly reduce labor content, further reduce device size, and enable economic production in the United States rather than offshore.

Research objectives include completion of electrical and mechanical transformer design and fabrication of prototypes. Fundamental phenomena underlying device operation and electrical performance will be evaluated. The principal investigator has expert knowledge in high frequency transformer design and will be supported by a consultant having expert knowledge in semiconductor manufacture. Prototype fabrication will occur at the University of Minnesota’s Institute of Technology-Microtechnology Laboratory and electrical performance will be determined at BH Electronics’ Engineering Laboratory.

The potential commercial applications as described by the awardee: Commercial applications include high frequency transformers and inductors for data and video transmissions, hybrid circuits, and related circuitry. Beyond existing markets, this new approach will enable development of miniature products in data and personal communications.

116. High Efficiency Diamond Micro Cathode for Electron Field Emission
Materials & Electrochemical Research (MER) Corp.
7960 South Kolb Rd.
Tucson, AZ 85706
tel: 520-574-1980; fax: 520-574-1983
e-mail: mercorp@opusl.com
Principal Investigator: Dr. Chenyu Pan
President: Dr. J.C. Withers
NSF Grant No. 9660272; Amount: $75,000

This Small Business Innovation Research Phase I project will develop a novel and high efficiency diamond micro-cathode and micro-cathode array by synthesizing and depositing nanocrystalline diamond thin films on conductive micro-fiber ends through a unique chemical vapor deposition (CVD) process. Diamond has recently emerged as a promising electron field emission cathode due to its unsurpassed electron field emission properties of low voltage and room temperature operation, operation robustness, simple design, and reproducibility. However, the present diamond cathodes are microcrystalline diamond thin films deposited on macro-substrate (mm to cm size) by a conventional diamond CVD process. Several drawbacks have recently been identified with these microcrystalline diamond cathodes. For example, only one to ten percent or less of the diamond cathode surface is active and contributes nearly all the current produced, resulting in an overall low emission efficiency. The distribution of the minority-populated active emission sites is also random and uncontrolled. The electron emission from each individual emission site cannot be independently controlled either. These drawbacks are expected to be overcome by the development of this novel nanocrystalline diamond micro-cathode by the demonstration of significantly improved field emission efficiency, very high current density at low operation field, and controlled emission performance and emission pattern.

The potential commercial applications as described by the awardee: The successful completion of the Phase I program will result in the development of a new generation diamond field emission cathode. The significantly improved efficiency, high available current density at low field, flexibility in emission control and emission pattern, operation robustness, and simple fabrication are expected to benefit a large variety of vacuum-electronic applications, ranging from flat panel displays, TV and computer screens, and aircraft vision displays to high energy accelerator physics. Because of the high efficiency of the new diamond cathodes, their cost will also be substantially lower than that of the present diamond cathodes.

117. Thin Film Circulators for Microwave/MMW Integrated Circuits
ElectroMagnetic Applications, Inc.
300 Commercial St., Suite 805
Boston, MA 02109
tel: 617-720-3968; fax: 617-720-3968
e-mail: HHOW@NEU.EDU
Principal Investigator: Hoton How
President: Hoton How
NSF Grant No. 9660427; Amount: $74,995

We propose innovative design of planar microwave and millimeter wave (MMW) circulators compatible with integrated circuits. Traditionally, ferrite circulators are made using bulk materials in which holes need to be drilled to a very small tolerance in the dielectric substrates, and, hence, the fabrication costs are high. In addition, the need for permanent magnets further impedes the development of circulator designs toward monolithic microwave/MMW circuits. In Phase I we will identify potential circuit geometries for designing practical planar microwave/MMW circulators and complete proof-of-concept experiments. A commercialization path will be outlined. In Phase II we will design, fabricate, and test a prototype thin-film circulator. Self-biasing circulators employing hexagonal ferrite films will be developed in phase II. We will explore major cost and applicability issues associated with commercialization of our circulator designs. This research and development will seek to provide low-cost production of circulators that will facilitate their commercialization so that high-performance circulators can find direct commercial applicability in the radar and communication industries.

The potential commercial applications as described by the awardee: The results of the novel and innovative program outlined in this proposal will enhance U.S. competitiveness by advancing the state of the art in knowledge and understanding of microwave/MMW integrated-circuit circulators.

118. Recurrent Adaptive Critics for Nonlinear Systems Control
Accurate Automation Corp.
7001 Shallowford Rd.
Chattanooga, TN 37415
tel: 423-894-4646; fax: 423-894-4645
e-mail: ccox@accurate-automation.com, kmathia@accurate-automation.com
Principal Investigator: Dr. Karl Mathia/Chadwick J. Cox
President: Robert M. Pap
NSF Grant No. 9660604; Amount: $75,000

We will develop a practical methodology for applying to real-world engineering applications new nonlinear adaptive critic principles that incorporate recurrent neural networks. We have recently developed a powerful new theory that guarantees stable adaptive critic control systems. This theory describes certain properties that the subsystems of the adaptive critic algorithm (action, model, critic) and their associated learning algorithms must have to ensure stable control. Recurrent neural networks are a powerful tool that can be applied to realize these properties. We will apply our theory to the development of a theoretical and experimental basis for understanding adaptive critics with recurrent neural network subsystems. Our algorithm will learn "on-line" to control a highly nonlinear system, with stability guaranteed and optimal performance guaranteed in the limit.

The potential commercial applications as described by the awardee: Our adaptive critic will be developed with a specific application to aircraft, so the most obvious commercialization is to the aircraft industry. Our adaptive critic algorithm is very general, so it will also have applications in any industry requiring good nonlinear controls. Examples of these industries are the chemical industry, the automobile industry, and the photocopier industry. Phase I will result in a prototype of a commercializable software system. In Phase II, we will develop special-purpose hardware for sale.

