R&D World Fall 2023

FALL 2023 W W W . R D W O R L D O N L I N E . CO M

2023

R&D 100 AWARDS

Cover FINAL - R&D 10-23.indd 1

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DSRD vapor deposition process creates powerful electrical components PB-UHF enables data monitoring through containment walls

Variorum measures and optimizes supercomputer 1 9 performance 5 2 — 2 0 2 2

CANDLE leverages machine learning to accelerate cancer research zfp saves storage, time, and compute power with flexible data compression

Making the impossible possible

Experiments at LLNL’s National Ignition Facility in December 2022 and July 2023 resulted in ignition, in which the energy produced from a fusion reaction exceeds that required to spark the reaction.

llnl.gov

This work was performed under the auspices of the U.S. Department of Energy by Lawrence Livermore National Laboratory under Contract DE-AC52-07NA27344. LLNL-MI-855191

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I N S I D E

R&D WORLD FALL 2023

06 2023 R&D 100 Winners 42 2023 R&D 100 Special Recognition 45 2023 R&D 100 Finalists 50 2023 R&D 100 Professional Winners 52 Ad index

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analytical / test WINNERS

A Novel Eye Drop, The Most Convenient Treatment for Wet Macular Degeneration TheratOcular Biotek Co. Ltd. Co-Developer: Industrial Technology Research Institute (ITRI) TO-O-1002, a cutting-edge treatment for wet macular degeneration, shows an extraordinary ability to deliver drugs to the back of the eyes, overcoming the limitations of current ocular injection therapy and providing patients with a non-invasive alternative. The eye drop stands as the most promising treatment worldwide for the condition due to its highly effective therapeutic delivery to the target site, eliminating the need for ocular injections. TO-O-1002 offers significant advantages to patients, allowing them to selfadminister the treatment at home and eliminating the need for frequent hospital visits, making it more accessible and convenient. This novel eye drop revolutionizes wet AMD treatment by providing a non-invasive and easily selfadministered option.

Additively Manufactured Thermally Conductive Collimators for Neutron Instrumentation

Automated Live Cell Imaging System, Celloger Mini Plus Curiosis

Oak Ridge National Laboratory The MMC additive manufacturing techniques allow for the bespoke production of components with reduced maintenance cost and production time savings. The resulting components have been found effective as neutron collimators and to make individualized components with complicated geometries for neutron scattering applications that are prohibitive using traditional manufacturing techniques. Incorporating an aluminum/ boron carbide matrix material in additively manufactured neutron-absorbing components provides a superior product compared to cyanoacrylate-boron carbide materials. The aluminum/boron carbide matrix has a greater thermal conductivity, does not decompose at elevated temperatures, and has a much smaller and preferred neutron scattering crosssection compared to cyanoacrylate-boron carbide collimators.

Cellpuri, cell concentration system Curiosis

Celloger Mini Plus is an innovative live cell imaging system that stands out for its exceptional technological excellence, combining advanced imaging technology with optimized analysis features to empower researchers with unparalleled capabilities in live cell studies. Its unique design features a fixed vessel and automated camera, ensuring uninterrupted imaging of live cells and mitigating challenges associated with vessel movement.

The compact and lightweight design enhances its practicality, allowing for easy placement inside incubators without complex installations.

The system’s image optimization, power management, and airflow optimization further ensure highquality imaging while maintaining optimal cell culture conditions.

The system is affordable, making it accessible to a wide range of research laboratories.

Cellpuri is a groundbreaking cell-concentration system that eliminates the need for centrifugal force, thereby significantly reducing the exposure of cells to fluid shear stress in seconds. This innovative technology ensures minimal impact on the cells in terms of mechanical stress. Furthermore, the entire cell concentration process can be conveniently conducted within a sterile clean bench environment, eliminating any risk of contamination. Its user-friendly interface and automated process make it accessible to researchers of all skill levels, streamlining their workflow. With its compact design and diverse applications in cell culture, stem cell therapy, immunotherapy, and diagnostics, Cellpuri drives scientific progress and empowers researchers in various disciplines.

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analytical / test WINNERS

EUV N&K and Phase Measurement Tool EUV Tech The EUV N&K and Phase Measurement Tool is an angle-resolved spectroscopic reflectometer for the precise measurement of optical properties of thin films using an actinic laser-produced plasma light source.

Before the development of this tool, such measurements were only possible at a handful of arena-sized accelerator-based light sources (synchrotrons) at massive, expensive government research facilities.

This constraint made producing EUV phaseshift masks in high-volume amounts nearly impossible. However, this new EUV N&K and Phase Measurement Tool creates a cost-effective pathway for the high-volume production of phase-shift masks with the added benefit of allowing the continued scaling of EUV Lithography tools.

FusionScope Quantum Design Microscopy FusionScope is the first true correlative microscopy platform designed from the ground up to seamlessly add the benefits of SEM imaging to a wide range of AFM measurement techniques inside one vacuum chamber. An innovative shared coordinate system automatically aligns AFM and SEM operations for measurement and sample positioning within a single software interface. Users can easily identify the area of interest, measure the sample, and combine the data in real-time, which was partly impossible in the past. In addition, the FusionScope Cantilever Technology is based on self-sensing cantilevers that allow for high-quality, low-noise detection of different surface properties without optical alignment.

