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Air Force Research Lab

If you bought a new car recently, you must have noticed that it warns you if one of its functions needs your attention. It even alerts the factory if repairs or major adjustments are needed. Wouldn’t it be nice to have similar capabilities for our bodies that will call for a “service” before we end up in an emergency room – or worse? The United States invests almost 18 percent of its Gross Domestic Product (GDP) in healthcare. Such a significant part of our economy deserves our industry’s attention – and it gets it. SEMI’s recent Smart MedTech webinar series tells not only patients and healthcare providers how electronic products can impact their lives, but also offers device makers plenty of ideas for developing new solutions.SEMI Gets SmartIn addition to working on many important topics with more than 2,200 member companies across the semiconductor supply chain, SEMI focuses on special areas: Smart Mobility (as covered here), Smart MedTech (covered below), Smart Manufacturing, and Smart Data. Smart MedTech was the topic of four recent webinars, organized by Melissa Grupen-Shemansky, executive director Nano-Bio Materials Consortium (NBMC), and Chief Technology Officer, SEMI. NBMC’s mission is to enable flexible, wearable human performance monitoring. In her introduction, she emphasized that healthcare will shift from today’s provider-centric approach to a personalized care model, with the following characteristics: Outcome-based Decentralized, not limited to geographies Specific to your personal health and medical needs With a team of providers, connected like never before To achieve all these characteristics, microelectronics will be an essential contributor. That is why SEMI and member companies are working on platforms to fund and commercialize R D as well as to educate potential users and beneficiaries. Grupen-Shemansky engaged a series of experts and organized four webinars to address this broad and complex field, and outline their contributions to meeting the above criteria. They have been recorded and are available to SEMI members. Call your SEMI contacts to find out where and how you can access slides and recordings of more than a dozen presentations.From Biomarkers to BioChemical Sensors Physiological RelevancyTo monitor a human body’s performance, researchers have to first understand which biomarkers indicate specific conditions of the body, then learn how to capture and process the data. Grupen-Shemansky moderated this August 5th session. Christina Davis from UC Davis, Jennifer Martin, and Sean Harshman from the Air Force Research Lab (AFRL), and Kenneth Ward from Pacific Diabetes Technologies presented their ongoing efforts in this field.Davis talked about the challenges of analyzing exhaled breath, which contains 99% water and 1% biomarkers. She showed a hand-held analyzer her team has developed (Figure 1). She also elaborated on how to interpret the captured data and, if needed, decide which follow-up treatments are advised.Figure 1: Palm-sized µCON exhaled breath micro-condenser used to analyze biomarkers. (Courtesy: UC Davis) AFRL’s Martin and Harshman outlined how ongoing and future minimally invasive techniques are being used to monitor airmen, and give them advice for self-treatment to maximize their performance. The Pacific Diabetes Technologies speaker, Ward, showed how to use minimally invasive, subcutaneous (=under the skin) oxygen sensors to detect hemorrhage (= blood loss) and control it.En Route Care (ERC) and Point of Care (POC) DiagnosticsTreating injuries right away and correctly shortens not only a patient’s suffering, but also improves his or her chances for a full recovery. AFRL’s Matthew Dalton moderated this August 12th session. Derek M. Sorensen from AFRL, Zheng Yan from the University of Missouri-Columbia, Melinda Eaton from the Virtual Health Program Management Office at the U.S. Department of Defense (DoD), and Azar Alizadeh from General Electric (GE) Research outlined their contributions to achieving instant and professional care.AFRL’s Sorensen described the many challenges a Critical Care Air Transport Team (CCATT) deals with when performing their work inside a noisy, dark, hot, or cold, shaking airplane, discussed their equipment and personnel constraints, and explained how difficult it is, even for experienced doctors, to perform emergency surgeries under these conditions.Professor Yan takes low cost very seriously and demonstrated how he and his students have developed on-skin wearable sensors that can be manufactured by using only pencil and paper.Eaton outlined the DoD’s strategy for assuring its medical force is ready to support soldiers. Then she discussed a broad range of the DoD’s traditional health management responsibilities and added that Covid-19 is now an important factor.Alizadeh addressed how GE microelectronic solutions improve the efficiency of care, reduce medical errors and length of hospital stays as well as improve workflows of caregivers. In addition to GE’s well-known, large/stationary medical equipment and communications infrastructure (Figure 2), Alizadeh showed that GE is also providing skin patches