119. A Neural Network Approach for Active Noise Control in a Three-Dimensional Enclosure
NeuroDyne, Inc.
One Kendall Sq.
Cambridge, MA 02139
tel: 540-955-9912; fax: 540-955-9917
e-mail: sofge@ai.mit.edu
Principal Investigator: Donald A. Sofge
President: Theresa W. Long
NSF Grant No. 9660605; Amount: $75,000

This Small Business Innovation Research Phase I project will develop and test a new approach to active interior noise control in a three-dimensional enclosure. The new thrust in the proposed research is a digital adaptive system that makes use of both analyses and directly measured data from a three-dimensional enclosure to carry out active noise control by using smart materials located on flexible boundaries of the enclosure. The system is intended to track the changes in the acoustic information due to movement, changes in open apertures, etc., and carry out on-line minimization to realize the desired acoustic performance. Unlike most methods that assume that the acoustic field inside the enclosure can be modeled by using standing waves, the proposed method is designed to accommodate diffuse sound fields in the enclosure. Furthermore, the noise is not assumed to be harmonic, and nonperiodic sound fields are to be considered. The neural network-based filter proposed herein can make use of analytical and experimental data to assign initial weights that are to be adapted to carry out (locally) on-line minimization of sound pressure in the enclosure.

The potential commercial applications as described by the awardee: Noise reduction in aircraft is a subject of serious commercial concern in the industry. The techniques developed in this effort will be widely applicable to noise reduction in rotorcraft cabins of commercial helicopters, and may be adapted for use in commercial airline cockpits, as well as in factory settings and other vibration-critical manufacturing environments.

120. Novel Crystal Growth Process for AgGaS₂
INRAD, Inc.
181 Legrand Ave.
Northvale, NJ 07647
tel: 201-767-1910; fax: 201-767-9644
e-mail: INRAD@aol.com
Principal Investigator: Dr. Ilya Tsveybak
President: Warren Ruderman
NSF Grant No. 9660638; Amount: $74,900

This Small Business Innovation Research Phase I project will develop a new crystal growth process for AgGaS₂ single crystals. The excellent nonlinear and optical transmission properties of AgGaS₂ make it a unique material for an optical parametric oscillator that can be pumped by a 1.06mm laser to provide laser radiation continuously tunable from 2.5 to 10mm. The very promising potential for AgGaS₂ crystals for this application has not yet been realized because commercially available crystals are too costly, take too long to produce, and are limited in size.

A new crystal growth process for AgGaS₂ will be developed that will overcome these limitations.

The potential commercial applications as described by the awardee: An infrared laser source continuously tunable from 2.5 to 10 mm will play an important role in environmental monitoring for chemical species, in spectroscopy, in microelectronics manufacturing, and in optical spectrometers.

121. Single Crystals for High Temperature, High Power Electronics
Nanomaterials Research Corp.
2620 Trade Center Ave.
Longmont, CO 80503
tel: 303-702-1672; fax: 303-702-1682
e-mail: staff@nrcorp.com
Principal Investigator: Dr. Shahid Pirzada
President: Tapesh Yadav
NSF Grant No. 9660642; Amount: $75,000

Silicon carbide has a unique combination of electrical and thermophysical properties, which make it very attractive to use in high temperature, high power, and high frequency electronics applications. The availability of single crystal silicon carbide wafers of the required quality at a reasonable cost will fully realize the benefits of these devices in many areas of high temperature, high power microelectronics. This Small Business Innovation Research Phase I project focuses on developing a novel process to produce single crystal silicon carbide. Nanomaterials Research Corporation (NRC) will, during Phase I, demonstrate the proof-of-concept. Phase II will optimize the technology, while Phase III will commercialize it.

The potential commercial applications as described by the awardee: The potential applications of the proposed research include automotive, aerospace, chemical refining, nuclear power, and energy production.

122. Nanomagnetic Memory Device
NanoSystems, Inc.
83 Prokop Rd.
Oxford, CT 06478
tel: 203-881-2827; fax: 203-881-2855
e-mail: nanosystem@aol.com
Principal Investigator: Dr. John Steinbeck
President: Charles P. Beetz
NSF Grant No. 9660782; Amount: $75,000

A novel nanomagnetic memory device is proposed that has performance characteristics similar to those of SRAM. Nanomagnetic structures are used to store data and to nondestructively read data out of the device using a fluxgate mechanism. The memory cells are passive devices that do not require transistors to be integrated at each memory cell and are built using proven semiconductor thin film techniques. Arrays of the nanomagnetic memory devices can be made at areal data storage densities comparable to hard disk drives. The thin film processes used to build the device coupled with the passive nature of the memory cells may make true three-dimensional integration of the devices possible both as three-dimensional memory arrays and as memory arrays integrated on top of logic circuits. The Phase I program will demonstrate that nanomagnetic memory arrays can be built at areal data storage densities of 100 Mbit/cm². The Phase II program will be used to build a complete 1K, 100 Mbit/cm² memory device.

The potential commercial applications as described by the awardee: Nanomagnetic memory technology could revolutionize the way memory subsystems are incorporated into electronic systems. The most exciting possibility is for full "systems on a chip" to become cost effective from the preservation of the silicon real estate afforded by the technology.

123. Point Sensor for Remote Off-Gas Monitoring
PXL, Inc.
1-H Deer Park Dr.
Monmouth Junction, NJ 08852
tel: 908-329-0505; fax: 908-329-8334
e-mail: pxl@superlink.net
Principal Investigator: Dr. Edward J. Miller
President: Dr. Ada Suckewer
NSF Grant No. 9660819; Amount: $74,996

This Small Business Innovation Research Phase I project will focus on the development of point sensor for high sensitivity, in situ, remote trace gas analysis. We expect the proposed technology to provide a two-to-three orders of magnitude increase in sensitivity over existing hear infrared technologies and allow the development of diode-based, portable instruments for high sensitivity (ppm-ppb range) point monitoring of trace gases. This technology also allows for the development of versatile sensors suitable for the detection of chemical/biological agents in both gas and liquid media for a broad scope of applications in science and industry.

In Phase I we will design and test a proprietary sensor component and will develop and experimentally confirm a numerical model that simulates the proposed system. Using the confirmed model, numerical simulations will be conducted to develop the instrument’s optimized design and to predict its performance.

In Phase II we will develop a point sensor based on the proposed technology for the remote monitoring of ammonia in off-gas waste streams in real time.

The potential commercial applications as described by the awardee: The proposed sensor will particularly benefit industrial process control, underground pipeline and tank leak detection, and geological exploration for oil and natural gas. It will also find applications in clinical/medical diagnostics, environmental monitoring, detection of chemical and biological warfare agents, and other personal safety devices. The broad scope of applications indicates a large potential market for this technology.