Intelligent Radio Frequency Ablation is a Highly Effective and Precise Radiofrequency Ablation Technology ITRI The advantages of radiofrequency ablation (RFA) over remission are fewer wounds and reduced risk of postoperative bleeding. However, various phenotypes and locations of liver tumors are challenging to the surgeon performing this minimally invasive procedure. ITRI’s iRFA considers both effective and precise ablation needs and is the first RFA system integrating radiofrequency ablation with ultrasound imaging.

Its adjustable electrode needle treats tumors of various sizes and locations and increases the effectiveness of tumor therapy with a closed-loop ablation control mode. It also has real-time imaging navigation and monitoring during the entire ablation procedure to achieve the precision tumor target and postoperative evaluation.

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High Throughput Sequencer DNBSEQ-T20×2 MGI and Complete Genomics

DNBSEQ-T20×2 was developed to make affordable whole genome sequencing (WGS) available, enabling individuals to sequence their inherited genomes for genetic mutations. At less than $100 per genome, scientists and medical doctors will be able to switch from partial genome analysis, such as WE7S, to whole genome analysis. Additionally, it will enable broader use on a larger number of samples and deeper sequencing per sample to get more informative results in genome sequencing, deep cell-free DNA sequencing, or yearly gene expression monitoring in thousands of single cells per person. Now many more samples can be sequenced, or deeper, more informative, and accurate sequencing can be afforded per sample.

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analytical / test WINNERS

NACHOS: NanoSatellite Atmospheric Chemistry Hyperspectral Observation System

MAVEN, New Glucose and Lactate On-Line Device for Bioprocess Monitoring and Control 908 Devices The online MAVEN device precisely measures glucose and lactate while preserving sample integrity. It eliminates manual sampling from a bioreactor with its novel aseptic sampling approach, which saves operator time, reduces contamination risk, and preserves expensive media and product.

MAVEN is GMP-compliant, has a small footprint in any lab, and is incredibly easy to use. In addition, its ability to precisely monitor nutrient and metabolite concentrations even at very low levels makes it particularly beneficial to cell therapy applications where tight control of cell culture conditions is vital. As more advanced therapies enter the pipeline, there is an increasing need for simple, automated online devices like MAVEN for measuring and monitoring critical process parameters and product quality attributes.

MockV RVLP Kit Maravai LifeSciences Viral contamination is an inherent risk during the manufacture of biopharmaceutical products. Demonstrating retroviral clearance is a regulatory requirement, but the process is expensive, timeconsuming, and requires specialized CRO facilities. Because of these constraints, viral clearance analysis is often delayed until the later stages of process development, resulting in an increased potential for validation failure and redevelopment expenses. The Cygnus MockV RVLP Kit circumvents this paradigm by using a non-infectious retrovirus-like particle (RVLP) spiking agent, enabling companies to perform these viral clearance tests at their own laboratory benches for a fraction of the cost of a live study.

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Los Alamos National Laboratory The NanoSatellite Atmospheric Chemistry Hyperspectral Observation System (NACHOS) is a novel CubeSat-based hyperspectral imaging system that detects harmful gases from space. Until now, this capability was provided exclusively by exceedingly large and expensive satellite systems. NACHOS offers revolutionary advances in size, weight, power, cost, single-pixel spatial resolution, trace-gas sensitivity, and data latency. It is the first hyperspectral imager flown on a CubeSat platform the size of a breadbox. Its unique design is over fifty times smaller and lighter and over ten times less power-hungry than existing technologies.

NACHOS’ onboard processing capability analyzes raw data on board the CubeSat using computationally efficient hyperspectral analysis algorithms.

NanoPak-C-SPE — Electrochemically-Controlled Selective & Rapid Solid Phase Extraction Millennial Scientific NanoPak-C-SPE is the first commercially available product that employs electrochemical modulation to alter the analyte’s retention onto electrically conductive carbon microbead substrates.

The conductive stationary phase material’s interfacial properties, such as surface charge and oxidation state, are tweaked by a voltage. This capability allows the stationary phase’s composition to be tuned before or during the extraction, thus manipulating the interactions between the stationary phase and analytes. The product’s innovative features allow tunable selective extraction of aromatic or charged small or large molecules. These molecules could be bioactive or interfering nuisance compounds; thus, the NanoPak-C-SPE could be used as a trap or guard cartridge.

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analytical / test WINNERS

Noncontact Laser Ultrasound (NCLUS) for Medical Imaging MIT Lincoln Laboratory Co-Developers: Massachusetts General Hospital (MGH) Center for Ultrasound Research Translation (CURT), and Sound & Bright

NCLUS is a novel laser system that acquires ultrasound images from human tissue without patient contact. It intended to mitigate operator variability; provide a fixed reference for comparing repeat scans over time; fully automate ultrasound image data acquisition; reduce the need for a sonographer; and transmit ultrasound in any array locations desired. NCLUS is designed for multiple applications: anatomical imaging, bone elastography, and disease feature tracking.

