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Company Information:

Company Name:
METAL MATRIX CAST COMPOSITES, LLC (DBA M
Address:
101 Clematis Avenue, Unit #1
Waltham, MA 02453-7012
Phone:
(781) 893-4449
URL:
EIN:
743045789
DUNS:
809965130
Number of Employees:
23
Woman-Owned?:
No
Minority-Owned?:
No
HUBZone-Owned?:
No

Commercialization:

Has been acquired/merged with?:
N/A
Has had Spin-off?:
N/A
Has Had IPO?:
N/A
Year of IPO:
N/A
Has Patents?:
N/A
Number of Patents:
N/A
Total Sales to Date $:
$ 0.00
Total Investment to Date $
$ 0.00
POC Title:
N/A
POC Name:
N/A
POC Phone:
N/A
POC Email:
N/A
Narrative:
N/A

Award Totals:

Program/Phase Award Amount ($) Number of Awards
SBIR Phase I $3,251,944.00 38
SBIR Phase II $12,836,032.00 17
STTR Phase I $170,000.00 3
STTR Phase II $998,201.00 1

Award List:

Near-Absolute Net-Shape Processing of Reinforced Aluminum Castings for Brake Calipers

Award Year / Program / Phase:
1994 / SBIR / Phase I
Award Amount:
$99,157.00
Agency / Branch:
DOD / DARPA
Principal Investigator:
James Cornie
Abstract:
N/a

Pressure Infiltration Processing of Reinforced Superalloys and Intermetalics

Award Year / Program / Phase:
1994 / SBIR / Phase I
Award Amount:
$70,000.00
Agency:
NASA
Principal Investigator:
James A. Cornie
Abstract:
N/a

Pressure Infiltration Processing of Reinforced Superalloys and Intermetalics

Award Year / Program / Phase:
1995 / SBIR / Phase II
Award Amount:
$600,000.00
Agency:
NASA
Principal Investigator:
James A. Cornie
Abstract:
Five innovations are offered: 1) Pressure in filtration casting of net-shaped components with sapphire reinforced NiA1 and alumina multifilament tow reinforced In 718 superalloy, 2) low cost tooling concepts, 3) exact geometric positioning of fibers during processing, 4) the elimination or reduction… More

Low-Cost Durable Tooling for High Production Rate Structural Reaction Injection Molding/Resin Transfer Molding Processing

Award Year / Program / Phase:
1995 / SBIR / Phase I
Award Amount:
$75,000.00
Agency:
DOE
Principal Investigator:
James A. Cornie
Abstract:
N/a

Acoustic and Magnetic Signature Reduction for Outboard Engines Using Metal Matrix Composites

Award Year / Program / Phase:
1995 / SBIR / Phase I
Award Amount:
$70,000.00
Agency / Branch:
DOD / SOCOM
Principal Investigator:
James A. Cornie, Ph.d.
Abstract:
N/a

Advanced Pressure Infiltration Casting of Thick Section Al Matrix Composites for Armor Applications

Award Year / Program / Phase:
1995 / SBIR / Phase I
Award Amount:
$69,998.00
Agency / Branch:
DOD / ARMY
Principal Investigator:
James A. Cornie
Abstract:
N/a

Near-Absolute Net-Shape Processing of Reinforced Aluminum Castings for Brake Calipers

Award Year / Program / Phase:
1996 / SBIR / Phase II
Award Amount:
$375,000.00
Agency / Branch:
DOD / DARPA
Principal Investigator:
James Cornie
Abstract:
Near-absolute net-shape processing utilizing MIT/MMCC's high rate pressure infiltration casting process for manufacturing brake calipers is proposed, with Allied-Signal providing design and mechanical testing support gratus. The first objective is to demonstrate the ability to manufacture… More

FRACTURE ANALYSIS OF MMCS PRODUCED BY THE APICTM PROCESS USING LASER MOIRE INTERFEROMETRY

Award Year / Program / Phase:
1996 / SBIR / Phase I
Award Amount:
$70,000.00
Agency:
NASA
Principal Investigator:
James A. Cornie , President
Abstract:
N/a