and other wearable sensors to capture data.Figure 2: The Future of Monitoring: In 2017, Mercy Hospital served 800,000 patients with telemedicine including those with chronic diseases. Patient:doctor ratio: US average 300:1. Mercy = 1100:1. (Courtesy: GE) Human Wearables Enabling Rapid Decision Making in the Integrated Care ContinuumAs Figure 2 above shows, microelectronic equipment can improve patient care and efficiency of medical personnel, but only if sufficient data can be captured timely and accurately – increasing the importance of wearables. AFRL’s Jeremy Ward moderated this August 17th session. Christopher Scully from the U.S. Food and Drug Administration (FDA), Ashleigh Coker from the AFRL’s Sensors Directorate, Ted Harmer from the AFRL’s Airman Systems Directorate, and AFRL’s Regina Shia presented for Oxana Pantchenko from NextFlex how they develop wearables jointly. Scully introduced the FDA’s organization and its responsibilities, described the high-value accurate data can provide, warned about the damage false alarms and equipment failures can cause, and explained the regulatory role the FDA plays in this context.AFRL’s Coker highlighted the essential role sensors play in modern warfare with several examples, described her directorate’s operations and showed their warfighter-centric design process (Figure 3).Figure 3: Warfighter-centric design process steps and the need to engage multiple heads/perspectives in this process. (Courtesy of AFRL) AFRL’s Harmer addressed the importance of good communications architecture and protocols to capture and compute data to assure efficient cooperation between land/air/sea/space-based forces.NextFlex’ Pantchenko prepared a presentation about standards-compliant wearable electroencephalography (EEG), electromyography (EMG), and electrooculography (EOG) devices, jointly developed with AFRL and several other companies. It was delivered by AFRL’s Regina Shia.Automation, Augmentation and AINatalie Wisniewski, Founder of Profusa, Inc. a and consultant in Wearables and Digital Health, moderated the fourth webinar, held on August 26. She emphasized SEMI’s role in this context, then introduced the speakers: Michael Kirby from Colorado State University, Kevin Zhao from Harmonize Health, Mary Clare McCorry from armi/biofab USA, and Andreas Caduff from ETH Zuerich.Professor Kirby outlined several mathematical principles that need to be applied to get meaningful results when analyzing data. He emphasized that genetic factors influence if an individual is susceptible, tolerant, or even resistant to certain pathogens and warned that bacteria can develop resistance to today’s antibiotics.Zhao from Harmonize talked about the importance of predictive analytics in remote care, how to filter out false alarms, and how to deliver the best available care cost-effectively. In closing, he emphasized that computers and algorithms are not replacing clinical staff.McCorry outlined how biofab USA, a program of armi, uses sensors and automation to grow replacement tissue and organs (Figure 4). She explained how they use engineering principles and life sciences to make guide cells grow into replacement tissue. The company’s plan is to expand the currently lab-based capabilities into an industrial scale tissue foundry.Figure 4: Growing ear cartilage in the lab. (Courtesy: armi/biolab USA) SummaryMcCorry summarized her presentation, and actually the entire webinar series, with these statements: The human body is a 3D, highly complex, dynamic, and multi-faceted biological construct Skin lends itself well as an interface between body and wearable sensors Connecting physiology (e.g. vital signs), behavior, and external factors is important for getting good results Verification, validation, and FDA involvement are important for making methods and devices successful Sensors, communication computing (AI/ML) are complementing, not replacing, medical personnel Today’s methods and devices will be outperformed by tomorrow’s solutions – stay up to date Personal CommentsSummarizing eight hours of presentations in a few pages requires a very high and lossy compression factor – please understand. I suggest you call on your SEMI contact to get access to these previous and following webinar recordings. Excellent contacts across the electronics supply chain enable SEMI to win experts in many areas to convey valuable information in these webinars.I am impressed that the USA military, specifically the AFRL, invests so much effort in medical support for airmen/women. They demonstrate that only healthy and fit personnel can take full advantage of the sophisticated weapon systems at their disposal if/when they are called upon to deploy them.This Smart MedTech webinar series confirms what many medical experts told me during exams and/or before and after surgeries: The human body is a masterpiece of bioengineering. These webinars also reminded me of what I learned at a brain-health class at Stanford University: Our brains only need about 20 Watts to perform computing and memory tasks that fairly quickly approximate the results of today’s computers – a benchmark for computer architects and AI/ML experts.Republished with permission from 3D InCites.
