Photostructural Glass Ceramics and Optimized Processing for Laser Initiated 3D Conductors (PhotoCon)

ABSTRACT: In this STTR effort a small business company Obalon LLC is teaming up with industry leader Aerospace Corporation for development of novel photostructural glass ceramic composition (PhotoCon) with capability of laser induced 3D conductor patterning inside the bulk material. The development fully utilizes available infrastructure and team's expertise for commercial glass ceramics processing. The photolytic process of laser exposure of PhotoCon is followed by the thermal development of latent image. Then the series of novel processing steps enable enhanced conglomeration of metal around the initially exposed areas towards the desired RF and DC conductivity of the patterned 3D structure. In Phase I effort through theoretical analysis and experimental testing the perspective glass ceramic composition with enhanced metal formation has been identified and initial induced conductivity has been demonstrated. In Phase II the Phase I material composition will be optimized for 3D shaping using chemical etching process and improved conductivity. We will produce liter size material samples and fully characterize the resulting material for both the photo initiated conductor formation and dimensional patterning using chemical etching. The path towards high temperature sensor fabrication inside bulk material will be established and high temperature resistant glass ceramic structures will be produced. BENEFIT: Novel glass ceramics with the ability to fabricate 3D conductors in bulk material using automated laser writing will find a number of applications in consumer electronics including touch screen displays, portable antennas and interconnects for processor chips. The capability of precise glass ceramic patterning with the ability to wire desired elements will enable the next generation 3D circuit boards. The electrode formation in combination with etched micro fluidic channel fabrication opens up a wide variety of biomedical sensor applications for both the massive low cost parallel sample processing such as DNA sequencing and the specific micro analytical probes for point of care testing. The novel high temperature glass ceramic sensors and RF components will increase the reliability and improve the manufacturability of system designs in aerospace industry.