Mold-in-Place Coatings

Mold-in-Place Coatings

Award Information
Agency: Department of Defense
Branch: Air Force
Contract: FA8650-09-C-5304
Agency Tracking Number: F081-042-0476
Amount: $4,899,810.00
Phase: Phase II
Program: SBIR
Awards Year: 2009
Solicitation Year: 2008
Solicitation Topic Code: AF081C-042
Solicitation Number: 2008.1
Small Business Information
225 Bodwell St., Avon, MA, 02322
DUNS: 187336503
HUBZone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Michael Heafey
 Project Manager
 (508) 580-2660
 mheafey@cumingcorp.com
Business Contact
 Larry Parkinson
Title: President
Phone: (508) 580-2660
Email: lparkinson@cumingcorp.com
Research Institution
N/A
Abstract
Many airborne vehicles require thick polymeric coatings on complex, concave and convex surfaces, which may be metallic, composite, or ceramic. The common method for applying these coatings involves spraying many individual layers, and allowing solvent flash and drying between each layer. A coating which is built up to 0.250” thickness, may require more than 100 layers of sprayed on coatings. This approach requires long staging times in a spray booth, issues with solvent emissions and abatement, detailed robotic programming to follow a complex curvature, and may still require grinding, sanding, and thickness measurement at the end to assure a uniform coating has been applied. Our proposed innovation allows for the injection molding of a thick coating in a single step directly on the aircraft. A tool which is machined to mate to the curvature of the substrate surface, providing a fixed spacing, can be mechanically or vacuum attached to the surface, creating an injection molding cavity. A thermosetting polymeric system can be mixed and injection molded into the cavity as a 100% solids formulation, thus eliminating all solvents. Once cured, the tool is removed manually or mechanically, depending on size, leaving the molded coating on the surface.

* Information listed above is at the time of submission. *

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