NCLUS systems could compete with MRI and CT while greatly reducing system cost and complexity, providing portability, and increasing patient throughput. Such systems would greatly expand the role of accurate imaging capabilities outside the hospital center and enable numerous new medical ultrasound applications.

OpeN-AM: A Platform for Operando Neutron Diffraction Measurements of Additive Manufacturing Oak Ridge National Laboratory OpeN-AM is a platform for performing operando neutron diffraction studies during metal additive manufacturing (AM) to address challenges associated with residual stress.

The platform consists of a deposition head, machining capabilities, and optical and infrared (IR) monitoring, all of which may be coordinated with neutron diffraction measurements at the VULCAN beamline at ORNL’s Spallation Neutron Source (SNS). Many motion axes offer a large degree of freedom to design experiments, which may be augmented by machine learning and automated processes using the open-source control system. This combination of capabilities provides unprecedented insight into the evolution of phase transformations and stresses during AM processing.

Physics-Informed, Active Learning–Driven Autonomous Microscopy for Science Discovery Oak Ridge National Laboratory There are multiple challenges to developing autonomous microscopy. It requires a balance between the workflows, development of task-specific machine-learning methods, understanding of the interplay between physics discovery and machine learning, and end-to-end definition of the discovery workflows. Researchers at Oak Ridge National Laboratory have developed a physics-informed, active learning (AL)-driven autonomous microscopy, which enables active autonomous discovery of physics during real-time experiments. This product is universal to any microscopic technique and can be adapted for application in other experiments, such as chemical syntheses and battery lifetime testing. The software suite comprises active learning algorithms and control software for microscopes and other experimental tools that expedite scientific discovery.

Pre-Symptomatic VOC Detector of Seizure Events Sandia National Labs Co-Developer: KNOW Biological Sandia National Laboratories and KNOW Biological have collaborated on pre-symptomatic detection of a seizure event using Volatile Organic Compounds (VOCs), which recent research has highlighted as biomarkers of specific health events or diseases. This portable and wearable detector identifies specific skin-emitted VOCs that indicate an imminent seizure. The instrument comprises several micro-electromechanical system (MEMS) devices made in Sandia’s silicon microfabrication facility. To simplify operation, researchers envision that the device will constantly sample VOCs emitting from the wearer’s skin. This pre-symptomatic VOC warning would enable the wearer to prepare and communicate with family and healthcare providers before the seizure occurs. It would dramatically improve the lives of those suffering from epileptic seizures.

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LOS ALAMOS NATIONAL LABORATORY

Solving National Security Challenges through Scientific Excellence

R&D 100 Awards and Special Recognition Awards FABIA: Fieldable Atomic Beam Isotopic Analyzer FEVER: Fast Evaluation of Viral Emerging Risks GRID-BAL: Grid Regulation Delivered by Aggregations of Loads Partners: University of Michigan, University of California-Berkeley, Pecan Street, Inc. HXI: Hyperspectral X-ray Imaging Detector Partners: National Institute of Standards and Technology (NIST) and University of Colorado-Boulder NACHOS: Nano-satellite Atmospheric Chemistry Hyperspectral Observation System Ordered Key-value Computational Storage Device (KV-CSD) Partner: SK hynix PowerModelsONM: Optimizing Operations of Networked Microgrids for Resilience Partners: National Renewable Energy Laboratory, Sandia National Laboratories, National Rural Electric Cooperative Association Rapid Response Steel Tooling using Additive Manufacturing Solution-processed Perovskite Crystalline films (SPeC) CANDLE (Cancer Distributed Learning Environment) Argonne National Laboratory led, Partners: Lawrence Livermore National Laboratory, Oak Ridge National Laboratory, Los Alamos National Laboratory, Frederick National Laboratory for Cancer Research For more information on scientific partnership and licensing opportunities, contact the Los Alamos National Laboratory Richard P. Feynman Center for Innovation P.O. Box 1663, Los Alamos, NM 87545•505-667-5061•www.lanl.gov. An Equal Opportunity Employer managed by Triad National Security, LLC for the U.S Dept. of Energy’s NNSA for DOE and NNSA.

rd_lanl_dbl_pg_sprd_2023.indd 1

Accelerating Partnerships for Commercial Impact The Laboratory’s Feynman Center for Innovation is developing new ways to connect with partners to meet our national security science mission.

PIONEERING PAST

Los Alamos has an 80+ year legacy of revolutionizing the nation’s understanding of science and engineering.

Photo Courtesy of Kitty Oppenheimer and the J. Robert Oppenheimer Memorial Committee.

INNOVATIVE PRESENT

Our most inspired minds are making revolutionary contributions in fields from satellites to cancer reseach, from materials to energy.

VISIONARY FUTURE

Los Alamos continues to transition scientific ideas into technologies for real world applications.

Visit our website www.lanl.gov/feynmancenter to explore the wide variety of technologies available.

www.lanl.gov/feynmancenter (505) 665-9090

Los Alamos National Laboratory is proud to be a part of the R&D 100 Innovation Network.