Acoustic and Magnetic Signature Reduction for Outboard Engines Using Metal Matrix Composites

Award Year / Program / Phase:
1997 / SBIR / Phase II
Award Amount:
$750,000.00
Agency / Branch:
DOD / SOCOM
Principal Investigator:
James A. Cornie, Ph.d.
Abstract:
Metal matrix composites (MMCs) are the proposed replacement materials for the ferromagnetic parts that exist in an outboard engine. MMCs have specific stiffness properties 2 to 4 times that of aluminum alloys, steel, and titanium, while having equal or greater specific strength. The resulting… More

Advanced Pressure Infiltration Casting of Thick Section Al Matrix Composites for Armor Applications

Award Year / Program / Phase:
1997 / SBIR / Phase II
Award Amount:
$749,405.00
Agency / Branch:
DOD / ARMY
Principal Investigator:
James A. Cornie
Abstract:
Proposed here is a method by which large area, thick sectioned, whisker and particulate reinforced, aluminum matrix composites may be produced for lightweight armor applications. The first objective of this work is to conduct preliminary process optimization producing reinforced specimens 6" by 6"… More

Graphite Fiber Reinforced Al and Cu Alloys for Replacement of W/Cu in Electronic Thermal Mangement -

Award Year / Program / Phase:
1998 / SBIR / Phase I
Award Amount:
$70,000.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James Cornie, Phd
Abstract:
Graphite/Al phased array antenna rnodules will reduce rnodule launch mass from 154 kg (for W/Cu modules) to 19.7 kg. At $40,000/kg launch rnass, savings would be $5,400,000/launch. A team of users, graphite suppliers, casting house, and evaluation/analytical organizations, will develop and bring to… More

Tooling-Free MMC Casting by Combining 3-D Printing of Ceram

Award Year / Program / Phase:
1998 / STTR / Phase I
Award Amount:
$70,000.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie
Research Institution:
Massachusetts Institute of Technology
RI Contact:
Michael Cima
Abstract:
Three-dimensional printed preforms will be used as mold patterns for MMCC's high-density, pressure resistant, castable refractory. Hard tooling will be eliminated from the Advanced Pressure Infiltration Casting process (APIC ). Cost for Al/Sic electronic housings will be slashed 75% over… More

Low Mass Metal Matrix Composites for Lines/Duct Flanges and Cooled Nozzle Stiffeners

Award Year / Program / Phase:
1998 / SBIR / Phase I
Award Amount:
$70,000.00
Agency:
NASA
Principal Investigator:
Abstract:
N/a

N/A

Award Year / Program / Phase:
1999 / SBIR / Phase II
Award Amount:
$599,549.00
Agency:
NASA
Principal Investigator:
Abstract:
N/a

N/A

Award Year / Program / Phase:
2000 / STTR / Phase I
Award Amount:
$0.00
Agency / Branch:
DOD / MDA
Principal Investigator:
Maxim Seleznew
Research Institution:
MASSACHUSETTS INSTITUTE OF TECH.
RI Contact:
N/A
Abstract:
N/a

N/A

Award Year / Program / Phase:
2000 / SBIR / Phase I
Award Amount:
$99,900.00
Agency / Branch:
DOD / USAF
Principal Investigator:
Maxim L. Seleznev, Chief Materials Scientist
Abstract:
N/a

Isotropic Graphite Fiber Reinforced Al for High Performance Thermal Management Applications

Award Year / Program / Phase:
2002 / SBIR / Phase I
Award Amount:
$70,000.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie, Chief Technical Officer
Abstract:
"The rise of next generation electronics depends on advances in microelectronic packaging materials. Power, frequency, and functionality are increasing while cost, size, and margin for error are declining. Military and commercial electronics are reachingperformance limitations since conventional… More