124. Multiport Wavelength Division Multiplexing Cross-Connect for All-Optic Networks
Aurora Associates
3350 Scott Blvd., Bldg. 20
Santa Clara, CA 95054-3106
tel: 408-748-2960; fax: 408-748-2962
e-mail: AurorAssoc@aol.com
Principal Investigator: I. C. Chang
President: Phoebe Chang
NSF Grant No. 9660113; Amount: $75,000

The objective of the proposed SBIR Phase I project is to develop a polarization independent (PI) wavelength division multiplexing (WDM) cross-connect for all-optical communication networks. At the core of the WDM cross-connect is a multiport wavelength routing switch using acousto-optic tunable filters (AOTFs). The salient features of the multiport AOTF switch (MAOS) are that it (1) is a single device with multiple input and output optical ports and a single RF input; (2) has low drive power, narrow passband and low sidelobes; (3) is capable of simultaneously and independently switching optical signals at different wavelengths; and (4) is scaleable to a large number of ports and wavelengths. During Phase I, a feasibility model of the PI MAOS will be built and demonstrated. The system performance and limitations of the N x N WDM cross-connect using the MAOS as the building block will be analyzed.

The potential commercial applications as described by the awardee: Applications of the MAOS include the following: dynamic gain equalizer for WDM amplifiers, add and drop multiplexers, and multiport wavelength routing cross-connect for wideband fiber-optic communication. The low power fiber pigtailed AOTF will also find use as a rugged fieldable spectrometer for process control, environmental monitoring, and medical diagnosis.

125. Enhanced Photorefractive Quantum Wells for Compensated Laser Ultrasonic Receivers Using Real-Time Holography
Lasson Technologies
1331 Avenida de Cortez
Pacific Palisades, CA 90272
tel: 310-459-0101; fax: 310-459-0101
e-mail: lassontec@aol.com
Principal Investigator: Marvin Klein
President: Marvin Klein
NSF Grant No. 9660966; Amount: $74,468

This Small Business Innovation Research Phase I project addresses enhanced photorefractive multiple quantum wells for laser ultrasonic receivers. Laser-based ultrasound is a promising nondestructive evaluation technique that can provide remote measurements of parts that are at high temperatures or in hostile environments. It can also be used for parts that are moving rapidly or that require scanning of large areas. Most current receivers for laser-based ultrasound are based on various types of interferometers. One promising type of interferometer uses real-time holography in a photorefractive material to combine a signal beam that interrogates a vibrating surface with a reference beam for coherent detection. In this configuration, the real-time hologram acts as an adaptive beamsplitter to overlap the wavefronts of the distorted signal beam and the plane-wave reference beam. In spite of their promise, none of the interferometric receivers have performed near their theoretical capability, due to limitations in the performance of the photorefractive material. In this program, we propose to design, grow, and characterize photorefractive multiple quantum wells with optimized parameters for use as a real-time adaptive beamsplitter in a homodyne interferometer. The goals are a low-cost laser ultrasonic receiver with improved signal-to-noise performance and the capability of operating at low light levels.

The potential commercial applications as described by the awardee: Laser-based ultrasound has applications in a wide range of industrial markets. It offers the capability to improve the inspection rate of existing scanning systems, and it will enable the inspection of many parts that cannot be tested with other techniques. It is particularly promising as an in-process diagnostic for 100 percent inspection of mass-produced parts.

126. Polymer Diode Arrays and Image Sensing Arrays: Large Area, Flexible Photon Sensors with High Photosensitivity
UNIAX Corp.
6780 Cortona Dr.
Santa Barbara, CA 93117
tel: 805-562-9293 x118; fax: 805-562-9144
e-mail: uniax@uniax.com
Principal Investigator: Gang Yu
President: Dr. Alan J. Heeger
NSF Grant No. 9660975; Amount: $74,932

There is considerable interest in large area, high sensitivity image sensors. Although linear diode arrays and small area, monochromatic and full-color CCD matrices have been developed (for use in scanners,video cameras, etc.), there are special opportunities for large area, flexible image sensors for use in military applications and in office automation. An example is a flexible or foldable thin-image sensor of book size to be used to directly and rapidly read images (without scanning) from papers or from a computer or TV screen into memory. The stored image could then be copied to another piece of paper or even sent by fax to a remote site. Polymer diode photodetector devices provide a novel and attractive approach to such large area, high sensitivity image sensors. Over the past six years UNIAX has invested resources and R&D effort with the objective of developing photonic and electronic devices based on semiconducting organic polymers. The proposed research will focus both on identifying materials appropriate for the spectral ranges of interest (such as full-color capability) and on optimizing device parameters. Device operating life and environmental stability are other parameters to be characterized.

The potential commercial applications as described by the awardee: The proposed work will focus on a true dual-use technology. There is a strategic need for large area linear diode arrays and image sensors for military applications, such as strategic threat warning, and target identification and tracking in aerial reconnaissance vehicles. These uses are balanced by a number of applications in the office automation and consumer electronics markets, as well as in astrophysics/space technology and in medical applications.

127. A Web-Based Automatic Database for an Electric Power System OASIS
The Web Foundry
P.O. Box 450
Dryden, NY 13053
tel: 719-637-8050; fax: 719-637-8050
e-mail: pmcconnell@web-foundry.com
Principal Investigator: Peter W. McConnell
President: Peter W. McConnell
NSF Grant No. 9661109; Amount: $52,500

This Small Business Innovation Research Phase I project is designed to prove the feasibility of real-time World Wide Web displays based on Internet transfer of polled data, automated data sanitizing and database loading, and dynamic creation of Web displays. The specific commercial opportunity has been created by a recent Federal Energy Regulatory Commission (FERC) order requiring all U.S. electric power transmission network providers to make transmission line availability and pricing data publicly available as Open Access Same-Time Information Systems (OASIS).

Research objectives include the development of an inexpensive database that can be queried via a Web browser and that can be integrated with a network provider’s existing resources; a standard data format for shipping OASIS input data via the Internet; and an automated sanitizing and loading process for transferred data. Research will involve determining a feasible database solution; defining a standard format for data transfer and loading; investigating sanitizing processes and transfer/loading mechanisms; and developing a prototype database/Web display interface.

Anticipated benefits include the ability to use the Internet and standard Web browsers for display of real-time data. Limited research has been accomplished in this area, particularly with regard to use in commercial applications using diverse hosting platforms.

The potential commercial applications as described by the awardee: The proposed technology is designed to be compatible with the growing specifications of information to be provided by transmission system owners as a result of the restructuring of the electric power industry. Research results will enable development of a commercial OASIS.

