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9 Phase I Selections from the 08.3 Solicitation

(In Topic Number Order)
Advanced Powder Solutions, Inc
14102 Halprin Creek Drive
Cypress, TX 77429
Phone:
PI:
Topic#:
(661) 373-1729
Dean Baker
DLA 08-001      Awarded: 4/14/2009
Title:Advanced Technologies for Discrete-Parts Manufacturing
Abstract:Understanding that saving weight without sacrificing performance on a vehicle is important, the objective of this program is to continue to demonstrate advanced lightweight materials that can have multi-functional capability and be discretely made into parts for DLA. Many applications will have specific requirements of high thermal conductivity, low thermal conductivity, radiation resistance, Modulus, tensile strength, ductility, and machinability, to name a few. This Phase I program is designed to achieve the final part success without sacrificing performance and reducing overall costs for potential DLA program components. Specific data for the various compositions of each engineered system will be generated and compared to current missile and aircraft requirements under the Phase I. Both coupon level and component testing and characterization will occur in Phase I. APS has assembled an expert team in the materials and characterization fields and has been provided overwhelming support to achieve a successful Phase I. The Phase II program will further define replacement parts and additional requirements for these unique materials.

Coventry Associates, Inc.
1 Lynwood Lane
West Boylston, MA 01583
Phone:
PI:
Topic#:
(508) 835-9209
Craig Gardner
DLA 08-001      Awarded: 10/20/2008
Title:Advanced Technologies for Discrete-Parts Manufacturing
Abstract:The eccentric positioning system makes linear motion from rotary motion by using eccentrics. This approach uses proven commercially available technologies such as rolling element bearings, servo motors and CNC controls to produce a precision grinding machine that is less expensive to manufacture, has a rapid motion capability to reduce non productive "dead time", reduces setup time by eliminating the need for a swivel plate and improves production rates as it is uniquely suited for implementation of the adaptive force grinding techniques developed by R. S. Hahn.

HT MicroAnalytical, Inc.
3817 Academy Parkway S, NE
Albuquerque, NM 87109
Phone:
PI:
Topic#:
(505) 341-0466
Jeff Sniegowski
DLA 08-001      Awarded: 3/6/2009
Title:Advanced Technologies for Discrete-Parts Manufacturing
Abstract:HT Micro proposes to establish a metal MEMS manufacturing process as an effective high rate component manufacturing technology. This will bring miniaturization and cost savings comparable to that provided by conventional silicon MEMS manufacturing to a very large number of important new applications. Metal MEMS micro-fabrication is established at the research and prototype level, but has not been matured for deployment into high rate product manufacturing. The fabrication technology is currently TRL 5, being performed strictly in a research laboratory environment, and is now ready to begin the transition from the research fab into the factory. Once this transition is complete, there are numerous high-value military and commercial components that will benefit. For specificity, HT Micro will use an impact switch, developed under contract to the US Army, as the component vehicle to move metal MEMS processes from prototype fabrication to product manufacturing.

IQL
332 Canonchet Road PO Box 70
Rockville, RI 02873
Phone:
PI:
Topic#:
(401) 539-8510
Robert Callaghan
DLA 08-001      Awarded: 10/20/2008
Title:Application Additions to the Long Range Ball Bar for Multi-axis Machine Capability Analysis
Abstract:Testing of machine tools has been evolving for nearly 100 years. The advent of low cost computer data analysis, control and communication has allowed the design, manufacture and inspection of complex contoured surfaces. The need to ever decrease the tolerances has led to the development of machine tools which can no longer be tested with these old methods. These machines must be evaluated within their whole work volume, not just along single axes. A further development has been the rapidly growing use of e-commerce. New terms such as “NCM” (Network Centric Manufacturing) and “PLM” (Product Lifecycle Management) have been coined to describe the methods being used to produce products using the “Global Economy”. Current practice limits the assessment of vendor machine performance and capability until after the first delivery of new product. These facts have produced a need to develop lower cost equipment and methods to rapidly assess the capability of new and old machine tools within their work volume. Independent Quality Labs, Inc. (IQL) has developed and built a Long Range Ball Bar capable of capturing machine position data within the work volume.These mechanical developments need to be accompanied by software Application Additions to keep pace with these advancements.

Luna Innovations Incorporated
1 Riverside Circle Suite 400
Roanoke, VA 24016
Phone:
PI:
Topic#:
(540) 552-5128
Bryan Koene
DLA 08-001      Awarded: 4/10/2009
Title:Advanced Technologies for Discrete-Parts Manufacturing
Abstract:Wet installation of fasteners offers proven corrosion protection and fuel sealing in aircraft structures, but it''''s a labor-intensive, messy, hazmat-laden process whose quality can vary significantly from fastener to fastener. Under a Navy SBIR Phase II, SMRC has developed a proprietary process called QwikSeal® for pre-coating fasteners with cure- blocked sealant, then overcoating the pre-applied sealant with a moisture-impermeable nanocomposite size coat. On installation – potentially weeks or months later - the size coat franges, allowing the uncured sealant to coat the hole. Ambient moisture absorbed by the sealant unblocks the reaction and initiates normal cure. Though interest among aircraft manufacturers and maintainers is extremely high, there are concerns for inadvertent installation of fasteners whose sealant has prematurely cured. A premature cure indicator (PCI) is, therefore, a prerequisite to widespread adoption of QwikSeal. SMRC proposes development of selectively-tuned molecular probes which when imbedded in the cure-blocked sealant or size coat layers will change color on exposure to thiol groups, a very early and direct sign that the sealant is about to prematurely cure. Successful PCI development, not funded under any existing/proposed initiatives, could clear the way for large-scale entry of QwikSeal into the aerospace marketplace through PPG Aerospace, SMRC’s commercialization partner.

