Affordable 3-Dimensional Ceramic Discrete Parts via Additive PDC Technology

Period of Performance: 09/30/2016 - 09/29/2018

$1.5MM

Phase 2 SBIR

Recipient Firm

Nanosonic, Inc.
158 Wheatland Drive Array
Pembroke, VA 24136
Firm POC
Principal Investigator

Abstract

NanoSonic, a 30,000 square foot specialty materials production facility, in the Wheatland Eco-Park, has developed an environmentally friendly, advanced manufacturing process to fulfill the Defense Logistics Agencys (DLA) need for affordable discrete-parts with fine features for legacy and future fielded weapon systems. We have developed a technically advanced and innovative manufacturing method to achieve significant unit cost reductions in discrete parts with breakthrough advances in thermal performance. The commercial potential for NanoSonics lean and green manufacturing technology on 3-D polymer derived ceramics (PDC) is significant as it can impact 9 of the Defense Logistics Agencys (DLA) 13 organizations; and it has attracted private sector co-investment and support from our local government and Phase II partners. NanoSonic has: 1) demonstrated breakthrough technology advancements in Thermal Array performance with a 950 F thermal knockdown, 2) increased the Thermal Array technology readiness level (TRL) from 4 to 6, with a corresponding 60 % unit reduction cost, 3) identified current Thermal Array parts that the DLA is in demand for, 4) partnered with new customers for DLA that are in need of our fiscally responsible 3-D PDC materials, and 5) identified a second high-risk affordable method to yield 3-D ceramic based fiber reinforced composites.