128. Next-Generation Speed Ferroelectric Liquid Crystal-VLSI Spatial Light Modulators
Displaytech, Inc.
2200 Central Ave.
Boulder, CO 80301
tel: 303-449-8933; fax: 303-449-8934
e-mail: mikeo@displaytech.com
Principal Investigator: Dr. Michael J. O’Callaghan
President: Mark A. Handschy
NSF Grant No. 9661235; Amount: $74,073

This Small Business Innovation Research Phase I project aims to develop next-generation analog and digital Ferroelectric Liquid Crystal (FLC)-VLSI spatial light modulators (SLMs) that surpass the speed of present generation SLMs by nearly an order of magnitude. In addition to their commercial use as miniature displays, current generation FLC-VLSI SLMs are enabling the development of long-awaited, commercially viable, optical image processing systems whose computing speed outstrips that of purely electronic processors. When used as part of a computing subsystem, present generation SLMs can tax the data bandwidth capabilities of inexpensive general purpose digital computers. Our intent is to greatly extend the performance of analog and digital FLC-VLSI SLMs to match or surpass the data throughput rates of current high performance digital systems. Our plan is to achieve this goal by drawing on, and extending, combined advances in both VLSI design and FLC performance.

The potential commercial applications as described by the awardee: The proposed high-speed SLMs can be used in biometric applications such as fingerprint and face recognition, high-speed image processing, volumetric three-dimensional displays, industrial machine vision, and improved sequential color miniature displays.

129. Enhancement of the EPRI-Operator Training Simulator for the Restructured Electric Utility
Decision Systems International
3060 Peachtree Rd., Suite 1462
Atlanta, GA 30305
tel: 404-504-3652; fax: 404-504-3651
e-mail: adebs@dsipower.com
Principal Investigator: Dr. Atif S. Debs
President: Dr. Atif S. Debs
NSF Grant No. 9661263; Amount: $74,985

This Small Business Innovation Research Phase I project will complete the research needed to introduce some basic new functionalities to the EPRI-Operator Training Simulator (EPRI-OTS) to meet the needs of deregulated (re-structured) electric utilities. A key element here is to upgrade the EPRI-OTS to become an effective tool for training the ISO (independent system operator) dispatchers for system operation. ISO engineers and management staff will be able to use the enhanced product for operation planning and other studies.

The main objective of this work will be to integrate new models and programs into the EPRI-OTS that will include (1) a novel multi-area optimal power flow, (2) a simultaneous transfer capability coordination program, and (3) a program for measuring and evaluating ancillary services. Other objectives relate to testing and evaluation of these programs and the preparation of a Phase II plan.

The result of the Phase I research will be a demonstrable product that will clearly differentiate itself in the arena of Operator Training Simulators for the deregulated electric utility.

The potential commercial applications as described by the awardee: The research will lead to widespread implementation at most major electric utilities. Our estimate is that over 100 U.S. and 50 international utilities, as well as over 100 energy marketers, will need the results of this research and development.

130. High-Pressure MOCVD Growth of GaN and InGaN
Spire Corp.
One Patriots Park
Bedford, MA 01730-2396
tel: 781-275-6000; fax: 781-275-7470
e-mail: email@spirecorp.com
Principal Investigator: Stanley M. Vernon
President: Roger G. Little
NSF Grant No. 9661323; Amount: $74,899

This Small Business Innovation Research Phase I project will develop an innovative, high-pressure metalorganic chemical vapor deposition (MOCVD) reaction chamber for improved growth of Group-III nitrides. Growth at pressures above one atmosphere will increase cracking efficiency of ammonia, limit material desorption, lower the density of nitrogen vacancies, and lead to better crystal quality by permitting higher temperature growth.

Phase I will demonstrate growth of GaN using a high-pressure MOCVD reaction chamber, operating up to ten-atmospheres pressure. The chamber will be a vertical, inverted-flow design to minimize convection.

MOCVD growth of the first GaN laser diode at Nichia used a configuration that simulates high pressure with a "push" flow orthogonal to the growth stream. At Spire, high-pressure MOCVD has been successfully employed for InP growth using substantially less phosphine than normally required. In fact, InP with specular surfaces and good crystal quality has been deposited at three atmospheres with a V:III ratio of 1:1, the lowest ratio ever reported for the successful growth of InP.

Phase II will develop growth parameters for GaN, InGaN, and AlGaN device structures. Process optimization will include use of nitrogen in the carrier gas to better confine heat to the wafer surface by reducing thermal conductivity.

The potential commercial applications as described by the awardee: The market potential for GaN is tremendous, especially in optical storage (blue lasers and LEDs) and high-temperature electronics. Products made from this material system are already in large demand. If successful, high-pressure MOCVD may be the process of choice for GaN growth. Spire will offer high-pressure reactors to device manufacturers, while we use this technology to expand our optoelectronics epitaxial service business to include structures for shorter-wavelength devices.

131. Micro Relay Switches
Aura Systems, Inc.
2335 Alaska Ave.
El Segundo, CA 90245
tel: 310-643-5300; fax: 310-536-9159
Principal Investigator: Hilary B. Cherry
President: Jerry Papazian
NSF Grant No. 9661471; Amount: $75,000

Aura Systems will develop a MEMS device for fast switching of high-frequency signals such as RF. The mechanical switching will achieve virtually no parasitic leakages when the switch is off. The device will utilize a piezo electric actuator that was originally developed for a display application.

The potential commercial applications as described by the awardee: Fast RF switching devices for microwave communications.

132. New, Reconfigurable MEMS Based Grating for Optical Sensors InterScience, Inc.
105 Jordan Rd.
Troy, NY 12180
tel: 518-283-7500; fax: 518-283-7502
e-mail: JC309@CSC.albany.edu
Principal Investigator: Dr. James Castracane
President: Dr. James T. Woo
NSF Grant No. 9661476; Amount: $75,000

This Small Business Innovation Research Phase I project will establish the feasibility of producing a micro-electro-mechanical system (MEMS) based, reconfigurable optical grating. This new device will form the heart of the next generation of compact spectroscopic instruments. Fundamental research into the operation of such MEMS devices is required to optimize their operation and enable widespread applications. Specifically, this Phase I effort will focus on perfecting a MEMS grating array whose ruling spacing can be reconfigured in real time to allow for rapid, full spectral analysis of several passbands critical for accurate laboratory and field-ready sensor systems. Objectives include production and packaging of several prototype micro-gratings and measurement of switching performance, optical efficiency, and spectral resolution. Exploiting the expertise that InterScience has developed in both electro-optic technology and the MEMS field, we intend to establish the operation of such a MEMS grating and develop a design for its integration into a compact, optical domain spectroscopic system. This Phase I project will combine material, mechanical, and optical research and development and pave the way for full implementation in Phase II and, ultimately, commercialization.