Graphite Fiber Reinforced Mg EKV Sunshade for Be Replacement and Cost and Mass Reduction

Award Year / Program / Phase:
2002 / SBIR / Phase I
Award Amount:
$70,000.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie, Chief Technical Officer
Abstract:
"Mg alloys reinforced with high modulus graphite fibers have nearly 1.5 times the specific stiffness of beryllium. Since the EKV sunshade is a stiffness critical application, a sunshade manufactured from graphite fiber reinforced magnesium could weigh athird less than the current Be design. Using… More

Manufacturing Cost Reduction for Key Enabling Thermal Management Applications Using CTE Controlled Graphite Fiber Reinforced Al

Award Year / Program / Phase:
2002 / SBIR / Phase I
Award Amount:
$69,999.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie, Chief Technical Officer
Abstract:
"This proposal shows how innovations in producing a family of CTE controlled, high thermal graphite aluminum composites will reduce manufacturing costs and improve system performance for specific BMDO, Navy, and commercial applications. Technologiesdeveloped by a graphite fiber producer, paper… More

Model Foundry for Low Cost Rapid Prototyping, Rapid Manufacturing of Metal Matrix Composites Parts

Award Year / Program / Phase:
2002 / SBIR / Phase I
Award Amount:
$70,000.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie, Chief Technical Officer
Abstract:
"Manufacturing technology development and integration of MMCC's 3- DPT, Tool-Less MoldT and Advanced Pressure Infiltration(APICT) technologies are proposed. Investment casting of preforms printed directly from a CAD or laser file and subsequent pressureinfiltration will enable parts to be… More

Low Cost Light Weight Graphite Fiber Reinforced Mg Space Mirrors

Award Year / Program / Phase:
2002 / SBIR / Phase I
Award Amount:
$100,000.00
Agency / Branch:
DOD / USAF
Principal Investigator:
James A. Cornie, Chief Technical Officer
Abstract:
"MMCC will develop an isotropic graphite fiber reinforced magnesium rigid mirror material that will result in an areal density of 5 kg/m2, reduce lead times for paraboloid blanks by two-thirds, and cut mirror costs by at least 50% over Be mirror systems.Phase I will design, build, and test graphite… More

Model Foundry for Low Cost Rapid Prototyping, Rapid Manufacturing of Metal Matrix Composites Parts

Award Year / Program / Phase:
2003 / SBIR / Phase II
Award Amount:
$850,000.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie, Principal Investigator
Abstract:
Manufacturing technology development of 3DPT, injection molding, Tool-Less MoldT and Advanced Pressure Infiltration(APICT) technologies are proposed. Investment casting of injection molded preforms or preforms printed directly from a CAD file andsubsequent pressure infiltration will enable parts to… More

Manufacturing Cost Reduction for Key Enabling Thermal Management Applications Using CTE Controlled Graphite Fiber Reinforced Al

Award Year / Program / Phase:
2003 / SBIR / Phase II
Award Amount:
$1,250,000.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie, Principal Investigator
Abstract:
Thermal expansion can be designed into a graphite fiber reinforced Al or Cu composite over a range of 2 to 10 ppm/K by controlling the fiber architecture an volume loading. Discontinuous graphite fibers have been arranged into a random in-planearchitecture to produce planar isotropic properties… More

Model Foundry for Low Cost Rapid Prototyping, Rapid Manufacturing of Metal Matrix Composites Parts

Award Year / Program / Phase:
2003 / SBIR / Phase II
Award Amount:
$750,000.00
Agency / Branch:
DOD / USAF
Principal Investigator:
James A. Cornie, Chief Technical Officer
Abstract:
Graphite fiber reinforced Mg alloys show high specific stiffness, CTE less than 2 ppm/K and higher conductivity than competing mirror materials. Mg/Gr was coated with Si and polished to less than 10 angstroms RMS. Most important, the material is cast tonear final figure and is easily machined and… More

Graphite Fiber Reinforced Magnesium as a Beryllium Replacement Material for EKV Seeker Mirrors and Substructures