LA-UR-23-31054

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analytical / test WINNERS

Revio Sequencing System Pacific Biosciences With the accuracy of short-read DNA sequencing and the utility of longread sequencing, Revio Sequencing System leverages HiFi sequencing technology to sequence entire human genomes, telomere-to-telomere, with 100% accuracy. A single Revio instrument has the bandwidth and speed to sequence 1,300 HiFi human genomes in a year. The combination of high accuracy and complete characterization of complex genomes empowers researchers and scientists to address challenges in agricultural genomics, conservation, genetics, cancer research, human health, and disease research, microbiology, and infectious diseases with increased accuracy and speed, driving the field forward. Revio Sequencing System offers a complete assembly of complex genomes, accurately constructing the full sequence of chromosomes, including centromeres and telomeres.

TESCAN TENSOR: The World’s First Integrated, Precession-Assisted, Analytical 4D-STEM TESCAN The TESCAN TENSOR is the world’s first integrated, precession-assisted, analytical 4D-scanning transmission electron microscope (4D-STEM) designed with usability in mind. The microscope frees researchers to interact with samples instead of microscopy optics. This is achieved by implementing “measurements” with preset optical properties such as beam current, convergence angle, spot size, and precession on or off adjusted and aligned automatically. The result is an analytical 4D-STEM microscope that is as easy to use as TESCAN scanning electron microscopes (SEMs), with all the efficiency and benefits of a results-driven electron microscope. This approach also potentially yields economic benefits, such as better accessibility for novice users, leading to more frequent tool use that ultimately supports a rapid return on investment.

Thermo Scientific DynaSpin Single-use Centrifuge Thermo Fisher Scientific The DynaSpin Single-Use Centrifuge was created to more efficiently and effectively separate proteins and antibodies from their cells as part of the vaccine and therapy development. It is a continuously operated single-use centrifuge that implements established disc stack principles in a novel single-use format, facilitating efficient separation of cell culture harvest material.

The material is continually fed, separated, and discharged through the DynaSpin Single-Use Centrifuge. Intuitive automation enables end users to constantly monitor and control processes in real time, allowing the most efficient use of manufacturing resources and increasing process quality. Its state-of-the-art filtering system reduces plastic waste, decreases run costs, and minimizes operational and warehousing footprints.

Thermo Scientific Orbitrap Ascend Tribrid Mass Spectrometer Thermo Fisher Scientific With new capabilities for multiplexed quantitative proteomics and native protein characterization, the Thermo Scientific Orbitrap Ascend Tribrid mass spectrometer delivers ultimate experimental throughput and versatility. Users can quantify more samples at lower concentrations, achieve greater coverage, and characterize the largest biopharmaceuticals with an optional mass range of up to m/z 16,000. The spectrometer combines versatility and usability with the exceptional performance afforded by its built-in intelligence and revolutionary Thermo Scientific Tribrid architecture to deliver an instrument designed to address the most difficult analytical challenges. These features make this instrument uniquely suited for accurate and high-throughput full-proteome quantitation, characterization of complex peptide and protein mixtures, small molecules, and deciphering higher-order protein structures.

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analytical / test WINNERS

Unique Eye Drop Formulation for Glaucoma Therapy ITRI

Glaucoma, a leading cause of blindness, requires effective control of intraocular pressure (IOP) to prevent optic nerve damage. Traditional eye drop treatments have limitations, including side effects and drug resistance. ITRI’s dual-target eye drop surpasses existing medications with three times the efficacy and low side effects, improving patients’ quality of life and simplifying treatment.

The unique eye drop provides a breakthrough solution by synergistically targeting trabecular meshwork blockage, improving aqueous humor drainage, and preserving optic nerve integrity.

This innovative medication provides glaucoma patients with a safer and more effective treatment option, addressing the need for diverse mechanisms of action and better safety profiles in glaucoma management.

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We are honored that Revio is one of the R&D 100 winners for 2023!

Thank you, R&D World for this prestigious recognition.

Revio is a game-changer for the genomics industry and we’re excited to see what scientific discoveries will be made using our new high-throughput, long-read sequencing system.

it/electrical WINNERS

A 250 kW All Silicon Carbide Motor Drive for Hybrid Electric Aircraft University of Arkansas Power Group

The motor drive for hybrid electric aircraft represents a leading-edge application technology based on wide bandgap (WBG) power semiconductor technology. It contains breakthroughs in performance, power density, integration, and thermal management contained.

WBG semiconductors like SiC promote high power density that enables increased range from electric vehicles. This is the first application of this technology to hybrid aircraft that has succeeded all the way to flight validation. The impact of these drives will be to inspire further research and development into electric planes and other forms of transportation, reducing greenhouse gas emissions, and addressing climate change concerns.

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Cerberus: Cybersecurity for EV Charging Infrastructure Idaho National Laboratory Researchers anticipate a large network of EV charging equipment to be an attractive target for adversaries or criminal enterprises. The Cerberus system — relying on basic sensors and computer hardware linked together in a smart configuration — sharply limits or sometimes eliminates damage to assets and human health. Recent work demonstrated that high-power EV charging infrastructure is, in fact, vulnerable to hackers and that Cerberus has a strong ability to detect signs of tampering. It detects malicious exploits by blocking them, limiting their damage, powering down if necessary, and quickly restoring full operational capabilities. Cerberus lends much-needed resilience to fast-charging systems.