The potential commercial applications as described by the awardee: Commercial applications of the proposed research involve bringing fundamentally new spectroscopic instruments to market in areas such as atmospheric analysis, remote surveillance, and compact pressure and chemical sensing. In addition, there exist medical applications for this new instrument, which include rapid, microanalytic immunoassays and multispectral fluorescence measurements in innovative cardiac treatment modalities. Initial discussions with interested companies in the compact sensor industry are already in progress.

133. Microfabrication of Planar Accelerating Structures for High-Frequency Electron Linear Accelerators
DULY Research, Inc.
1912 MacArthur St.
Rancho Palos Verdes, CA 90275-1111
tel: 310-548-7123; fax: 310-548-6094
e-mail: duly@technologist.com
Principal Investigator: Dr. David U.L. Yu
President: David U.L. Yu
NSF Grant No. 9661539; Amount: $74,962

A planar structure has been proposed for acceleration of a flat electron beam in a high-frequency linear electron accelerator. The proposed structure, different from the conventional cylindrically symmetric disk-loaded structure, can be mass produced with modern microfabrication techniques using deep-etch X-ray lithography. Phase I will study the physics issues and fabrication techniques of the planar accelerating structure (PAS), and the feasibility of their application to future linear colliders and compact commercial linear accelerators operating at high frequencies. The PAS can be designed with a nearly constant axial electric field in the central region of the cavity through which the beam passes. Such a structure would reduce wakefields and accommodate a high-current beam while maintaining a low current density. The PAS can also be used to accelerate electrons emitted by an asymmetric photoinjection gun, possibly eliminating the need for an expensive damping ring to control emittances. Asymmetric RF quadrupole beam focusing in a PAS-based linac is also possible. Precision microfabrication techniques are especially suitable for repeatable production of small, high-aspect-ratio structures with tight tolerances. These techniques would replace tedious machining and brazing manufacturing processes for very small and intricate structures and would substantially reduce their manufacturing cost.

The potential commercial applications as described by the awardee: The proposed asymmetric planar accelerating structure (PAS) is a revolutionary design applicable to a new generation of commercial linear accelerators and linear colliders. Microfabrication of PAS using lithography techniques will save production cost and increase precision in manufacturing tolerances. Microfabricated, PAS-based linacs can be used as compact medical and industrial accelerators. They can also be used as compact injectors to microfabricated free electron lasers to produce coherent, tunable radiations.

134. Electrostatic-Surge Protection Tape
Oryx Technology Corp.
1100 Auburn St.
Fremont, CA 94538
tel: 510-492-2080; fax: 510-492-2089
Principal Investigator: Gerald Behling
President: Phillip Micciche
NSF Grant No. 9661574; Amount: $75,000

Electrostatic discharge (ESD) is a transient over-voltage event that poses a serious threat to integrated circuits (ICs), rendering them irreparably damaged due to the associated over-current flow through the circuit. The standard means of contending with over-voltage threats is to place a surge suppressor in parallel to the IC. These suppressor types include diodes and varistors. A need exists for a new generation suppressor concept that exhibits far lower leakage current and capacitance than existing devices. Oryx Technology has successfully developed such a material in the form of a conductor-filled, polymer matrix, thick-film ink that can be applied to the fabrication of small, discrete device structures. The goal of this research is to transfer materials design "know-how" about the formulation and use of these inks into the development of extruded, thermoplastic matrix composite tapes that can be used for widespread, innovative, and cost-effective over-voltage surge suppression applications. These applications will include direct mounting of such tapes onto printed circuit boards as well as the creation of on-leadframe and in-IC package placement.

The potential commercial applications as described by the awardee: Use in all electronic equipment that has to be protected against static discharge.

135. Real-Time Spectrogram Inversion for Ultrashort Laser Pulse Measurement
Southwest Sciences, Inc.
1570 Pacheco St., Suite E-11
Santa Fe, NM 87505-3987
tel: 505-984-1322; fax: 505-988-9230
e-mail: sws@rt66.com
Principal Investigator: Dr. Daniel J. Kane
President: Alan C. Stanton
NSF Grant No. 9661596; Amount: $75,000

This Small Business Innovation Research Phase I project will develop an algorithm for the real-time inversion of spectrograms for ultrashort laser pulse measurement. Ultrafast laser systems have a large number of applications in biochemistry, chemistry, physics, and electrical engineering. These systems generate laser pulses with durations of 10 picoseconds or less and are used to explore kinetics in proteins, examine carrier relaxation in semiconductors, or image through turbid media. Ultrafast diagnostic systems can be used to develop highly advanced semiconductors, electronic circuitry, and even biomedical products and test them for commercial applications. Furthermore, new applications requiring shaped ultrashort pulses—in both intensity and phase—such as coherent control of chemical reactions are beginning to be developed. The continued development of these applications will require fast, high quality, and easy-to-use ultrafast laser pulse diagnostics. Frequency-resolved optical gating (FROG) has been proven to be a reliable and effective ultrashort laser pulse diagnostic, but requires an iterative algorithm to obtain the ultrashort pulse’s characteristics (intensity and phase). Current inversion algorithms are slow. We propose the development of a new inversion algorithm that will obtain the intensity and phase of an ultrashort pulse from the FROG device’s output in real time, facilitating the development of a real-time oscilloscope for ultrashort laser pulses.

The potential commercial applications as described by the awardee: Immediate commercial applications are directed toward use as a diagnostic for existing ultrafast laser systems, few of which are currently available. Other commercial applications for the algorithm include scanning transmission electron microscopy.