Award Year / Program / Phase:
2003 / SBIR / Phase I
Award Amount:
$70,000.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie, Principal Investigator
Abstract:
Graphite fiber reinforced Mg alloys with quasi-isotropic architecture has nearly the same specific stiffness (Young's modulus/density) as beryllium and 12 x the thermal stability (thermal conductivity/coef. thermal expansion). Compared to beryllium, Sicoated and polished Mg-Gr mirrors will be… More

Light Weight Thermally Balanced Graphite Reinforced Mg Structural Substrates for Replicated Mirror Membranes

Award Year / Program / Phase:
2003 / SBIR / Phase I
Award Amount:
$70,000.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie, Principal Investigator
Abstract:
Magnesium reinforced with a quasi-isotropic high stiffness graphite preform has the highest combination of specific stiffness (E/r) and thermal stability (thermal conductivity/CTE) of any material other than expensive CVD/SiC.This unique combination of properties coupled with ease of fabrication and… More

Super High Thermal Conductivity CTE Matched GaN and SiC Power Amplifier Packaging: Hybridized Graphite Fiber Reinforced Al and Cu Alloys

Award Year / Program / Phase:
2003 / SBIR / Phase I
Award Amount:
$70,000.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie, Principal Investigator
Abstract:
An order of magnitude increase in heat flux of multi-die passive heat sink materials is proposed. High performance graphite fiber reinforced aluminum and copper alloys are precisely CTE matched to diverse substrates such as CVD diamond, SiC, Si, GaN,GaAs, alumina and beryllia, by varying the volume… More

Super High Thermal Conductivity CTE Matched Power Amplifier Packaging: Hybridized Graphite Fiber Reinforced Al and Cu Alloys

Award Year / Program / Phase:
2003 / SBIR / Phase I
Award Amount:
$70,000.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie, Principal Investigotor
Abstract:
An order of magnitude increase in heat flux of multi-die passive heat sink materials is proposed. High performance graphite fiber reinforced aluminum and copper alloys are precisely CTE matched to diverse substrates such as CVD diamond, SiC, Si, GaN,GaAs, alumina and beryllia, by varying the volume… More

Graphite Fiber Reinforced Mg EKV Sunshade for Be Replacement and Cost and Mass Reduction

Award Year / Program / Phase:
2004 / SBIR / Phase II
Award Amount:
$1,254,639.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie, Principal Investigator
Abstract:
In Phase I, we demonstrated that Mg-AZ31 alloy reinforced with graphite fibers has over 27% higher specific stiffness than beryllium. Since EKV sunshade is a stiffness critical application, sunshades manufactured from graphite/Mg could weigh 27% less than the current Be design. Further, testing at… More

Low Expansion Metallic Nanolaminate Replicated Mirrors with CTE Matched High Conductivity Graphite Fiber Reinforced Magnesium Mirror Substrate Structu

Award Year / Program / Phase:
2004 / STTR / Phase I
Award Amount:
$100,000.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie, Chief Technology Officer
Research Institution:
Lawrence Livermore National Lab
RI Contact:
Troy W. Barbee
Abstract:
Magnetron sputtering of "Invar-like" nanolaminates onto a pre-finished/figured mandrel is proposed to produce strong, stiff, damage tolerant, low CTE replicas. The structural substrate will be a high performance discontinuous graphite fiber reinforced Mg AZ31 metal matrix composite manufactured by… More

Three-Stage Hybridization of Ultra High Thermal Conductivity Heat Sinks and Spreaders for Advanced Radar and RF Components

Award Year / Program / Phase:
2004 / SBIR / Phase I
Award Amount:
$100,000.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie, Principal Investigator
Abstract:
By combining discontinuous graphite fiber preforms with inserts of ultra high thermal conductivity materials, we will create hybridized composites with thermal expansion matching to GaAs, SiC or GaN semiconductor amplifiers in advanced radar systems. Specifically, we will use a conventional MetGraf… More

