Date: Mar 01, 2007 Source: DARPA Success Stories (
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Technology and Innovation:
Under the auspices of a DARPA SBIR, NanoSonic, Inc. (NanoSonic) has developed molecular-level self-assembly manufacturing processes (not requiring guidance or management from an outside source) that can be used to fabricate materials having properties not previously obtainable using other production methods. The ability to form lightweight, mechanically flexible materials in sheet and fabric form that have electrical conductivities approaching those of bulk metals and metal alloys has been of particular importance for this program. This material, called Metal RubberÖ, flexes and stretches like rubber, yet conducts electricity like a solid metal. Such materials have a wide range of possible applications, either as improved replacements over existing materials or in new applications made possible by their unique characteristics.
Conventional self-assembly processing had been limited in both the thickness (typically less than one micron) and the two-dimensional size (typically tens of millimeters square) of materials that may be formed. NanoSonic has developed variations on conventional processing methods allowing thick (millimeters rather than microns) and physically large (sheets up to 4' x 8' so far) free-standing materials to be formed. This is a major advance for the many large military systems such as aircraft, spacecraft, land vehicles, and ships.
Joint Collaborations:
NanoSonic has developed collaborative relationships with many defense contractors, government laboratories, and research universities. The DARPA SBIR has enabled the company to expand its existing network of contacts in the area of flexible electronic materials and devices, an area in which NanoSonic had little previous exposure or experience. Additionally, the company has obtained recognition and support from government research laboratories through journals and conference publications, presentations at technical meetings, briefings at specific defense installations, and cooperation with larger defense companies that have direct relationships with end users.
Lessons Learned:
- Understand the requirements of the end user and the implications on the technology to be developed. The end-user requirements are key to guiding development and providing a framework for the transition to military and private sector applications and products.
- To achieve desired collaborations, establish many contacts in military organizations and private sector companies, invest the time to maintain those contacts, and bring them a useful technology.
- Commit early to transitioning into specific military and commercial applications. Transitioning is challenging because it requires allocating resources away from research, hiring new people with broader manufacturing experience versus research, and convincing sponsors that your technology merits other applications.
Economic Impact:
This DARPA SBIR has had a significant impact on company growth. Since its founding in 1998, the company has grown from three employees to 62, and annual revenues have grown to $6.5 million. Aside from the direct impact of SBIR contract proceeds, funding received under the DARPA SBIR program helped NanoSonic obtain funds from other government organizations and industry partners. For specific variations of its technology, 100 percent of its funds came from the DARPA SBIR and, since its founding, approximately 90 percent of the company's technology had its beginnings in SBIR programs. The company expects about 50 percent of its gross income in the current fiscal year to derive from non-SBIR sources. NanoSonic has developed a portfolio of issued patents and patent applications currently in process as a direct result of its SBIR work.
About the Company:
NanoSonic Inc is headquartered in Blacksburg, Virginia. The company has created a competitive advantage in its industry by developing a set of manufacturing processes that produces unique materials not available from other suppliers. The company's Metal Rubber material - with the electrical conductivity of metal, but the mass density and flexibility of polymers - is one example.