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SEMI’s annual FLEX Conference Exhibition returns to Monterey, California, February 18-21, 2019, bringing together nearly 100 speakers on the major developments at the leading edge of printed/flexible/hybrid sensors and electronics technology.The maturing technology for smarter sensors, in a wider range of flexible formats, is enabling new opportunities across a wide range of applications, from healthcare to agriculture. And that means sensor suppliers need to connect with a broader range of users to build the next generation of innovative outside-the-box solutions. SEMI gathers the flexible/hybrid integration supply chain, leading researchers and potential customers at this annual event to help advance the sector.Collaborative efforts for sensors emerging markets: global health, faster crop development, military monitoringThere’s huge potential for smarter, more accessible sensor systems to detect infectious diseases and aid decision-making for community health workers around the globe, but new technologies and manufacturing methods alone will not be enough to meet the needs of these resource-constrained environments, argues Arunan Skandarajah, program officer at the Bill and Melinda Gates Foundation. He’ll introduce the foundation’s funding and partnering priorities for sensing and imaging for diagnostics and decision support and discuss potential paths forward for development.Recent advances in plant genomics and high-throughput phenotyping have big potential to enable faster development of crop varieties that better withstand adverse conditions – but that will depend on getting fast feedback from sensor data from the field. There’s immediate need for robust, high-efficiency, low-cost sensor technologies to collect on-the-ground microclimate and resource-use data from tractor-based sensors to field scanners, says Nadia Shakoor, Danforth Plant Science Center. She’ll discuss the sensors researchers need to develop high-yielding, energy- efficient crops that are resilient to variable climates.Military interest in biosensor patches to monitor human physiology and performance, and other sensor solutions for flexible imaging and point-of-care diagnostics, are also drivers of collaborative research between industry and universities. The Nano-Bio Materials Consortium (NBMC), a SEMI strategic association partnership with the Air Force Research Lab, will offer a workshop to discuss its potential needs, and how to get involved in its development program to create an integrated suite of nano-bio materials and production technology. Progress in scaling printed/hybrid flexible electronics manufacturing technologyThe maturing manufacturing supply chain continues to make progress towards scaling volume manufacturing of higher performance products, with recent innovations in materials and assembly technologies.Cal Poly researchers will report results from the recent FlexTech benchmark study of the flexible hybrid electronic industry. The study looks at the current state of maturity of the technology, its manufacturing processes, and its main applications while projecting the roadmap for future development. The study covers passives, sensors, batteries, antennas, speakers, PV and energy harvesting, and flexible hybrid integration.Catch up on new process development capabilities and recent work at the NextFlex Flexible Hybrid Electronics Manufacturing Institute’s San Jose Technology Hub for prototyping and pilot manufacturing. The institute has been adding engineers and projects as it looks towards the next generation of technology for sector growth. Innovations in scalable assembly of thin die on flexible substratesSeveral companies will update on recent progress developing solutions for the industrial-scale, high-yield assembly of fragile thinned die on to flexing substrates. American Semiconductor reports new automated assembly capacity for flip chip die attach and interconnect for devices with up to 100 I/Os and 100um pitch pads. The company also notes that it now has flexible Bluetooth ICs from two major suppliers available in semiconductor-on-polymer chip-scale packages, finally enabling improved wireless capacity for flexible hybrid systems.CEA-Leti will present its latest developments in flip chip bonding of thin bare die on flex. It uses gold stud bumps on the die, with 150°C thermocompression bonding to PEN Film. The researchers have also developed a wafer-level die process that thins and encapsulates die before removing them from the carrier wafer. systeMECH will also present its results for direct die placement of 300nm die on flexible polyester. Innovations in materials for easier processing, higher performanceDevelopments in substrates and processing may now enable use of photonics for laser patterning and flash curing on flexible substrates. Brewer Science will report developments on new polymers that can be quickly and cleanly etched with the mid-UV wavelengths commonly used for laser drilling and etching on printed circuit boards, bringing this improved performance to printed electronics as well. The polymers can be processed at less than 200°C with desirable qualities for substrates, adhesives, protective layers and the like for many electronics applications.Novacentrix will update on improvements in photonic curing equipment for fast heating to enable the use