High Performing Dual Phases Nano Immersion Coolant for 5G Servers Nano and Advanced Materials Institute NAMI’s dualperforming coolants, based on segregated fluorination technology, with specific operating temperature, high heat of vaporization, specific heat, and thermal conductivity, can overcome the drawback of high-power usage effectiveness (PUE) of single-phase cooling and the high maintenance cost of a twophase cooling system. Through molecular engineering, NAMI can achieve high heat of vaporization of over 150 kJ/kg, high specific heat capacity of over 1500J/kgK, and higher thermal conductivity of up to 0.1W/mK. The coolant is chemically robust with high material compatibility. Immersion cooling also offers the chance for servers to operate in a more energy-saving direction, reducing the energy footprint by up to 50%, as well as low global warming potential (GWP) and zero ozone depletion potential (ODP) levels to minimize environmental concerns.

Intelligent Pillow for Healthy Sleeping Nano and Advanced Materials Institute Nano and Advanced Materials Institute (NAMI) has developed Pillooo, a pillow designed to ease neck discomfort and chronic fatigue during sleeping. It automatically adjusts shape based on a contact pressure map collected through a flexible sensor mat that captures pressure on the neck and head area. The sensor mat is a column-row structured matrix sensor array consisting of three layers of soft fabric placed on a pillow surface. It measures pressures at hundreds of points on the pillow surface simultaneously, providing the pressure map indicating the hot spots of pressure. Sleeping postures, such as back sleeping or side sleeping, can be identified based on the pressure map and a program on an MCU controller.

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it/electrical WINNERS

Joint Communication Architecture for Unmanned Systems (JCAUS) Security/ Cyber Module End Cryptographic Unit MIT Lincoln Laboratory

Ordered Key-value Computational Storage Device (KV-CSD) Los Alamos National Laboratory Current methods for scientific data analysis fall short by consuming excessive ORDERED KEY-VALUE COMPUTATIONAL amounts of time and computational STORAGE DEVICE (KV-CSD) resources. Moving applications to keyvalue-oriented I/O and incorporating advanced hardware and software-based computational-storage techniques, the KV-CSD reduces the amount of time required for the analysis of output from a supercomputer simulation by a factor of 183 when experimenting at a small scale, and that figure is expected to grow to 1000 when large experiments are conducted. Offloading data reduction and other resourceintensive operations to the KV-CSD storage system maximizes the efficiency of data retrieval and reduces the total amount of data unnecessarily passed between storage and computational components. This technology can be paired with existing key-value applications to benefit many areas of computing.

2 0 2 3 R & D 10 0 J O I N T E N T R Y

The JCAUS SCM ECU transforms the development landscape for uncrewed systems that handle sensitive information. It opens the tradespace to small and emerging businesses, which are often sources of innovation.

It is the first crypto device to provide highly secure communications for a wide range of uncrewed systems within the JCAUS architecture, which the DoD officially standardized in 2022. Adherence to JCAUS means the SCM is built on industry standards for easy integration with commodity hardware and delivers a strong set of well-thought-out capabilities for future use cases.

These capabilities include innovative key management for secure encryption of classified data without keyfill using a certificate-based key-distribution scheme, remote unlock, and a configurable bypass function to decouple the crypto from the radio.

FPO SAFE AREA R&D 100 Award Sticker

Revolutionary information storage hardware efficiently records, sorts, and indexes supercomputer simulation output to streamline big-data analysis

PRODUCES a billion-fold reduction in unnecessary data movement

SLASHES the time to scientific insight

PROVIDES needle-in-a-haystack identification of phenomena of interest

INDEXES multitrillion-particle and other petascale datasets SUPPORTS multidimensional point and range queries

Scalable Photonic Quantum Memory Module

SCHOTT TO PLUS headers

MIT Lincoln Laboratory

SCHOTT

The Scalable Photonic Quantum Memory Module is the first to combine, into a single module, the three capabilities required for networking together quantum systems: a photonic interface, efficient heralded operation, and scalable architecture. This is achieved by using silicon-vacancy color-center technology — a promising technology that has a photonic interface and can operate in an efficient heralded manner. The module incorporates both a novel integrated photonics interposer and a novel packaging process that scales eight quantum memories into a single module. This modular architecture can be further scaled by using multiple modules. The resulting quantum memory is the first that combines all required capabilities needed to network together spatially separate quantum systems.

SCHOTT TO PLUS is a transistor outline (TO) header packaging solution that enables unprecedented transmission speeds for fiber-optic data transmission.

Hermetically sealed with glass-to-metal sealing technology, SCHOTT TO PLUS headers deliver twice as much data over a single fiber than existing technology while being more economical. The headers unlock an unprecedented delivery of 50 GB of data per second over a single channel. This means more customers can be supplied with data on an existing line than ever before, enabling telecommunications providers to bring optical fibers to the end consumer at a low cost.

