SBIR-STTR Award

Low Cost Automated Module Assembly for 180 GHz Devices
Award last edited on: 2/1/2023

Sponsored Program
SBIR
Awarding Agency
NASA : JPL
Total Award Amount
$686,171
Award Phase
2
Solicitation Topic Code
S1.03
Principal Investigator
Donald Hashigawa

Company Information

NxGen Electronics Inc (AKA: MeltroniX Inc)

9771 Clairemont Mesa Boulevard Suite C
San Diego, CA 92124
   (858) 309-6610
   info@nxgenelectronics.com
   www.nxgenelectronics.com
Location: Single
Congr. District: 52
County: San Diego

Phase I

Contract Number: NNX09CD88P
Start Date: 00/00/00    Completed: 00/00/00
Phase I year
2009
Phase I Amount
$90,720
Emergence of Indium Phosphide IC's has made possible devices operating at frequencies up to 200GHZ and beyond. Building modules using these devices opens a goldmine of military and commercial applications. Systems integration of these devices into affordable and reliable modules has been a challenge due to costs associated with assembly requirements. Research into: placement precision requirements, material selection and cost, assembly processes, and automation are the subjects of this proposal. Because of its capabilities, NxGen Electronics is uniquely qualified to perform this research.Since 2003 JPL has been developing Miniature MMIC low power Radiometers for GeoSTAR and PATH Missions. Current weather and surface observational satellites employ both infrared (IR) and microwave (MW) atmospheric sounders. Since clouds are almost completely opaque at infrared wavelengths, sounds require cloud free observation. POES satellites provide coverage but provide coverage in relatively narrow swaths, and with revisit time of 12-24 hours. GeoSTAR offers the possibility of MW temperature and water vapor soundings as well as rain mapping from GEO. The results of this SBIR research will be a direct benefit to these programs by using their requirements as a focus for the study, and provide the groundwork for broader support for the commercialization process.

Potential NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) For years NASA/JPL and NOAA have been engaged in providing weather forecasting data to the meteorological community. Current systems are lacking in terms of real time, continuous measurements of temperature and water vapor. As recent Hurricane events have demonstrated, this data would be crucial to minimize dangers and damage from such events. Another important project involves research into how global precipitation, evaporation, and cycling of water changes. Together the GeoSTAR and PATH projects have developed instruments to support this need based on 90 GHz MMIC technologies. Satellite deployable designs will require assembling large arrays of 180GHz MMIC devices, which has proven to be costly and labor intensive. For the past two years NxGen has been a participant by providing many of the 90GHz modules. NxGen believes it can lead the research into assembling low cost MMIC module assemblies at 180 GHz which will benefit many future NASA/JPL designs.

Potential NON-NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) Non NASA applications for low cost MIMIC devices operating at frequencies above 60GHz are enormous. Traditionally microwave designers have used discrete devices at great expense and size penalties limiting their applicability. The emergence of Indium Phosphide heterojunction bipolar transistors (HBT's) has now made it possible to offer 60-100GHz system solutions at lower cost with unprecedented performance advantages. Missile Radar (smaller antennas), Telecommunications (competing with cable), and Collision Avoidance systems are but a few of the applications where operation at these high frequencies in a compact and low cost implementation would benefit. Two major obstacles needed to be overcome are cost of assemblies in large volume and substrate costs. NxGen Electronics believes that full implementation of the proposed SBIR would greatly enhance its abilities to compete for some of these applications. NASA's technology taxonomy has been developed by the SBIR-STTR program to disseminate awareness of proposed and awarded R/R&D in the agency. It is a listing of over 100 technologies, sorted into broad categories, of interest to NASA.

Technology Taxonomy Mapping:
Airport Infrastructure and Safety Attitude Determination and Control Composites Guidance, Navigation, and Control Integrated Robotic Concepts and Systems Manned-Maneuvering Units Metallics RF Semi-Conductors/Solid State Device Materials Telemetry, Tracking and Control Teleoperation

Phase II

Contract Number: NNX10CA78C
Start Date: 3/18/2010    Completed: 12/31/2014
Phase II year
2010
Phase II Amount
$595,451
Despite the obvious advantages of millimeter wave technology, a major barrier to expanded use is high assembly costs due to: need for specialized equipments; need for precision impacts on yields; design technologies for manufacturability; and experienced personnel with demonstrated track records.The challenges of this R&D project are to expand and fully develop the Phase 1 technologies for:•Methods to use common manufacturing equipment to achieve the high accuracy die placement required for millimeter wave frequencies (+/- 5 micron accuracy)•Automation methods and processes to achieving speed and precision for production of low cost modules•Modeling to arrive at cost effective trade-offs for achieving customer specifications with minimum capital investment and labor costAs part of the research, NxGen will conduct a demonstration effort utilizing two existing JPL module designs facilitating the collection statistical data both in terms of yields as well as baseline data for cost estimating.

Potential NASA Commercial Applications:
(Limit 1500 characters, approximately 150 words) Since 2003 JPL has been developing Miniature MMIC low power radiometers for a number of observational satellites employing both infrared (IR) and microwave (MW) atmospheric sounders. Clouds are almost completely opaque at infrared wavelengths, satellites require cloud free observation. Polar Orbiting Environmental Satellites (POES) provide coverage in relatively narrow swaths, and with revisit time of 12-24 hours. GeoSTAR offers the possibility of MW temperature and water vapor soundings as well as rain mapping from GEO. The project will develop the infrastructure to assemble thousands of devices necessary to support these and other similar NASA/JPL projects, while providing the opportunity for commercialization in Phase 3.Bids on future requirements at NASA will be:GeoSTAR Surface Water Land Hydrology & topology (SWOT) Polar Orbiting Environmental SatelliteWilkerson Microwave Anisotropy Probe (WMAP)



Potential NON-NASA Commercial Applications:
:

(Limit 1500 characters, approximately 150 words) Commercial applications of millimeter wave modules are important to many applications which include: ?Radar applications (e.g., imaging radar, radio frequency identification, speed detection)?Wireless uncompressed video/audio transport (MP3, HDTV), ?Wireless local and personal area networking (WLAN and WPAN), ?High accuracy sensors (e.g., Doppler, displacement, sub-wavelength resolution microwave impedance microscopy, passive radiometry measurements)?Extremely high security communications and sensors with very low probability of intercept (LPI).The drive for millimeter wave products and systems in wireless applications results from: •Improved performance for both short and long range distance applications•Operate at higher data rates•Results in small diameter transmitter and receiver elements•Have good propagation characteristics under all weather conditions•Opens new frequency operating regionsThese are only some of the examples of applications that will benefit from our proposed work to establish automated low cost assembly processes for mmWave modules. NASA's technology taxonomy has been developed by the SBIR-STTR program to disseminate awareness of proposed and awarded R/R&D in the agency. It is a listing of over 100 technologies, sorted into broad categories, of interest to NASA.

Technology Taxonomy Mapping:
Architectures and Networks Data Input/Output Devices Guidance, Navigation, and Control Highly-Reconfigurable Large Antennas and Telescopes Microwave/Submillimeter RF