High Conductivity Hybridized Graphite Reinforced Al Heat Sinks for Advanced Interceptor Missile Systems

Award Year / Program / Phase:
2004 / SBIR / Phase I
Award Amount:
$100,000.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie, Principal Investigator
Abstract:
Hybrid metal matrix composites are offered to meet the needs of high thermal conductivity heat sinks for electronic processors in advanced interceptor systems. MMCC's graphite fiber reinforced composite MetGraf 4-230 will serve as a skin to highly conductive cores of advanced graphitic materials. … More

Application of Copper-Graphite Composite in Active Radar System Thermal Management

Award Year / Program / Phase:
2004 / SBIR / Phase I
Award Amount:
$70,000.00
Agency / Branch:
DOD / NAVY
Principal Investigator:
Yuejian Chen, PRINCIPAL INVESTIGATOR
Abstract:
Discontinuous pitch-based graphite fiber reinforced copper (Cu/Gr) composites have been under development for semiconductor thermal management. The composites consist of a high thermal conductivity copper-chromium alloy matrix and short pitch-based graphite fibers randomly oriented in planar… More

Three-Stage Hybridization of Ultra High Thermal Conductivity Heat Sinks and Spreaders for Advanced Radar and RF Components

Award Year / Program / Phase:
2005 / SBIR / Phase II
Award Amount:
$749,983.00
Agency / Branch:
DOD / MDA
Principal Investigator:
Yuejian Chen, SENIOR R&D ENGINEER
Abstract:
The results of Phase I showed that a 900 W/mK mechanically stable and CTE matched heat sink for T/RIMM module could be upgraded to 1200 W/mK. Phase II work is aimed at 1) establishing the manufacturing and producibility bases for design and deployment of advanced radar and RF components; 2)… More

Thermal Pyrolytic Graphite (TPG) Embedded Copper Graphite Composite Heat Sink for High Power or Small Form Factor (SFF) Tactical Radios

Award Year / Program / Phase:
2005 / SBIR / Phase I
Award Amount:
$70,000.00
Agency / Branch:
DOD / ARMY
Principal Investigator:
Yuejian Chen, Senior R&D Engineer
Abstract:
A manufacturing technique is developed to strategically embed thermal pyrolytic graphite (TPG) insert into copper graphite composite. TPG will then be located in the critical thermal path of the power amplifier heat sink so that heat can be conducted from its edge into the radio chassis. The… More

Thermal Pyrolytic Graphite (TPG) Embedded Copper Graphite Composite Heat Sinking Slat for Phase Array Radar Antenna

Award Year / Program / Phase:
2005 / SBIR / Phase I
Award Amount:
$148,000.00
Agency / Branch:
DOD / MDA
Principal Investigator:
Yuejian Chen, SENIOR R&D ENGINEER
Abstract:
A manufacturing technique is developed to strategically embed thermal pyrolytic graphite (TPG) insert into copper graphite composite. TPG will then be located in the critical thermal path of phase array radar antenna slat so that the slat is allowed to be cooled from its edge. The enhancement of… More

Discontinuous Graphite Fiber Reinforced Al 520 Matrix Composite for Structural Reactive Material

Award Year / Program / Phase:
2005 / SBIR / Phase I
Award Amount:
$100,000.00
Agency / Branch:
DOD / DTRA
Principal Investigator:
Yuejian Chen, SENIOR R&D ENGINEER
Abstract:
Discontinuous graphite fiber reinforced aluminum magnesium matrix composite with microscopically dispersed add-on oxidizer coating is proposed for the application of enhanced lethality munitions. The composite with the coating is light-weight and reactive, which will generate high reaction… More

Graphite Fiber Reinforced Mg for EKV Mirrors and Optical Support Structures for Be Replacement and Enhanced Performance: Component Demonstration and Contractor Evaluation

