Low density 6500 meter man-rated syntactic foam

Period of Performance: 05/23/2012 - 05/23/2014


Phase 2 SBIR

Recipient Firm

Utility Development Corp.
112 Naylon Avenue
Livingston, NJ 07039
Principal Investigator


UDC proposes to further optimize and improve the performance of a low density, 6,500 meter man-rated syntactic foam material at a composite density of 30 +2/-1 pcf. The Phase I program proved the feasibility of developing a formulation for producing a low density material that is capable of use on a 6,500 meter operational depth Human Occupied Vehicle (HOV). The selected formulations will be tested for density, water absorption, crush pressure, tensile strength, compressive strength and modulus, and shear strength. Physical properties will be tested in accordance with ASTM methods. Hydrostatic pressure testing and water absorption will be tested in accordance with Military Specification MIL-S-24154A and Specification Document #205/010. UDC will manufacture prototype syntactic foam blocks and will conduct hydrostatic pressure and water absorption testing to validate the 6,500 meter depth rating specified performance level. Test data will be analyzed and the performance compared with syntactic foam that is currently used for 6,500 meter depth rating applications. Towards the end of the Phase II program, UDC will provide 100 cubic feet of prototype 30+2/-1 pcf syntactic foam material for the Navy to evaluate, classify and certify for the 6,500 meter depth man-rated requirements. Specifications will be written for the new syntactic foam formulation, fabrication methods, and quality control procedures in order to provide a smooth transition to the Phase III production program.