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it/electrical WINNERS

The Cryo-FE: A Near-Monochromatic Tuneable Cryogenic Niobium Electron Field Emitter for Ultra-High-Resolution Electron Microscopy and Spectroscopy Lawrence Berkeley National Laboratory Co-Developer: National Renewable Energy Laboratory The Cryo-FE represents a quantum leap for the electron sources used in electron microscopy and spectroscopy. This innovation enables new advances in materials science, solid-state physics, biology, chemistry, and industrial applications, such as vibrational spectroscopy, high-resolution electron energy-loss spectroscopy (EELS), low-energy electron microscopy (LEEM) with ultra-low aberration, the detection of defects in semiconductors with sub-nanometer resolution, and quantum electron microscopy. The CryoFE leverages the properties of superconducting niobium and the quantum confinement produced by an innovative nanoscale tip design to produce an electron beam with an unprecedentedly narrow energy distribution down to 16 meV — 10 to 20 times better than the best commercial sources.

Transformer Watchman National Energy Technology Lab Co-Developer: University of Pittsburgh Sensible Photonics The Transformer Watchman is a simple-touse and integrated measurement system that monitors large power and distribution transformers and reports on the health of these critical components. It is an optical fiber-based sensor system with several key measuring devices to check transformer health in real-time. Transformers fail when overheated or when insulating oil degrades, so temperature monitoring and dissolved gas analysis (DGA) for the insulating oil are critical for transformer health monitoring. With Transformer Watchman, system operators have real-time distributed temperature measurements, vibration data, and most importantly, dissolved gas concentrations in real-time. The system’s AI-driven data engine then reports on the current health of the transformer system.

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Wearable Thin-Film Thermoelectric Cooling Device (TFTEC) for Prosthetics and Haptics The Johns Hopkins Applied Physics Laboratory State-of-the-art prosthetic limbs that can restore near-natural hand and arm control for people living with the loss of limb and limb differences have long been the dream of researchers.

Researchers at The Johns Hopkins APL have developed the wearable thin-film thermoelectric cooling (TFTEC) device, one of the world’s lightest, thinnest, and fastest refrigeration devices. The devices’ low profile and lightweight nature — resembling an adhesive bandage — make them suitable for skin surface applications without weight or volumetric hindrances that could affect movement. The device’s reliability, intensity, size, and efficiency offer a world of possibilities, from revolutionizing prosthetics to enabling enhanced virtual and extended reality applications, pain management, neuromuscular disease remedies, and beyond.

Wideband Conformal Continuous-Slot Antenna Array Southwest Research Institute (SwRI) SwRI’s novel AS-750 family of Wideband Continuous-Slot Antenna Arrays offers UHF/ SHF capabilities without experiencing the grating lobes that plague modern higherfrequency direction-finding antenna arrays.

They provide beamformed omnidirectional acquisition and direction-finding outputs for signal intelligence processing. It is the first practical implementation of the current sheet concept, initially proposed in the mid-20th century and until now largely relegated to theory. The low-profile system is seven inches in height with up to an 18-in. diameter when installed in sections conformed around a ship’s mast. It offers an alternate and viable approach from traditional antennas’ that must be mounted to the very top of a mast to achieve high performance at higher frequencies.

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it/electrical WINNERS

Wrinkle-Free, Flexible, and High Contrast Screen for Portable Display Nano and Advanced Materials Institute Co-Developer: Arovia Hong Kong Ltd. A wrinkle-free, flexible, and high-contrast screen, for the world’s only collapsible, large, and portable display shows a 24.5-inch image with 2K high resolution that seamlessly expands and folds away in just seconds. The whole display weighs only 2.5 lb and folds to the size of a book, making it suitable for anyone on the go. It has broad applications in various scenarios, for example, a dual or portable display for work or personal use. It can be used at trade shows, coffee shops, presentations, or for camping, gaming, or around the house when cooking, teaching, or relaxing.

Smarter Surfaces for a Better World

mechanical / materials WINNERS

5-tonne per day (TPD) CO2 Capture from Blast Furnace Gas Tata Steel Ltd. To decarbonize the steel industry globally and in a growing country such as India, an economical solution for capturing and using CO2 at scale is essential. The collaborative approach of Tata Steel and Carbon Clean enabled co-development and installation of a first-of-its-kind plant for CO2 capture from blast furnace gas. This process generates the highest purity CO2 (>99% purity) at lesser OPEX which can be converted into value-added products, such as methanol and mineral carbonates. Captured CO2 is used for in-house wastewater treatment to promote a circular carbon economy.

80° F Thermostatic Microcapsules Ultra-fine Fiber Leather Taiwan Textile Research Institute (TTRI) Researchers at TTRI have developed temperature-regulated leather material by combining two waterbased elements: microcapsule technique and water-based long-fiber foundation fabric. The former can regulate temperature by keeping or releasing heat to maintain an ideal skin temperature of 80° F (27° C) on average; the latter can provide softness and sturdiness to the leather material. The manufacturing process is zero-VOC, specially designed for products with prolonged skin contact.

This material has a wide range of application potential for household, automotive, and headphone products.