Award Year / Program / Phase:
2005 / SBIR / Phase I
Award Amount:
$100,000.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie, CHIEF TECHNOLOGY OFFICER
Abstract:
MMCC will manufacture its standard discontinuous graphite fiber reinforced Mg alloy AZ31 optimized to a CTE of 2 ppm/K for evaluation by Raytheon Missile Systems for EKV mirror and Be applications. Additionally, MMCC will provide Raytheon evaluation panels of its new products based upon filament… More

Ultra-Lightweight Hybrid Structured Mirror

Award Year / Program / Phase:
2005 / SBIR / Phase I
Award Amount:
$69,999.00
Agency:
NASA
Principal Investigator:
Abstract:
MMCC is proposing herewith a hybrid structured mirror that combines the advantages of SiC membrane and magnesium graphite composite. The significance of magnesium graphite composite is that it can be produced with quasi-isotropic properties and closely matched CTE down to cryogenic temperatures. … More

Thermal Pyrolytic Graphite Embedded Copper Graphite and Aluminum Graphite Composites for Thermal Management of Phase Array Radar Systems

Award Year / Program / Phase:
2006 / SBIR / Phase II
Award Amount:
$749,999.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornnie, CHIEF TECHNOLOGY OFFICER
Abstract:
In Phase I, MMCC combined discontinuous graphite fiber preforms with ultra high thermal conductivity (1700 W/mK TPG) inserts and created hybrid composites with thermal expansion matching to GaAs, SiC and GaN semiconductors and thermal conductivities from 800 to 1200 W/mK. A conventional Cu MetGraf… More

Advance Thermal Management of Large Multiband Phased Arrays

Award Year / Program / Phase:
2006 / SBIR / Phase I
Award Amount:
$100,000.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie, Chief Technology Officer
Abstract:
The main issue preventing widespread use of x-band antennae systems throughout various military platforms is cost. Cheaper assembly processes, such as automated pick and place, are needed to produce antennas using wideband gap semiconductor materials such as GaN and SiC. Higher power and frequency… More

Thin Copper-Graphite Composite Cold Plate for Thermal Management of High Density Electronics

Award Year / Program / Phase:
2007 / SBIR / Phase I
Award Amount:
$100,000.00
Agency / Branch:
DOD / MDA
Principal Investigator:
Yuejian Chen, Senior R&D Engineer
Abstract:
Copper-graphite composite is proposed for a thin liquid-cooled cold plate for high density electronic thermal management. The proposed cold plate will have CTE in the range of 2~9x10-6 / degrees C to match those of semiconductors such as SiC, silicon, GaAs, as well as ceramic substrates. The… More

Pressure Infiltration Casting, Lamination Theory Prediction and Mechanical Property Evaluation of High Performance Continuously Reinforced Metal Matri

Award Year / Program / Phase:
2007 / SBIR / Phase I
Award Amount:
$69,999.00
Agency / Branch:
DOD / ARMY
Principal Investigator:
James A. Cornie, Chief Technology Officer
Abstract:
Pressure infiltration casting technology will used to develop low density continuous fiber reinforced structural metal matrix composites in the form of tubes and plates. Three different reinforcement systems will be investigated with the idea of producing a spectrum of choices for a wide range of… More

Advance Thermal Management of Large Multiband Phased Arrays

Award Year / Program / Phase:
2007 / SBIR / Phase II
Award Amount:
$999,999.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie, CHIEF TECHNOLOGY OFFICER
Abstract:
The main issue preventing widespread use of x-band antennae systems in military platforms is cost. Cheaper assembly processes, e.g. automated pick and place and larger formats are needed to implement wideband gap semiconductor devices (GaN and SiC). Lessons learned in GaAs based systems are… More

SBIR Phase I: Ultra High Thermal Conductivity Aluminum/Graphite Composites from Recovered Scrap Graphite and Low Cost Natural Graphite

