INTELLISENSE SYSTEMS INC — Department of Defense SBIR Phase I: AF191-094

Description

To address the Air Force need for an advanced system to detect foreign object debris (FOD) in thin mat materials in manufacturing, Intellisense Systems, Inc. (ISI) proposes to develop a new TErahertz Thin Mat Material Inspection (TETMMI) system, based on novel integration of compact THz source, THz/optical imaging sensors, and automated detection software. Specifically, integration of a high-performance yet small size, weight, and power THz source and imagers with advanced software enables the detection of small visual/nonvisual FOD during manufacturing in real time, aiding information assessment and significantly reducing inspection cost. The TETMMI system offers high detection sensitivity, full automation, speed, mobility/portability, and versatility to inspect different mat materials, which directly addresses the Air Force requirements. In Phase I, ISI will demonstrate the hardware and develop software algorithms for a <40-in.-wide system capable of inspecting an array of representative thin mat materials up to 54 in. wide, at up to 13 ft/min in lab environments. In Phase II, ISI will design and build an advanced prototype, and demonstrate it in representative manufacturing environments through extensive testing. A detailed report documenting the results, engineering test data, recommendations for full implementation, and a manufacturing plan for a TETMMI system will be presented.