Acousweep The Hong Kong Research Institute of Textiles and Apparel Ltd. (HKRITA) Microplastic pollution threatens marine ecosystems and human health. Despite existing filter systems, their processing generates other environmental issues: the use of plastic materials to produce membrane filters, filter disposal, energy consumption in filtration system suspension and restarting, and the release of chemicals into the water.

Acousweep aims to develop a new approach to improve the existing filter system. Sweeping acoustic waves to separate microplastic in water is innovative and sustainable, considering both separation effectiveness and environmental performance. The integrated system with a specially designed separation chamber to handle 100 L of water can tackle microplastic pollution.

A Continuous Hot-Roll Process to Manufacture Nanograin Neo Magnet Oak Ridge National Laboratory Powerful Nd-Fe-B-based magnets are essential for wind turbines and EV applications.

These magnets require additions of the critical element Dy to function at elevated temperatures. Though nanograin Nd-Fe-B magnets may function the same as Nd-FeB-Dy magnets, the current manufacturing process for nanograin Nd-Fe-B magnets is too expensive to be widely used. ORNL’s novel hot-roll process addresses the shortcomings in nanograin magnet production by implementing the deformable die concept. This simplifies the traditional hot-press densification and hot-deformation texture development process into one continuous process. It also eliminates the need for expensive tools and furnaces and dramatically improves productivity.

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mechanical / materials WINNERS

Additive Manufactured Cutting Tool for Precision Machining

Aquair University of Maryland, College Park By engineering an atmospheric water harvesting technology that collects and produces water from the air without electricity, researchers at the University of Maryland have developed a safe and reliable solution for obtaining drinking water and addressing water scarcity when access is limited. The eco-friendly biomass-based composite enables efficient water harvesting from the air across a wide range of humidity and temperature conditions. Notably, this technology uses solar energy conversion directly to facilitate water harvesting, eliminating the need for complex operating systems, space-occupying units, and intricate installations. Additionally, the portability of Aquair technology allows for water moisture absorption in both stationary and mobile units, offering on-the-go water harvesting capabilities.

Kennametal Inc.

Kennametal has developed a new class of additive manufactured tools using innovative lightweight structures to increase the stiffness-to-weight ratio, reducing mass and increasing machining performance for challenging applications. The innovative cutting tool was engineered with numerical refinement techniques and finite element analysis simulation. These techniques made it possible to easily create a complex, highly refined design that resembles natural structures and maximizes the specific stiffness for such large diameters. This novel approach was proven in real-life mass production, achieving a 50% reduction in machining time while significantly improving the tool handling and maintaining the demanding geometric and surface tolerances on the workpiece.

BETAMATE Broad Bake Adhesives for Sustainable Mass Manufacturing of Battery Electric Vehicles DuPont OEMs are increasingly shifting focus toward fully electric vehicles and sustainable manufacturing processes. One complex automotive challenge is the high, energy-demanding oven process temperatures needed to cure crash-durable adhesives. These adhesives have become a pivotal technology in body structure, enabling lightweighting, increasing vehicle longevity, and drastically improving passenger safety.

DuPont BETAMATE broad bake adhesives cure already at 25° C lower temperatures than stateof-the-art adhesives and even shorter oven cycle times, enabling e-coat oven temperature reduction at OEMs and significant energy saving.

Bio-inspired Silicone Sealant for Wet Surface Adhesion Nano and Advanced Materials Institute Inspired by mussels adhering to wet rocks, NAMI has invented a catechol-grafted silicone sealant with excellent bonds on hard-to-attach surfaces. The unique catechol groups in the silicone sealant system designed by NAMI can repel water molecules and form strong chemical covalent and physical electrostatic bonds on wet surfaces. In particular, the adhesive strength on the wet substrate of NAMI’s bio-inspired silicone sealant can achieve more than 0.5 MPa, while commercial silicone sealant performance is less than 0.15 MPa. NAMI’s bio-inspired silicone sealant also has good flexibility with a movement capability of ±50%, good durability, and long-term resistance to ultraviolet radition, high and low temperatures, and outdoor exposure.

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mechanical / materials WINNERS

Closed-loop System for PI Film Manufacturing Processes that 99% of VOCs are Recycled and Reuse Taimide Tech Co-Developer: Industrial Technology Research Institute (ITRI) PI film manufacturer Taimide Tech teamed with ITRI to implement an in-plant close loop system that follows the 3 Rs (reduction, reclamation, and recycling) principle. The VOC-3R System was implemented on Taimide’s site and achieved a remarkable result with a >95% solvent recovery rate and a total of 99% VOC exhaust gas reuse rate. There is no direct carbon emission and there is zero wastewater discharge. In 2022, Taimide had an annual production capacity of about 1,200 tons and recovered 7652.3 metric tons of reusable solvent, which had a market value greater than $16 million. Its annual purchase of new solvent was reduced by 90%, a multimillion-dollar saving. The return on investment for the facility installation is three years.