Award Year / Program / Phase:
2007 / SBIR / Phase I
Award Amount:
$100,000.00
Agency:
NSF
Principal Investigator:
Abstract:
This Small Business Innovation Research (SBIR) Phase I project will use recycled or natural graphite to develop low cost graphite/aluminum composites with high thermal conductivity for electronic thermal management applications. Highly conductive graphite flakes randomly dispersed at ~75 volume… More

Thin Copper-Graphite Composite Cold Plate and High Performance Al/Gr Composites for Thermal Management of High Density Electronics

Award Year / Program / Phase:
2008 / SBIR / Phase II
Award Amount:
$749,943.00
Agency / Branch:
DOD / MDA
Principal Investigator:
James A. Cornie, Chief Technology Officer
Abstract:
Two approaches to high performance base plates for advanced thermal management applications are proposed. Inexpensive high performance Al/Gr composites have been developed with a quasi-isotropic thermal conductivity (TC) of 600 to 750 W/mK and corresponding thermal expansion (CTE) of 7 to 3 ppm/K. … More

SBIR Phase II: Ultra High Thermal Conductivity Aluminum/Graphite Composites from Low Cost Natural Graphite

Award Year / Program / Phase:
2008 / SBIR / Phase II
Award Amount:
$499,994.00
Agency:
NSF
Principal Investigator:
Abstract:
The Small Business Innovation Research (SBIR) Phase II project will develop and present for commercialization natural graphite (NG) reinforced Al (AlGr). In this project, inexpensive natural graphite flake (NGF) will be manufactured into a preform and pressure infiltrated with Al-Si alloys to form… More

SBIR Phase I: Low Cost Natural Graphite Reinforced Copper (Cu-Grp) Composites for Ultra High Thermal Conductivity Electronic Thermal Management Heat Sinks

Award Year / Program / Phase:
2009 / SBIR / Phase I
Award Amount:
$99,997.00
Agency:
NSF
Principal Investigator:
Abstract:
This Small Business Innovative Research Phase I project is to develop extremely high thermal conductivity heat sinks that are thermal expansion matched to advanced semiconductors for high performance electronic and electro-optical systems. With low cost natural graphite platelet reinforcement, CuGrp… More

Ultra-High Thermal Conductivity, Thermal Expansion Matched, Low Density Materials for Dimensionally Stable Space Structures

Award Year / Program / Phase:
2009 / SBIR / Phase I
Award Amount:
$100,000.00
Agency / Branch:
DOD / USAF
Principal Investigator:
James A. Cornie, Chief Technology Officer
Abstract:
Ultra high thermal conductivity low-cost materials with thermal expansion matched to electronic devices, actuators and thermal electric cooling systems are proposed. These passive materials enable other technologies but provide for the thermal leveling required for advanced optics and sensing… More

High Thermal Conductivity Graphite Reinforced Al Composites for Thermally Stable Structural Panels and Frame with Passive Thermal Control Features for

Award Year / Program / Phase:
2010 / SBIR / Phase I
Award Amount:
$99,999.00
Agency / Branch:
DOD / USAF
Principal Investigator:
James A. Cornie, Chief Technology Officer
Abstract:
Pressure infiltration cast graphite fiber and platelet reinforced Al materials are proposed. Structural materials that have high stiffness, low thermal expansion, very high thermal conductivity and low density will be developed for use as a satellite structural frame. The same composite preform… More

Ultra-High Thermal Conductivity, Thermal Expansion Matched, Low Density Materials for Dimensionally Stable Space Structures

Award Year / Program / Phase:
2010 / SBIR / Phase II
Award Amount:
$749,742.00
Agency:
DOD
Principal Investigator:
James A. Cornie, Chief Technology Officer – (781) 893-4449
Abstract:
High stiffness structural composite skins with high thermal conductivity thermal cores (>800 W/mK) for mounting satellite sensors and electronics were demonstrated. Further hybridization with 800 W/mK"z"inserts with local thermal expansion matching provides for thermal management. … More

Enhanced Electrical and Thermal Conductivity of Wires Drawn from Cast Cu/Nanophase Composites