136.Terahertz Time-Domain Spectrometer
Clark-MXR, Inc.
P.O. Box 339
Dexter, MI 48130
tel: 734-426-1391; fax: 734-426-6288
e-mail: ecanto@cmxr.com
Principal Investigator: Edesly Canto-Said
President: Philippe Bado
NSF Grant No. 9661638; Amount: $75,000

The goal of this program is to develop a compact, reliable, THz time-domain spectrometer. This instrument will be used to provide comprehensive far-infrared absorption measurement. Our THz time-domain spectrometer will use a compact femtosecond laser gated to a coherent receiver. This approach offers superb signal-to-noise ratios (10⁸:1 in power). The coverage of our spectrometer will extend continuously over a wide spectral range, from 0.1 to greater than 6 THz, permitting the simultaneous detection of many species. Our THz source generates a well-collimated, low-divergence beam for which the receiver has a corresponding small acceptance angle. Thus, the proposed technique combined with mathematical techniques commonly used in tomography should provide three-dimensional data. Our program goals will be reached in collaboration with the inventor of THz-TDS, Professor D. Grischkowsky (Oklahoma State University).

THz time-domain spectroscopy is conceptually a very general technique. However, until now, the complexity of the required femtosecond source has severely limited the diffusion of this spectroscopic technique. This SBIR program addresses that issue. During Phase I, we will demonstrate a prototype THz spectrometer operating with one of our compact femtosecond sources. In our Phase II, we will develop a field-portable Terahertz time-domain spectrometer.

The potential commercial applications as described by the awardee: Applications include noncontact measurement of water vapor, noncontact measurement of doping levels in semiconductor wafers, detection of concealed explosives, noncontact monitoring of flame emission and flame temperature, etc.

137. In Situ, Fiber-Optic Magnetic Field Sensor Array for Real-Time Process Control in Physical-Vapor Deposition Cluster Modules
Intelligent Fiber Optic Systems (IFOS)
1778 Fordham Way
Mountain View, CA 94040-3662
tel: 650-967-4107; fax: 650-967-8630
e-mail: rjb@intelfos.com
Principal Investigator: Dr. Richard J. Black
President: Dr. Behzad Moslehi
NSF Grant No. 9661691; Amount: $74,966

This Small Business Innovation Research Phase I project proposed by Intelligent Fiber Optics Systems (IFOS) involves development of a novel magnetic field sensor for in situ process sensing. The system responds to the need for new techniques for real-time process control in semiconductor fabrication. In Phase I, using an innovative combination of technologies including fiber optics and magnetic coatings, IFOS proposes to create a room-temperature benchtop testbed comprising a magnetic orientation electromagnet and a portion of a semiconductor substrate chuck in conjunction with a magnetic sensor. During Phase I, IFOS will (1) establish details of the sensor specifications, and design and model the sensor probes and system, (2) fabricate fiber sensor probe substrates and coated by magnetic material, (3) construct a feasibility prototype testbed, (4) test and evaluate the prototype, and (5) deliver a final report and submit a Phase II proposal. This first-time incorporation of magnetic sensors in plasma physical-vapor deposition (PVD) is expected to offer improved process control for thin film head fabrication with higher sensitivity and reliability than conventional approaches.

The potential commercial applications as described by the awardee: The design is electrically passive, in-line, multiplexible, low cost, and mass producible with applications that include in situ process sensing and use by the aerospace industry and power utilities. These features make the proposed sensors marketable and can attract non-federal and private sector commercialization funding. IFOS has already established collaborative relationships with government and industrial laboratories needing such sensors.

138. Millimeter Wave Imaging System Using Evanescent Wave Coupling Antenna
WaveBand Corp.
376 Van Ness Ave., Suite 1105
Torrance, CA 90501
tel: 310-212-7808; fax: 310-212-7726
e-mail: manasson@aol.com
Principal Investigator: Vladimir Manasson
President: Ryszard Gajewski
NSF Grant No. 9661743; Amount: $74,980

This proposal addresses a central problem of millimeter wave (MMW) imaging. MMW imaging is becoming an attractive option for remote sensing because millimeter waves can penetrate adverse weather or other atmospheric obscurants while retaining reasonable spatial resolution.

While a major goal of MMW imaging developers is to create an MMW equivalent of an IR staring array, the difficulties associated with providing the necessary MMW detector performance at an affordable price are immense. Use of a single, high quality MMW detector with a rapidly scanning, low-cost antenna can make MMW imaging systems more readily achievable.

The WaveBand antenna concept uses an evanescent wave grating coupler to form a two-dimensional scanning antenna that can work at very high frame rates. The proposed research will demonstrate a proof of concept while advancing the understanding of the underlying physical phenomena. Phase II will result in fabrication of a prototype low-cost MMW radiometric imaging system.

The potential commercial applications as described by the awardee: MMW imaging systems are being considered for autonomous landing guidance for aircraft; automotive traffic monitoring, fire detection; concealed weapons detection; and other surveillance functions.

The potential commercial applications as described by the awardee: The increase in toughness of low-cost alumina ceramics will expand the application base and markets for technical ceramics.

152. New Method to Minimize the Evaporation of Volatile Colorant
MO-SCI Corp.
4000 Enterprise Dr., P.O. Box 2
Rolla, MO 65402
tel: 573-364-2338; fax: 573-364-9589
e-mail: MOSCICO@rollanet.org
Principal Investigator: Yiyong He
President: Delbert E. Day
NSF Grant No. 9661043; Amount: $74,936

The purpose of the work described herein is to determine the feasibility of developing a new method to minimize the evaporation of volatile colorants during the glass-melting process. This is a proposal for the development of a nonconventional method that consists of extremely rapid melting (few seconds) and spheridization of colorant-rich glass spheres that will be added to the molten glass. By introducing these colorants in a pre-melted glassy form, we expect to reduce the degree of volatilization that these materials currently demonstrate.

The potential commercial applications as described by the awardee: The processing techniques developed in this work will constitute a revolutionary advance in colored-glass manufacturing. The process for producing colorant-rich glass spheres will allow the introduction of colorants in the form of a new raw material that offers less volatilization and higher retention in the finished glass product. The glass manufacturer will benefit from lower raw material costs, greater process stability, and significant environmental improvements as a direct result of this process.

153. A Computational Model for Electromagnetic Processing of Materials
Innovative Research, Inc.
2520 Broadway St. NE, Suite 200
Minneapolis, MN 55413
tel: 612-378-0320; fax: 612-378-0535
e-mail: winstead@inres.com
Principal Investigator: Dr. Charles H. Winstead
President: Dr. Suhas V. Patankar
NSF Grant No. 9661064; Amount: $75,000

This Small Business Innovation Research Phase I project will develop and experimentally validate a comprehensive computational model for electromagnetically coupled metallurgical processes. The model incorporates an efficient approach for predicting the interaction among electromagnetic, fluid dynamic, and heat transfer subsystems, and will be applicable to several commercial processes, such as continuous casting, induction heating, and magnetic stirring.

