1 Distribution Statement A: Approved for Public Release. Distribution is unlimited. Case # 88ABW-2016-1256. Integrity Service Excellence Flexible Hybrid Electronics for Aerospace Applications B.J. Leever, M.F. Durstock, J.D. Berrigan, C.E. Tabor, A.T. Juhl AFRL/RXAS Materials & Manufacturing Directorate Air Force Research Laboratory Wright-Patterson AFB, OH 45433
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1Distribution Statement A: Approved for Public Release. Distribution is unlimited. Case # 88ABW-2016-1256.
Integrity Service Excellence
Flexible Hybrid Electronics
for Aerospace Applications
B.J. Leever, M.F. Durstock, J.D.
Berrigan, C.E. Tabor, A.T. Juhl
AFRL/RXAS
Materials & Manufacturing Directorate
Air Force Research Laboratory
Wright-Patterson AFB, OH 45433
2Distribution Statement A: Approved for Public Release. Distribution is unlimited. Case # 88ABW-2016-1256.
Outline
• AF Motivation for Flexible Hybrid Electronics
• Development Strategy
• Advanced Development Projects
• Gallium Liquid Metal Alloys
• Stretchable & reconfigurable electronics
• Printed Interconnects and Capacitors
• Stretchable & resilient electronics
• Soft Packaging
• Summary & Conclusions
3Distribution Statement A: Approved for Public Release. Distribution is unlimited. Case # 88ABW-2016-1256.
AFRL: Turning Science Into Capability
*Updated after PrintFY10 Funding
Driven by Service Core FunctionsVectored by Air Force Strategy + S&T Vision/Horizons + Product Center Needs + MAJCOM Needs
Initial Operating Capability Timeline
6.1
Basic
Research
6.2
Applied
Research
6.3
Advanced
Tech Demo
4Distribution Statement A: Approved for Public Release. Distribution is unlimited. Case # 88ABW-2016-1256.
Space Vehicles
• Intelligence,
Surveillance &
Reconnaissance
•Responsive Space
•Space Situational
Awareness
Materials and
Manufacturing
•Materials & Processes
•Materials Applications
•Manufacturing
Technology
Sensors
•RF Sensing and
Warfare
•EO Sensing and
Warfare
•Trust in Complex
Systems
•Damage Mech Science
•Fuze Technology
•Munitions AGN&C
•Energetic Materials
•Terminal Seeker
Sciences
•Munitions System
Effects Science
Munitions
Aerospace Systems•Turbine Engines
•High-Speed/Hypersonics
•Space and Missile Prop
•Aeronautical Sciences
•Structural and Control
Sciences
Directed Energy
•Lasers
•Beam Control
•High Power
Microwaves
Information
•Computing
Architecture
• Information
Exploitation
•Command & Control
Human Performance
•Forecasting
•Training
•Decision Making
AF Office of
Scientific Research
•Aero-structure power
and control
•Physics and electronic
•Mathematics,
Information, and life
sciences
Air Force Research Laboratory
Technical Competencies
5Distribution Statement A: Approved for Public Release. Distribution is unlimited. Case # 88ABW-2016-1256.
6Distribution Statement A: Approved for Public Release. Distribution is unlimited. Case # 88ABW-2016-1256.
How could Flexible Hybrid Electronics Impact the Air Force?
Man-Machine InterfaceAirman performance limits capability in MANY military missions….and new technologies are needed to sense, assess and augment the “Airman-in-the-Loop”
• Information Overload• Missed Intelligence• Threat/Danger Missed
Embedded/Conformal Electronics for ISR/EW
Information and tracking in contested environments is foundational to decision making and force projection
Integrated & Flexible Power (Mike Durstock)Energy limits operational capabilities and mission impact for unmanned vehicles and wearable electronics
• Communication (conformal apertures)• Distributed electronics for feedback and structural health
monitoring• Reconfigurable Electronics
Survivable ElectronicsPrecision effects with smaller, low profile munitions pressing requirement for current and future platform effectiveness
• Robust electronics in extreme environments (shock, vibration, thermal)
Issues:•Cost & Weight•Scale-up•Durability
Integrated Power harvesting, storage, and management
Today
Future
Lewis
7Distribution Statement A: Approved for Public Release. Distribution is unlimited. Case # 88ABW-2016-1256.