Award Year / Program / Phase:
2010 / SBIR / Phase I
Award Amount:
$69,998.00
Agency / Branch:
DOD / NAVY
Principal Investigator:
James Cornie, Chief Technology Officer
Abstract:
Multi walled carbon nanotubes MWNTs will be coated to enable wetting by molten OFHC copper. Coated MWNTs will be made into a preform and pressure infiltration cast with molten Cu to form a Cu/MWNT master composite. Master composites will be added to molten Cu and shear dispersed/diluted to form a… More

Lightweight, CTE Matched Copper Graphite Composite Cores For Enhanced PCB Thermal Management

Award Year / Program / Phase:
2010 / SBIR / Phase I
Award Amount:
$69,999.00
Agency / Branch:
DOD / NAVY
Principal Investigator:
Robert Hay, VP Business Dev./Technica
Abstract:
Thermal Management, CTE control, and mechanical stability are critical for lightweight aerospace/defense printed circuit board (PCB) applications. Current materials for PCBs do not adequately address thermal, reliability, and weight reduction in a single material solution. Historically, the… More

Development of Ultra High Performance Thermal Management Technology for High Power Solid State Lasers for MDA Directed Energy Systems

Award Year / Program / Phase:
2011 / SBIR / Phase I
Award Amount:
$99,999.00
Agency:
DOD
Principal Investigator:
Robert A. Hay, VP Business Development – (781) 893-4449
Abstract:
High efficiency heat-sinks for thermal management of high energy solid state lasers are proposed. Advanced heat sink technology enables increased performance of directed energy solid state lasers. Efficient high performance thermal management materials representing next generation thermal… More

Copper Graphite Composite Passive Thermal Control for High Density Interconnect PCB's

Award Year / Program / Phase:
2011 / SBIR / Phase II
Award Amount:
$999,979.00
Agency / Branch:
DOD / NAVY
Principal Investigator:
Robert Hay, VP BUSINESS DEVELOPMENT – (781) 893-4449
Abstract:
Thermal management, CTE control, and mechanical stability are critical for lightweight aerospace/defense printed circuit board (PCB) applications. Current materials for PCB"s such as copper and graphite epoxy laminates with copper foil cladding do not adequately address thermal requirements,… More

High Performance, Low-Cost IGBT Power Module Thermal Management for HEV/EV Applications

Award Year / Program / Phase:
2012 / SBIR / Phase I
Award Amount:
$149,964.00
Agency:
DOE
Principal Investigator:
James Cornie, Dr. – 781-893-4449 x
Abstract:
This proposal addresses a critical need to develop low cost packaging solutions to reduce size, weight, and increase performance in hybrid electric vehicle (HEV) and electric vehicle (EV) motor drive power electronics. IGBT (integrated gate bipolar transistor) and inverter/converter devices for… More

Thin Copper-Graphite Composite Cold Plate and High Performance Al/Gr Composites for Thermal Management of High Density Electronics

Award Year / Program / Phase:
2012 / SBIR / Phase II
Award Amount:
$157,800.00
Agency:
DOD
Principal Investigator:
James A. Cornie, Chief Technology Officer – (781) 893-4449
Abstract:
Two approaches to high performance base plates for advanced thermal management applications are proposed. Inexpensive high performance Al/Gr composites have been developed with a quasi-isotropic thermal conductivity (TC) of 600 to 750 W/mK and corresponding thermal expansion (CTE) of 7 to 3 ppm/K. … More

New Radar/EW Transmit/Receiver Modules and Assemblies Technologies

Award Year / Program / Phase:
2013 / SBIR / Phase I
Award Amount:
$79,936.00
Agency:
DOD
Principal Investigator:
Robert Hay, VP Business Development – (781) 893-4449
Abstract:
This proposal addresses an opportunity for the Navy to establish an integrated business and technical strategy to provide an Open Systems active array technology for emerging Naval radar and EW systems, and for modernization/sustainment of existing systems at lower cost. Transmit/ Receive (T/R)… More