Manufacturing Laboratories, Inc.
889 South Rainbow Blvd. PMB 690
Las Vegas , NV 89145
Phone:
PI:
Topic#:
(702) 869-0836
Thomas S Delio
DLA 08-001      Awarded: 10/20/2008
Title:Advanced Technologies for Discrete-Parts Manufacturing
Abstract:Significant advances have been made in machining technology, most notably machining centers capable of spindle speeds and feedrates that are an order of magnitude higher than conventional. However, the use of this new technology requires much more technical expertise, and experience and intuition are no longer sufficient. Specifically, machine tool productivity can be greatly enhanced if information related to machine tool dynamics can be measured and presented to the user in a way that facilitates intelligent selection of the cutting conditions. Chatter in machine tools is cause by inadequate information about the process limitations imposed by machine tool dynamics. Although chatter is a phenomenon for which a solution is well-known in academia, it is still the most problematic condition experienced in machining operations. Through this research project, Manufacturing Laboratories, Inc. (MLI) will create a new Machine Tool Integrated Multisensor Chatter Detection and Avoidance System (MICA) to address exactly this problem. There is a distinct need to transition the existing technologies available for chatter detection from a user-intensive process to an automatic process integrated into existing machine tools. MICA will provide real-time data to the machine controller allowing adjustment of the machining parameters, avoiding chatter. MICA will build on MLI’s patented Harmonizer, by (1) extending its functionality to include the ability to accept signals from multiple sensors, extending its diagnosis capability to lower frequency ranges, (2) providing a machine-integrated solution instead of a handheld manual device (3) identifying methodologies to adapt the chatter recognition theory to include specialty cutters. We have already identified this need within the market and have made strategic agreements with two leading machine tool suppliers, who will provide additional support for this research.

Systems and Materials Research Corporation
1300 West Koenig Lane Suite 230
Austin, TX 78756
Phone:
PI:
Topic#:
(512) 535-7791
Denise Deppe
DLA 08-001      Awarded: 10/20/2008
Title:Advanced Technologies for Discrete-Parts Manufacturing
Abstract:Wet installation of fasteners offers proven corrosion protection and fuel sealing in aircraft structures, but it''''s a labor-intensive, messy, hazmat-laden process whose quality can vary significantly from fastener to fastener. Under a Navy SBIR Phase II, SMRC has developed a proprietary process called QwikSeal® for pre-coating fasteners with cure- blocked sealant, then overcoating the pre-applied sealant with a moisture-impermeable nanocomposite size coat. On installation – potentially weeks or months later - the size coat franges, allowing the uncured sealant to coat the hole. Ambient moisture absorbed by the sealant unblocks the reaction and initiates normal cure. Though interest among aircraft manufacturers and maintainers is extremely high, there are concerns for inadvertent installation of fasteners whose sealant has prematurely cured. A premature cure indicator (PCI) is, therefore, a prerequisite to widespread adoption of QwikSeal. SMRC proposes development of selectively-tuned molecular probes which when imbedded in the cure-blocked sealant or size coat layers will change color on exposure to thiol groups, a very early and direct sign that the sealant is about to prematurely cure. Successful PCI development, not funded under any existing/proposed initiatives, could clear the way for large-scale entry of QwikSeal into the aerospace marketplace through PPG Aerospace, SMRC’s commercialization partner.

Third Wave Systems, Inc.
7900 West 78th St. Suite 300
Minneapolis, MN 55439
Phone:
PI:
Topic#:
(952) 832-5515
Cory Arthur
DLA 08-001      Awarded: 10/20/2008
Title:Low Cost Machining of Nickel Alloys for Aerospace Components
Abstract:The use of nickel alloys is pervasive in jet engine components and includes cases and fatigue critical rotating parts in the compressor and turbine sections. Machining nickel alloys represents a singular challenge due to the alloys¡¦ exceptional high temperature strength characteristics. This is marked by low material removal rates (MRR), long cycle times and high tooling costs. Our program will demonstrate the feasibility of innovative high-performance machining (HPM) enabled by physics-based modeling for low-cost fabrication of nickel-based aerospace engine components required for fixed wing and rotorcraft fleet sustainment. HPM will reduce costs of nickel aerospace components through a 100% increase in (MRR) while maintaining tool life. This unique approach will allow the use of conventional machine tools and eliminate the need for expensive capital equipment investment, leading to improved fleet sustainment through shorter cycle times, reduced costs, and increased supplier base. Our technical objectives include: (1) advancing physics-based modeling of nickel alloys, (2) demonstrating increased MRR via HPM for fundamental operations, and (3) demonstrating increased MRR via HPM for feature machining. The anticipated results include the demonstration of the feasibility of enabling physics-based modeling approach to analyze and dramatically improve machining of nickel alloys via the application of HPM.

Transition45 Technologies, Inc.
1963 North Main Street
Orange, CA 92865
Phone:
PI:
Topic#:
(714) 283-2118
Edward Chen
DLA 08-001      Awarded: 10/20/2008
Title:Innovative Hybrid Molding Casting Technology
Abstract:This SBIR Phase I effort proposes to develop a more affordable casting technology for discrete manufacturing based on innovative hybrid molding technologies. Rammed graphite molding is a lower-cost casting process not traditionally used to manufacture aerospace titanium components, while hybrid molds are a combination of two or more non-traditional molding technologies. The new process is expected to yield sufficient microstructure, mechanical properties as compared with the current investment casting method, with sufficient part geometrical complexity capability and surface finish when supplemented with added-value fabrication methods.