Contents:

1 ASSEMBLY TECHNOLOGIES, EXECUTIVE SUMMARY Executive Summary 2 ASSEMBLY TECHNOLOGIES, ADVANCES IN PROCESS MONITORING Embedded Sensors Lens Technology Adapted to Embed Sensors into StructureS Optical Sensors System Improves Dimensional Process Monitoring Systems Optical Processor Sharpens Images Machine Vision Optical Sensor Tracks Six Degrees of Freedom Sol-Gel Improves Optical Fiber Sensors Chemical Sensors Dendrimers Offer New Avenues to Chemical Sensing Photoelectric Sensors Try Photoelectric Sensors for Manufacturing Control Read/Write Sensors Memory Tags - Read-Write Sensors Speed Machine Setup Magnetic Sensors Toolbox Features Microsensors and Actuators Micromachined Accelerometers Micro Accelerometer for Gesture Recognition Position Sensors Keep an Eye on Traffic Detection Sensors Specialty Sensor Systems In-Process Monitoring Possible with Sensor System 3 ASSEMBLY TECHNOLOGIES, FABRICATION; FORMING AND MACHINING Fabrication And Forming Superplastic Forming Fabricating Plastic Parts Machining Calibration Chemical Deburring 4 ASSEMBLY TECHNOLOGIES, FIXTURING AND ROBOTICS Fixturing Surface Mount Technology Places Oddly Shaped Connectors Locator Lets You Rapidly Set Up Parts Robotics Apply Control Algorithms for Fixture-Free Assembly Intelligent Software Controls Assembly Cell Virtual Reality Enables Telerobotics Robotic Hands Hold Key to More Assembly Capability Robot Helps Humans in the Factory 5 ASSEMBLY TECHNOLOGIES, CONTROL SYSTEMS Augmented Reality Guides Assembly Fuzzy Logic Enables Precision Assembly Control Your Process with Modular; Digital Drives Initiative to Further Control Program Generation Analysis 6 ASSEMBLY TECHNOLOGIES, SPECIALTY ASSEMBLY SYSTEM Consortium Develops New Approach to Manipulators Automating Assembly of Microscale LIGA Parts Costs Reduced with Automated Module Assembly 7 ASSEMBLY TECHNOLOGIES, WELDING TECHNOLOGY Specific Welding Methods Friction Stir Welding Explosive Welding Welding Both Sides Simultaneously Friction Seam Welding Capacitor Discharge Welding Laser Welding Rotating Arc Welding Ultrasonic Welding Welding Control Systems Sensors Fiber Optic Viewing System Control Systems Computer Models Weld Monitoring Ergonomics Weld Shielding and Fluxes Weld Shielding Filler Metals/Fluxes Welding Specific Metals Borated Stainless Steel Aluminum and Other Reflective/Conductive Metals Titanium Welding Metal/Matrix Composites and Thermoplastics X-rays for Metal/Matrix Composites Welding Thermoplastics Welding Standards NIST Developing Standards for Automated Welding Systems 8 ASSEMBLY TECHNOLOGIES, JOINING METHODS OTHER THAN WELDING Soldering Lead-Free Solder Proves Environmetally Friendly Joining Ceramics Join Ceramics and Metals with a Jolt Adhesive Bonding Systems Replace Permanent Fasteners with Strong Bonding Tape Goodbye to Weak Adhesive Bonds 9 ASSEMBLY TECHNOLOGIES, MATERIALS RELATED ASSEMBLY Heat Treating of Metals Magnetic Field Technology Keeps the Heat Uniform Composite Technology Raptor Unveiling Illuminates Some Surprises Composite Molding in One Step Footbridge Shows Composites’ Potential in Infrastructure Sheet Molded Composites Penetrate Auto Industry Composites Lower Microvehicle Costs Advanced Materials Advanced Materials Mold the Car of the Future Proven Reptation Theory Could Lead to Better Materials Composite Bridge Decks Get a Test Run Corrosion/Coatings/Wear Corrosion Protection Polymers Metals 10 ASSEMBLY TECHNOLOGIES, COMPUTER RELATED INNOVATION Specialty Software Agile Server Lets You Send in a Sub on the Fly Software Troubleshoots Electronics Assembly Software Inegrates PCB Layout; Test and Assembly Tolerance Software Takes You Out of a Tight Spot Simulation Software Works with Most CAD Programs Reverse Engineer with CMM Software Collaborate on Product Design with Visualization Software Get Cost Estimates for Injection Molding Internet Software Shows How Parts Behave Group Develops Standards for Virtual Manufacturing Develop Products with Far-Flung Colleagues Specialty Computer Chips Connect Chips to More Things 11 ASSEMBLY TECHNOLOGIES, NOVEL COMPONENT DESIGN Battery Packs Wear Hats Braid Flat and Intersecting Parts Adapting Plug and Play Concept to Interconnects MEMS Focuses Prosthetic Lens Reliable Lynx Motors Purr at High Torque 12 ASSEMBLY TECHNOLOGIES, STREAMLINING THE PRODUCTION PROCESS: DEMAND FLOW TECHNOLOGY Background Applications Vary Product Type and Volume with Flexible Cell Software Speeds Integrated Product Design Production Models Maximize Assembly Line and Job Shop 13 ASSEMBLY TECHNOLOGIES, SELF-ASSEMBLY AND NANOTECHNOLOGY Introduction Applications of Self-Assembly Technology Polymers Sensors Corrosion Protection/Coatings DNA-Based Electronic Devices Nanoscale Devices Single Nanotube Makes a Transistor Ultrathin LEDs Emit with Low Voltage Defective Computer Shows Way to Nano AFM Lets You Sense; Push Nanometer Particles Molecular Rotor Realized; but Practical Applications Aren’t Use DNA Scaffold to Build Nanowires Other Potential Nanodevice Applications Let the Parts Do All the Work Produce Wide Range of Shapes Chemically Build Complex 3D Microstructures Mesoscale Devices Micromachine Arrays Divide the Work 14 ASSEMBLY TECHNOLOGIES, PATENTS Introduction Introduction Positioning Device That Corrects For Deflection and Temperature Errors Assembly System Improving the Fatigue Resistance of Hollow Titanium Alloy Parts Corrosion Protection Radiation Protection Reducing Residual Stresses in Welds Real Time Weld Monitoring Weld Monitoring Adhesive Bonding of Aluminum Alloy Parts Calibrated Positioning of an Object Friction Stir Welding Tool Corrosion Protection Monitoring System Laser Welding Magnetic Sensor Position Sensor 15 ASSEMBLY TECHNOLOGIES, RESOURCES Advances in Process Monitoring Fabrication; Forming and Machining Fixturing Robotics Control Systems Specialty Assembly Systems Welding Technology Joining Methods other than Welding Materials-Related Assembly Computer-Related Innovation Novel Component Design Streamlining the Production Process Self-Assembly and Nanotechnology