SBIR-STTR Award

The objective of the proposed work is to develop Lattice Block Material (LBM) as a cost effective fabrication technology for ultra-light steel structures. Specifically, JAMCORP proposes to develop manufacturing methods for producing LBM with densities less than 50% that of the bulk alloy. Lattice Block Materials are a new class of materials which make use of the well understood principles of trusses and space frames. These principles are applied at a size previously thought to be impractical for manufacturing. JAMCORP has successfully developed and demonstrated a manufacturing process to produce components having unusually high strength to weight ratios. The physical properties of LBM, such as temperature resistance and hardness, closely reflect the physical properties of the parent material whether it be a metal, an alloy, or a polymer. Cost-effective LBM manufacturing will enable significant reductions in structural component weight. Analysis indicates that hundreds to thousands of pounds could be eliminated from military and commercial naval craft if LBMs were used to replace solid structural components. Weight reductions directly increase maneuverability, range, and fuel efficiency.

The development of light weight materials with advanced performance, coupled with reduced manufacturing costs, is critical to maintaining the superiority of next generation Naval vessels as well as to the applications within the broader society. The objective of this research project is to continue development of LBM casting processes, produce production grade tooling, and develop a product for possible insertion into a submarine platform. The feasibility of production using novel tooling methods was demonstrated in Phase I. The techniques under development are modular. This enables the production of a range of internally complex components from small numbers of reusable tool sets, and makes possible structurally efficient parts at very low cost. Single, monolithic castings in all commercially available alloys enable reductions in labor and materials costs across a broad platform of applications. Phase II will pursue development of production grade tooling, manufacture of test articles for material characterization, and development of a submarine application.