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Revitalization of Aircraft Carbon Fiber Composites in New Additively Manufactured Parts

Award Information
Agency: Department of Defense
Branch: Navy
Contract: N68335-22-C-0296
Agency Tracking Number: N21A-T002-0069
Amount: $800,000.00
Phase: Phase II
Program: STTR
Solicitation Topic Code: N21A-T002
Solicitation Number: 21.A
Solicitation Year: 2021
Award Year: 2022
Award Start Date (Proposal Award Date): 2022-06-16
Award End Date (Contract End Date): 2024-07-01
Small Business Information
158 Wheatland Drive
Pembroke, VA 24136-1111
United States
DUNS: 008963758
HUBZone Owned: No
Woman Owned: No
Socially and Economically Disadvantaged: No
Principal Investigator
 Jennifer Lalli
 (540) 626-6266
Business Contact
 Amanda Moye
Phone: (540) 626-6266
Research Institution
 Virginia Tech
 Michael Bortner
300 Turner St. SW
Blacksburg, VA 24061-1111
United States

 (540) 231-4213
 Nonprofit College or University

During Phase I of this NAVAIR STTR program, NanoSonic physically developed a commercially viable process for carbon fiber composite reclamation via scalable (> 8,000 lb/year), safe (non-toxic), and environmentally friendly (fiber and reagent reuse) methodologies.  Our mild chemical and low temperature recycling method was used successfully with both commercial and aircraft-grade epoxy-based resin carbon fiber composites.  Together, NanoSonic and our STTR partner, Virginia Tech, demonstrated that this gentle process does not degrade the carbon fibers for reuse with feasibility for near-net strength of the original composites.  We have demonstrated reuse of the fibers using several additive manufacturing (AM) methods (filament winding and 3D printing) and an innovative breakthrough technology that keeps the fibers aligned during and after the reclamation process.  NanoSonic has partnered with VT, Honeywell Special Projects, Lockheed Martin Aeronautics (LM Aero), and Northrop Grumman Undersea Systems (NGUS) to establish a customer base that encompasses a range of fibers (from carbon to Spectra) for multiple commercial, military, and aerospace platforms.  During Phase II of this program, this carbon fiber reclamation process shall be initially developed for end-of-life aircraft parts and scraps from the Joint Strike Fighter (JSF) and aerial targets that support of NAVAIR’s PMA-208 program (such as the BQM-177A).  The BQM-177A is an advanced, high-subsonic, recoverable aerial target equipped with sea-skimming capabilities and a high payload capacity due to the extensive use of carbon-fiber composites in its external payload bodies.

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

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