Inexpensive Large Scale Manufacturing of High Specific Modulus and Strength Ceramic Fibers

Award Information
Agency: Department of Defense
Branch: Army
Contract: W911QX-11-C-0046
Agency Tracking Number: A102-062-0538
Amount: $69,989.00
Phase: Phase I
Program: SBIR
Awards Year: 2010
Solitcitation Year: 2010
Solitcitation Topic Code: A10-062
Solitcitation Number: 2010.2
Small Business Information
Free Form Fibers L.L.C.
26 F Congress Street, No. 312, Saratoga Springs, NY, 12866
Duns: 780362815
Hubzone Owned: N
Woman Owned: N
Socially and Economically Disadvantaged: N
Principal Investigator
 Joseph Pegna
 Chief Scientist
 (518) 269-5059
 joseph.pegna@freeformfibers.com
Business Contact
 John Schneiter
Title: Chief Executive Officer
Phone: (518) 330-8047
Email: john.schneiter@freeformfibers.com
Research Institution
N/A
Abstract
This ARMY SBIR Phase I project will determine the best opto-mechanical approach for massively parallel Laser Chemical Vapor Deposition of ceramic fibers by building on work already performed at RPI, Univ of Montreal, and Free Form Fibers (FFF). Ceramic fibers are typically produced using polymeric precursors, which means that stoichiometrically pure fibers are almost impossible to attain, limiting (usually severely) their potential performance in the severe applications they are intended for in the first place. FFF’s direct Laser Chemical Vapor Deposition production of pure fibers produces high purity monofilaments in a single “extrusion microtube” but commercial scale-up requires a sea change in manufacturing approach. This work investigates (in Phase I) creating a massively parallel array of laser beams, via either monolithic laser diode arrays, or a single laser and a high-power diffraction grating, and using this pattern (in a Phase I Option) to create a matching extrusion microtube array so that hundreds of stoichiometrically pure fibers can ultimately be grown at commercial scale via LCVD. Two approaches to the microtube array fabrication will be investigated, and one selected depending in part on the quality of the laser beam array and in part on results of microtube array fabrication experiments.

* information listed above is at the time of submission.

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