SBIR-STTR Award

Physical Sciences Inc. and George Mason University will use a biomimetic approach to develop novel biopolymer foams which exhibit high energy dissipating characteristics, low-cost, long-term shelf-stability, and the potential to be entirely produced from cellulosic waste. The team will focus on bio-inspired structures that provide significant advancements over conventional engineered structures to achieve excellent energy absorption capacities. The unique combination of material properties and form factor has the potential to provide a new paradigm for applications ranging from enhanced airdrop to packing and shipping materials and to other fields such as aerospace and construction. In Phase I, PSI will develop a 100% bioderived material integrated into a form factor with high energy dissipation characteristics as confirmed by finite element analysis (FEA) modeling. The Phase I results will provide the basis for Phase II, where we will produce 6öx6ö samples for impact testing, and incrementally scale-up the process to a full sized 36öx96ö sheet of energy dissipating material. In the Phase II option, we will develop and execute a strategy for scale-up and implementation. The outcome of a successful project will be the development of a new bio-derived energy dissipating material with a bio-inspired form factor that can be inexpensively produced at scale.

Physical Sciences Inc. and George Mason University developed a biomimetic approach to produce novel energy dissipating biopolymer foams produced from upcycled cellulosic waste feedstocks. After the completion of a successful Phase I SBIR program, the team proposes a subsequent Phase II program to mature and demonstrate the technology validated in Phase I. The team has successfully demonstrated the feasibility of the developed foam materials in a 6-month Phase I SBIR program. This 100% bioderived biopolymer foam made from cellulosic waste feedstocks was integrated into novel, bio-mimetic form factors and demonstrated high energy dissipation characteristics. The Phase I results achieved a >7.5X improvement in SEA from state-of-the-art (SOA) paper honeycomb. The team performed a preliminary techno-economic analysis that shows PSI’s technology has a 1.1-5.3X reduction in material cost compared to commercially available paper honeycomb. The Phase II Base program seeks to enhance material properties to achieve a specific energy absorption (SEA) of > 40 J/g EDS at normal impacts, and > 20 J/g EDS when impacted at a 30° incline. The team will incrementally scale-up the material production, creating 6” x 6” test coupons to demonstrate mechanical properties. In the Phase II Option, the team will further scale up the Energy Dissipating Structure (EDS) production to create a proof-of-concept full size (36”x96”) foam panel and demonstrate its mechanical properties at scales relevant to airdrop applications. Additionally, PSI will produce a detailed design and plan for constructing and operating a pilot plant capable of producing one full size EDS panel per hour. The team will build the pilot plant and operate it to generate at least 10 full-sized EDS panels over a fabrication campaign. This SBIR program will enable a scalable, domestically produced enhanced material for U.S. air drop capabilities across the world. PSI’s foam material will increase air drop mission success rates, providing efficient airborne and airlift operations to resupply missions, unit deployments, and humanitarian aid.