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Multi-Cavity Die Technology

Award Information

Department of Defense
Missile Defense Agency
Award ID:
Program Year/Program:
2002 / SBIR
Agency Tracking Number:
Solicitation Year:
Solicitation Topic Code:
Solicitation Number:
Small Business Information
ENSER Corporation, The
5430 70th Avenue North Pinellas Park, FL 33781-
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Woman-Owned: No
Minority-Owned: Yes
HUBZone-Owned: No
Phase 1
Fiscal Year: 2002
Title: Multi-Cavity Die Technology
Agency / Branch: DOD / MDA
Contract: DASG60-02-P-0134
Award Amount: $69,807.00


"Thermal batteries are mission-critical components utilized in virtually every weapon system. Thermal batteries require four types of pellets that comprise the energy-producing portion of the battery. These include: (1) anode pellets, composed of Li(Si)alloy and electrolyte salt, (2) cathode pellets, consisting of either FeS2 or CoS2 and electrolyte salt, (3) separator pellets, consisting of MgO and electrolyte salt and (4) heat pellets containing iron and potassium perchlorate. Pellet size and numbervary by battery type and application. A pellet is manufactured by compacting its powdered constituents in an automated press. The powder is loaded into a feed shoe, which automatically fills a die cavity. Press tonnage is a function of pellet diameterand thickness.Currently, pellet production is the rate-limiting step in thermal battery manufacture, hence, it is essential to optimize press throughput. At present, only one pellet is produced at a time, i.e., the press tooling is comprised of only one die cavity andone punch. This proposed SBIR project focuses on identifying and addressing the design challenge to implement two (or more) die cavities and punches in order to double, or perhaps even triple, pellet production rate. Virtually every thermal battery production program will benefit as a result of increased production rate capability and concomitant lower unit cost."

Principal Investigator:

Harry Straub
Sr. Mechanical Engineer

Business Contact:

Robert R. Jackson
Small Business Information at Submission:

Enser Corp. The
5430-B 70th Avenue North Pinellas Park, FL 33781

EIN/Tax ID: 630921815
Number of Employees:
Woman-Owned: No
Minority-Owned: No
HUBZone-Owned: No