of high-temperature solders without damaging low-temperature substrates. Atotech will report results from its multiyear initiative to develop lower temperature solder pastes for better performance than SAC-based materials on a variety of substrates. Printed graphene and carbon nanotubes find applications in sensors and RF devicesBonbouton will introduce its commercial smart insole using a printed graphene sensor to monitor skin temperature to detect early signs of foot ulcers in diabetic patients. The company inkjet-prints graphene oxide followed by thermal reduction to fabricate graphene supercapacitor electrodes for temperature and pressure sensing.C2Sense will update on its development of carbon nanotube gas sensors to monitor food condition to prevent waste. The sensitized carbon nanotubes selectively detect ethylene from fruit or ammonia from chicken to accurately track the condition of the foods as they pass through the supply chain. Georgia Tech will report results of printing not only sensors from carbon nanotube ink but even RF and mm-wave diodes and transistors for high-frequency, long-range, low-cost RFIDs. Innovations in display materialsMaterials for flexible displays continue to see innovations – from solutions for foldable displays to plenty of new options for improved transparent conductive films and force-sensitive films. Solotech will introduce a cross-inked polymer that it says offers both high hardness and excellent foldability as a reliable covering for foldable/bendable displays. Atotech will describe its development of selective electroless copper deposition for metal mesh and TFT electrode patterns for touch screens to eliminate the need for costly mask and etching steps after deposition. Chasm Advanced Materials suggests hybrids of the conductive metals and carbon nanotubes offer a promising alternative for flexible transparent conductive films.C3Nano reports on nanowire ink, fused after printing, for flexible transparent conductors. Peratech will report on its printable pressure touch technology that it describes as high-resolution and low-cost for better localized, force-sensitive touch. Jabil will share the results of its evaluations of five of the available printed force-sensitive sensors. E Ink will introduce new capabilities for its electrophoretic display technology – it’s now possible to write on it with a magnetic stylus, and there’s a variable transmission version for electronic windows. Next generation technologies from universities and startupsResearchers from major research institutions and startups will talk about developments in flexible/printed/hybrid electronics including innovations in biological/electronics interfaces, via skin or neurons, and demonstrations of piezoelectric and better stretchable circuits. Emerging technologies for biosensors and human/machine skin interfaces Georgia Tech researchers will detail their electrical interface with human skin for wireless control of a remote-control car and a wheelchair by electrical signals from the body. They’ve developed a flexible elastomer skin patch patterned with thin film metal/polymer nanostructures made by CMOS processes, and metal pads compatible with conventional reflow soldering. Other Georgia Tech researchers will report their work on better cochlear implants made of encapsulated polymer printed with conductive microcoils for pulsed micro-magnetic stimulation that can focus more tightly on specific areas of auditory neurons. Seoul National University will introduce its flexible organic artificial nerves that can activate an insect’s leg muscle. Researchers there have devised a pressure sensor connected to a ring oscillator that converts the pressure signal into voltage pulses, which are then integrated by a transistor into a signal that replicates a post-synaptic current to communicate with the biological nerves.Epicore Biosystems will report on its advances in manufacturing and packaging technology that enable its skin-interface electronics and microfluidics systems in thin stretchable format to continuously monitor electrical, acoustic and biochemical signals. The technology is now entering commercial development with industrial partners. GE Global Research will update on its field testing of sweat-sensing devices to monitor hydration. Emerging technologies for piezoelectric actuators and improved stretchable sensors and circuits PARC will report on audio speakers made of PVD piezoelectric film on polyimide with inkjet-printed flexible hybrid operating circuits, and Novasentis will talk about its piezoelectric electroactive polymer for different kinds of vibrations for wristband notifications. UTC will share its learnings from deploying large numbers of stretchable flexible hybrid sensors conformably over large areas on aerospace and infrastructure assets to sense temperature, vibration, strain and damage for critical safety.The Air Force Research Lab reports promising results for stretchable circuits made with liquid metals, which maintain their high conductivity even when stretched. Silent Sensors will discuss its printed flexible manufacturing technology for low-cost, stretchable energy storage and piezoelectric energy harvesting for monitoring the condition of automobile tires.By Heidi Hoffman, senior director of technology community marketing, SEMI
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