The objectives of the Phase I effort are to demonstrate the feasibility of the unified approach by developing a two-dimensional model that solves for AC magnetic fields, turbulent fluid dynamics, conjugate heat transfer, and phase change. It will be capable of modeling processes that involve deformation and containment of free-surfaces, metal solidification, and particle transport. Phase I provides a foundation for later extension to three dimensions and additional electromagnetic configurations, making it applicable to many industrial processes.

The potential commercial applications as described by the awardee: The proposed computational model will provide guidance for many material manufacturing processes involving electromagnetic fields. Currently, these processes include induction furnaces, electromagnetic casting, and refining, stirring, shaping, pumping, and braking systems. It will be essential in the scale-up and optimization of laboratory processes, eliminating the prohibitively expensive trial-and-error approach currently employed, thereby reducing manufacturing costs and producing higher quality materials.

154. Target Tracking and Identification Using a Holographic Correlation Filter
Accuwave Corp.
1651 19^th St.
Santa Monica, CA 90404-3809
tel: 310-449-5540; fax: 310-449-5539
Principal Investigator: Koichi Sayano
President: Neven Karlovac
NSF Grant No. 9661084; Amount: $75,000

An optical correlator for tracking and identifying objects in a cluttered or noisy field will be demonstrated. Filter algorithms for improved signal to noise and reduced rotation dependence will be developed and tested in the optical correlator system with multiple in-class and out-of-class objects.

The potential commercial applications as described by the awardee: Commercial applications include manufacturing process control, automated inspection, image analysis, and surveillance.

155. Aluminum Nitride Cold Cathodes for Field Emission Displays
Spire Corp.
One Patriots Park
Bedford, MA 01730-2396
tel: 781-275-6000; fax: 781-275-7470
e-mail: email@spirecorp.com
Principal Investigator: Nader M. Kalkhoran
President: Roger G. Little
NSF Grant No. 9661089; Amount: $74,985

This Small Business Innovation Research Phase I project proposes to demonstrate large area cold cathode arrays for field emission displays based on GaN/Al_xGa_1-xN/AlN grown using Spire’s unique low-temperature plasma-assisted chemical vapor deposition and surface texturing facility. With a bandgap of 6.2eV, AlN may exhibit negative electron affinity, and thus electrons emanating from the high conductivity GaN contact will readily pass through the graded Al_xGa_1-xN region and be emitted into vacuum at low applied voltages. GaN stripes deposited on glass or another substrate will form row electrodes, while ITO stripes above the phosphor on the faceplate will serve as column electrodes. Due to the expected negative electron affinity of AlN, no grid may be required. This new cathode material can alleviate the present high voltage problems associated with high work function metal "microtip" cathodes, as well as the lack of n-type conductivity in thin film diamond cathodes.

The proposed GaN/AlN cold cathode will mate effectively with Spire’s cathodoluminescent phosphor development program, allowing Spire to manufacture flat panel displays under controlled conditions with in-house cathode and phosphor components. Spire has recently developed several fully adherent thin film cathodoluminiscent phosphors based on ion implanted ZnS, ZnSiO_4, GaN, SrS, and, recently, ZnGa₂O₄. In Phase II, the GaN/Al_xGa_1-xN/AlN cold cathodes will be optimized and used for lighting pixels on faceplates coated with these types of cathodoluminiscence phosphors, allowing an operating flat panel display to be demonstrated.

The potential commercial applications as described by the awardee: Efficient cold cathode field emitters will find extensive commercial use in flat panel displays. They can also be used in new subminiature vacuum tubes for ultra-high-frequency applications, such as in communication systems.

156. A Noninvasive Viscometer for Materials Analysis and Process Control
Quantum Magnetics, Inc.
7740 Kenamar Ct.
San Diego, CA 92121
tel: 619-566-9200; fax: 619-566-9388
e-mail: Geoff@qm.com
Principal Investigator: Geoffrey Barrall
President: Andrew D. Hibbs
NSF Grant No. 9661122; Amount: $74,921.77

This Small Business Innovation Research Phase I
program will demonstrate the technical feasibility of magnetic resonance (MR) viscometry and develop specifications for an economically viable prototype MR viscometer to be fabricated in Phase II. Many manufacturing and processing technologies are critically dependent on the flow or rheological properties of fluids, suspensions, slurries, or melts. For example, the steady-state shear-dependent viscosity of thermopolymers is often indicative of key properties such as molecular weight and molecular weight distribution. Viscometric measurement of molecular weight distribution requires measuring shear viscosity over two or three decades in shear rate with at least five points per decade. Current in-line and on-line viscometers are not capable of making the required measurements quickly enough to allow real-time process control. The proposed MR viscometer will measure shear viscosity over two decades in shear rate within one minute (about thirty times faster than the present commercial state of the art). It will be noninvasive, capable of investigating particulate-filled systems (which can clog present viscometers), and amenable to large flow streams. The MR viscometer will further be capable of simultaneously measuring other important properties such as diffusion coefficients, of which present viscometers are completely incapable.

The potential commercial applications as described by the awardee: A low-cost, in-line system to measure viscosity over several decades in shear rate will find wide application in industries that process melts, slurries, and emulsions. Target markets include thermoplastics, resins, petroleum derivatives, heterogeneous food products, coal, paper, and waste disposal management. The overall process control market is in excess of $1 billion annually, of which our market of opportunity is approximately $100 million per year.

157. Recycling Painted Automotive Thermoplastics
American Commodities, Inc.
2945 Davison Rd.
Flint, MI 48506
tel: 810-767-3800; fax: 810-953-9219
Principal Investigator: Ralph L. Wisner
President: Mark Lieberman
NSF Grant No. 9661155; Amount: $75,000

This Small Business Innovation Research Phase I project will test a new process for recycling painted automotive thermoplastic parts. Approximately 350 million pounds per year are currently used to produce automotive bumpers, facias, etc., in North America. Of that amount, 20 to 25 percent is generated in producing the part (post-industrial). American Commodities, Inc., has been helping the industry recycle approximately 10 percent of the post-industrial material, and a joint relationship with 350 dismantlers is beginning to recycle a portion (1 percent) of the post-consumer material. The basic problem in recycling these products is residual paint particles in the recycled material. The proposed new process focuses on (1) segregating the individual plastics, (2) debonding the paint chemically and removing it, (3) recovering the thermoplastics, and (4) ensuring that the recycled plastics meet the critical application needs of the end user. A research team of industrial and academic experts has joined American Commodities in this project. The goal is to deliver recycled material with properties very near virgin material at a cost that is lower than the virgin price.

