American Science and Technology

Microelectronics Division

To support the South Dakota State University’s Materials Evaluation and Testing Laboratory (METLAB), AST has established the Microelectronics Division in Brookings, South Dakota.

In addition to performing R&D with METLAB and the ability to quickly design and produce prototype electronics, the AST Microelectronics Division has also concentrated on renewable energy technologies. Such efforts include an energy scavenging power supply, a control system for charging an electrical vehicle battery bank using an auxiliary power unit, the development of a control system for bio-fuel production, and electronic evaluation of wind turbines.

To guard against fatigue-based component failures in one of the most critical weapon systems elements,
gun barrels, advanced sensors and systems that record changes are needed to monitor and detect possible
weapon systems health issues, and more significantly, lead to more accurate tracking of actual remaining
life for specific component parts.

Building upon recent advances in mechanical-based and microelectronics-based systems for sensor miniaturization and computing technologies, AST, in cooperation with the Army Benet Weapons Laboratories, Augusta Systems, and South Dakota State University has developed, tested and demonstrated a fatigue monitoring system to predict the remaining life of individual system components.

Fatigue Odometer Sensor

Presently, most mobile robotic systems, such as unmanned ground vehicles (UGVs) and unmanned aerial vehicles
(UAVs), are powered either by petroleum-derived fuel engines or by batteries. The limitations of these strategies,
however, are revealed as these robotic vehicles have been deployed for extended periods of time in the battlefield.

Fuel-cells are ideal for robotic vehicle applications, and in fact, for some mission profiles they would be the only
suitable choice. By replacing conventional power supply systems with fuel-cell technology packages designed
specifically for mobile robotics systems, the potential for enhanced mission capabilities, maintenance efficiency, and,
ultimately, cost-savings for the Federal Government can be met.

American Science and Technology, in conjunction with Chicago State University and EnerFuel Inc., designed and developed an innovative High-Temperature PEM Fuel Cell system. This system has demonstrated the capability to operate without need for liquid water management and a major simplification in the balance of plant design.

High Temperature PEM Fuel Cell

Bio-Diesel

AST is presently working on the design and construction of a 1 million gallons per year, state of the art biodiesel pilot plant. Progressive efforts are being implemented to improve quality, reduce production costs, and use non-edible raw materials. To achieve its goals, AST is using sophisticated computer modeling and simulations to assist in the design of the processes and the development of advanced control systems for consistent production.

The AST bio-diesel pilot production plant will be operational by the middle of 2010. Upon completion, the pilot plant will be used by a team of experts from AST, the University of Wisconsin-Superior, the University of Wisconsin-Stevens Point, and Argonne National Laboratory as the base facility for continuous research and development toward the further optimization of the next generation of biodiesel fuel.

Bio-Refinery Development

Biomass-derived energy has been identified as one of the foundations of future energy. Recognizing this, AST has teamed
up with the University of Wisconsin-Stevens Point (UWSP) to transfer their available bio-technology to the industrial floor.
This technology provides high yield, energy-dense, and inexpensive bio-fuel and other high value chemicals from forestry
waste products. Currently a team of experts from AST and UWSP is in the process of installing a bench top bio-refinery to
validate the technologies developed in the laboratories.

At the same time, AST experts have also designed a pilot bio-refinery production plant to demonstrate the capabilities of the
process beyond the bench top, which will be operational by 2012. Upon completion, AST plans to scale up the production of
bio-fuel by transferring the manufacturing technologies to its partners’ facilities within the paper industry in Central Wisconsin.

This project will use novel pulping chemistry and metabolic pathways which have not been used in the commercial production of bio-products to date. The new refining technology will use leftover wood chips and process them with enzymes, chemicals and catalysts to produce a sustainable source of bio and renewable energy. Given the availability of the resources, there is a high potential to revitalize the struggling paper manufacturing facilities and bring many jobs back to Wisconsin and the nearby regions.

Bio-JP8

As a major consumer of fuel, the Department of Defense has standardized its fuel of choice to JP-4 and JP-8, which are obtained from imported fossil fuels. Presently, no commercial processes produce alternative fuels that meet the higher energy density and the wide range of operating temperature necessary for military aviation use.

A team of AST and the University of Wisconsin-Superior researchers and engineers are currently working to develop a bio-based JP-8 production process which will not only meet the technological needs of the U.S. military at a lower cost, but also provide a sustainable source of jet fuel. The project employs two technological breakthroughs: biochemical and chemical treatments of biomass in order to accelerate the production process from an economical perspective.

Sustainable Energy Systems

American Science and Technology recognizes the crucial connection between both energy
generation and utilization and the health of our planet. We envision an energy system that interacts
with the Earth, rather than using up its resources with no regard to the future.

In this manner, we believe that energy systems and the utilization of resources do not have to be
detrimental to the air we breathe or the water we drink, nor do they have to be harmful to the multiple
ecosystems that sustain amazing varieties of life around the globe. Not only are environmentally-
friendly energy generation and harvesting systems better for the planet, they also can revitalize our
national economy, strengthen our national security, and improve the overall quality of life, not just in
this country, but around the world.

For these reasons, AST is committed to developing new and improved energy technologies, systems, and services.

Center for Alternative Energy Technology.

As a joint initiative between American Science and Technology and Chicago State University, the Center for Alternative Energy Technology (CAET) is performing basic and applied research to evaluate, develop, and commercialize alternative fuels, such as hydrogen, as well as alternative energy technologies such as fuel-cell, bio-fuel, direct carbon, and energy harvesting from solar, wind, and other natural resources.

For more information on CAET and the upcoming 2009 Alternative Energy Symposium, please visit www.caetonline.com

Automatic Control

As the U.S. military moves towards a robotic army and the missions for the unmanned vehicles continue to expand, the need to increase their capabilities becomes more crucial. The more that these vehicles are able to accomplish in hostile environments, the fewer American lives are placed at risk.

To help with this effort, American Science and Technology has teamed up with West Virginia University Institute of Technology to enhance the autonomous, automatic control that can be used by the ground stations to control the unmanned vehicles.

This application allows the user of the ground station to wirelessly retrieve sensory information from many different sensors. The sensory data can include multimedia feeds (video and audio), environmental feeds (temperature, humidity, and wind speeds), and location feeds (latitude, longitude, and elevation).

Solar Energy

The power requirements of Special Operations forces in deployment environments have created the need for the
development, integration and enhancement of a sustainable light weight power system comprised of a flexible solar cell
power generator, a durable storage system, and an intelligent sensor to manage power consumption and distribution.

AST scientists, along with Chicago State University Professors and Center for Alternative Energy Technology, under
the direction of the US Army Research Laboratory (ARL), have focused on leveraging recent advances in flexible solar
cells to produce special size and shape solar panels for special applications. The team is utilizing CAET’s state of the art
clean room to develop a new generation of less expensive amorphous silicon solar cells with higher efficiency.

In addition, a team of CSU and AST scientists are working on their proprietary patent pending die sensitizing solar cell which is projected to drastically
reduce the cost of solar cell manufacturing. AST also has a solar panel manufacturing line that is being use for R&D as well as production, capable of producing uniquely shaped solar panels up to 30” by 60”.

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Fatigue Odometer Sensor