Technology Development Strategy
• Accelerate development and transition of FHE
technologies to Air Force functional materials community
• Phased plan for FHE technology insertions
Embedded Sensors & Structural Antennas
Rugged Flexible Electronics
Human Performance
Conformal Antennas
15 16 17 18 19 20 21 22 23
Critical Pre-requisites:
• Composite Certification
• Hybrid-Materials Design
Critical Pre-requisites:
RPA Demo
AM Design Rules
• Improved Conductive
& Dielectric Inks
• Qual. Risk Reduction
8Distribution Statement A: Approved for Public Release. Distribution is unlimited. Case # 88ABW-2016-1256.
Plasma Spray Direct WriteMesoScribe Technologies
Conformal & Integrated Antennas
9Distribution Statement A: Approved for Public Release. Distribution is unlimited. Case # 88ABW-2016-1256.
Integrated Direct Write Electronics
PM: Ted Finnessy, AFRL/RXME
ManTech Program: Integrated Direct
Write Electronics
• Simplify fabrication by locating
electronics on vehicle exterior (vs.
inside wing).
• Demonstrate printed heaters &
thermistor for wing de-icing
• Demonstrate printed conformal
antennas
• Demonstrate flexible IC as analog-to-
digital convertor
• Complete TRL/MRL assessment
• Fabricate and test
10Distribution Statement A: Approved for Public Release. Distribution is unlimited. Case # 88ABW-2016-1256.
Direct-Write Conformal Antenna on
MQ-9
Need
• Additional communications capabilities are
required on the MQ-9.
• Conventional approaches to add antennas
often requires new tooling (high cost, long
lead time) and drilling of holes in the carbon
fiber structure.
• Fuselage is crowded with apertures for
communications, leading to co-site
interference.
Technical Approach
• Retro-fit existing fleet with conformal
antennas by simply replacing existing servo
covers.
• Design and direct-write Cu antenna onto
servo cover using plasma spray technique.
• Minimize co-site interference by installing
onto unique locations of aircraft.
Phase I Results
• Indoor range data showed VSWR and
directivity comparable with COTS
components.
• Cu removal from part required a grinder.
• Significant directivity benefit in cross-
polarization performance due to location
11Distribution Statement A: Approved for Public Release. Distribution is unlimited. Case # 88ABW-2016-1256.
Ford Demo: Ford Focus Console Thermoformed Silver Ink Electronics
Automotive: Printed Console Electronics
Air Force could achieve similar benefits such as elimination/reduction of wire harnesses in aircraft.
12Distribution Statement A: Approved for Public Release. Distribution is unlimited. Case # 88ABW-2016-1256.
Moving Beyond Commercially Available
Human SensorsAF Mission Areas
• COTS products focus on primarily on
motion sensing, with limited cardiac
sensing
• AF needs advanced biosignatures
sensing for cognition, stress, fatigue, etc.
• Consumer products will not survive
challenging AF environments
• AF needs unobtrusive devices with
chemical and mechanical durability
Traditional electronic components and
packaging will not meet Air Force requirements.
13Distribution Statement A: Approved for Public Release. Distribution is unlimited. Case # 88ABW-2016-1256.
Potential for Human Monitoring
FHE Devices
Flexible Hybrid Oral Biochemistry Sensing SystemSensing lactate as indictor for fatigue.
Numerous FHE materials & manufacturing challenges must be
overcome to enable reliable & durable wearable sensing platforms.
14Distribution Statement A: Approved for Public Release. Distribution is unlimited. Case # 88ABW-2016-1256.
Flexible Materials & DevicesResearch Leader: Dr. Benji Maruyama
Developing critical Materials & Processes to enable flexible hybridelectronic systems for airman performance monitoring