The potential commercial applications as described by the awardee: A process that will deliver recycled material with properties very similar to virgin material is expected to significantly increase the recycling of post-industrial material to nearly 80 percent and post-consumer material to at least 20 percent (in excess of 100 million pounds per year). If we had a 50 percent market share, our current business would increase several fold. Recycling 100 million pounds instead of allowing it to be landfilled would represent one-third of all material currently being landfilled.

158. One-Step Manufacturing Process for Low-Cost SiC-SiC Composites
Materials and Electrochemical Research (MER) Corp.
7960 South Kolb Rd.
Tucson, AZ 85706
tel: 520-574-1980; fax: 520-574-1983
e-mail: mercorp@opus1.com
Principal Investigator: Witold Kowbel
President: Dr. R.O. Loutfy
NSF Grant No. 9661185; Amount: $75,000

This Small Business Innovation Research Phase I project will investigate a low-cost process to produce SiC-SiC composites. SiC-SiC composites exhibit excellent mechanical, thermal, and corrosion properties. Their applications for aerospace and energy-related areas are greatly hindered, however, by a high manufacturing cost, lack of oxidation-stable interfaces, and selectively poor creep resistance of the SiC fibers. This proposed effort offers a unique way to produce pure b-SiC/b-SiC composites via a direct chemical vapor reaction (CVR) of low-cost C-C composites. CVR-derived fibers are expected to exhibit excellent creep resistance, while an in situ generated porous SiC interface is expected to provide good fiber pull-out and good environmental stability.

The potential commercial applications as described by the awardee: Lowering the cost of S-C SiC composites not only will expand applications in aerospace industries, but also provide opportunities in civilian industries such as automotive, burners, combusters, process equipment, heat recovery equipment, and separation/filtration.

159. Laser Engineered Net Shaping for Injection Mold Tooling Applications
Optomec Design Co.
2701-D Pan American, NE
Albuquerque, NM 87107
tel: 505-761-8250; fax: 505-761-6638
e-mail: dkeicher@optomec.com
Principal Investigator: David M. Keicher
President: Thomas A. Swann
NSF Grant No. 9661204; Amount: $74,407

This Small Business Innovation Research Phase I project is an extension of current rapid prototyping technology. Rapid prototyping systems allow manufacturers to reduce design cycle time by producing prototype plastic parts directly from computer-generated designs. A related emerging technology, the Laser Engineered Net Shaping (LENSä) process initially developed at Sandia National Laboratories and being commercialized by Optomec, has demonstrated the ability to produce near-net-shape functional parts directly from computer-generated designs. The opportunity exists for commercialization of this technology beyond the military defense applications for which it was developed. The objective of the project was to determine the feasibility of applying this technology for rapid tooling of injection molds. To determine feasibility during Phase I, Optomec designed a mold for a simple geometry, produced the mold using the LENSä, and then used the mold to actually produce a quantity of plastic parts.

The potential commercial applications as described by the awardee: The tooling industry within the United States is estimated to be a $100 billion industry. This technology has significant applications for commercial utilization within this industry due to its potential of saving time and cost in the preparation of tooling hardware.

160. A System for High-Speed Metal Machining
Aesop, Inc.
19 Harvey Rd. #9
Bedford, NH 03110
tel: 603-644-3664; fax: 603-644-3668
Principal Investigator: Dr. Kevin L. Wasson
President: Dr. Alexander Slocum
NSF Grant No. 9661445; Amount: $74,012

Machine tool spindles are key components in systems used to high-speed machine aluminum, titanium, steel, and other metals. State-of-the-art spindles used to mill aluminum are currently under development and are expected to achieve speeds of 50,000 rpm and cutting powers of 50 kW. We propose to develop an innovative new high-speed machining method that will more than double the speed capability to 100,000 rpm and double the cutting power to 100 kW. The production cost of this new system will be comparable to the cost of a high-end machine tool spindle that has half of the speed and power capabilities of the proposed method.

If successful, the proposed method will substantially increase the removal rates of aluminum, titanium, steel, and other metals. Improved removal rates will increase productivity and advance the ability of the United States to competitively manufacture important components such as aircraft frames and automotive dies.

The potential commercial applications as described by the awardee: Commercial applications for this technology include the production of commercial aircraft and automotive components. The new spindle technology could be directly integrated into commercial high-speed machining centers.

161. A Meshless Topology Optimization Design and Analysis Tool
Altair Computing, Inc.
1757 Maplelawn Dr.
Troy, MI 48084-4004
tel: 248-614-2400; fax: 248-614-2411
e-mail: dkm@altair.com
Principal Investigator: Dhiren K. Marjadi, Ph.D.
President: James Scapa
NSF Grant No. 9661604; Amount: $75,000

This Small Business Innovation Research Phase I program will develop and test an innovative software tool that will merge the tasks of design and structural analysis into one truly concurrent task. The proposed technology has the potential to dramatically reduce the design cycle time by reducing the iterative process of analytical validation into one single concurrent design and CAE step. In the proposed method, Altair Computing will combine the technologies of topology optimization with the emerging h-p adaptive meshless (Clouds) method of structural analysis. For given package space and loads and boundary conditions, this method will compute structures that are optimum in terms of topology as well as size and shape. The error prediction feature of the H-P adaptive method will hold the modeling and computational errors within user-prescribed bounds, thus significantly reducing design iterations, the most costly and time-consuming portions of the design process. The Phase I research will demonstrate the feasibility of merging the two technologies with analysis formulation efforts focused on linear static analysis using two-dimensional structures. Phase II will include design for more practical three-dimensional solids and shells.

The potential commercial applications as described by the awardee: The software tool proposed will cut design time and decrease product design cost while increasing accuracy of design. The anticipated ease of use will mean that not only CAE experts but designers as well will be capable of applying the technology. This will have particular impact on the automotive and aerospace industries, which account for 50 percent of all mechanical software applications and face significant pressures to reduce product cycle times while producing better designs.