Critical Rare Earth Free Cerium Gap Magnets Critical Materials Institute, Ames National Laboratory Co-Developer: BUNTING-DuBois Permanent magnets, a key component for electrification, are crucial for a sustainable green economy. However, there is a disconnect among presently available permanent magnets as they often fit either high- or low-energy applications. The Cerium Gap Magnet represents the next generation of permanent magnets with affordable pricing and performance that will satisfy a wide range of middle energy applications. The magnet can be processed effectively in the U.S., making it less supply-dependent, and it does not use any critical rare earths. This magnet frees up critical neodymium and dysprosium from their current middle energy applications, mitigating the existing supply risks and accelerating the transition to green energy.

DuPont Styrofoam Plazamate XR Extruded Polystyrene Foam with 30% Higher Thermal Resistivity DuPont de Nemours, Inc., Water and Protection, Performance Building Solutions Styrofoam Brand Plazamate XR has the highest thermal resistance (R) per inch of any extruded polystyrene (XPS) roofing insulation (6.7 R/in). This means 30% more thermal resistance in every inch of its thickness compared with typical XPS insulations. This reduces assembly thickness and increases design flexibility while meeting critical needs in height-constrained roof replacement and new construction conditions that require XPS’ moisture resistance. With Plazamate XR, fewer layers and an overall lower volume of insulation may be required to achieve the code-mandated roof insulation (R-values), resulting in labor savings, shipping and handling less material, and waste reduction.

Dual-Purpose Impact Dissipating Bollard for Road Safety Nano and Advanced Materials Institute NAMI’s dual-purpose impact dissipating bollard (IDB) is the world’s only product that achieves the dual objectives of being both the highest occupant safety and effective in stopping moving vehicles by leveraging its bioinspired smart high-impact dissipating material. The performance of NAMI’s IDB against the moving errant vehicle is certificated

by PAS 68 collision testing and able to stop a 7.5-ton truck at a speed of 48 km/h while attaining Class A of impact severity level, which is the highest safety level of the vehicle occupants. Furthermore, its compact design with a shallow foundation makes it suitable for both road sections and urban regions.

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NARI National Atomic Research Institute

https://www.nari.org.tw/english/ Nuclear safety and nuclear backend Radiation applications for people’s livelihood New energy and system integration

The advertising budget comes from the National Science and Technology Council(NSTC), Institute of Nuclear Energy Research was transformed and reorganized into the Independent Administrative Institution "National Atomic Research Institute" starting from September 27, 2023.

PHAs-based bioplastic: an eco- friendly alternative to mitigate marine plastic pollution PHAs (Polyhydroxyalkanoates)-based bioplastics are one of the most promising alternatives to traditional petroleum plastics and they are aliphatic polyesters produced from renewable feedstock. Compared to other plastics, PHAs bioplastics has good marine biodegradability and are synthesized directly via fermentation of a carbon substrate inside a microorganism. A variety of PHAs with different structures are produced depending on the types of bacterial species and carbon source provided.

NARI (National Atomic Research Institute) uses high-throughput screening system, micro-fermenter and ton-scale fermenters with competitive PHAs fermentation performance to speed up R&D progress. The cell dry weight (CDW) is 65.2 g/L with stable PHAs content of 43.2%, which is better than the results of international literature.

PHAs bioplastics have various applications in industries such as food packaging, agriculture (e.g., mulching film) and medicines (e.g., wound grafts, and artificial membranes for kidneys). With PHAs bioplastics, the reliance on non-renewable resources can be reduced and the carbon footprint can also be minimized.

The Sustainable production process of PHAs

Development of key technologies for flow battery

Flow battery is promising for large-scale energy storage and has characteristics of high safety, long lifetime, high design flexibility, easily recycled material, no fire/explosion probability, and separated design for storage power and capacity. NARI developed the following technologies to enhance flow battery performance and the possibilities of commercialization.

Electrodes with high efficiency : The hydrophilicity and electrochemical reactivity of the electrode can be increased by atmospheric plasma technology-based modification, which improving the energy efficiency and battery capacity by 5% and 20%, respectively. The capacity degradation rate can be reduced by 20%.

Integrated battery cell : The integrated design of bipolar plates and frame reduces assembly contacts and improves processing convenience. The mold hot press forming technology was used to replace the CNC (computer numerical control) processing mode to reduce mass production cost in the future. The flexible composite bipolar plates instead of hard pure graphite plates was used. Overall costs can also be reduced by over 20%.

VRFB stack with high efficiency : The integrated structure design of bipolar plates and frame greatly improves the sealing performance and reduce the leakage possibility. The battery cell is reduced from 10 mm to 5.6 mm, with the volume power density reaching 40 kW/m3 (+50%).

Electrodes with high efficiency

Integrated battery cell VRFB stack with high efficiency

TRODAT-1 precursor preparation for the diagnosis of Parkinson's disease using AI retrosynthesis

Chemical retrosynthesis analysis is a technique for planning the synthesis of target molecules. The target molecules are first analyzed through recursive analysis with a search tree and are gradually disassembled into precursors with simpler structures until the obtained molecules are commercially available.

The AI (artificial intelligence) system uses a DNN (Deep neural network) model combined with Monte Carlo tree search (MCTS), referred to as 3N-MCTs for chemical retrosynthesis analysis. The chemical reactions and basic molecular database, which proposes a suggested scheme for the retrosynthesis of the target molecule, each of which has a patent or literature basis therefore guarantees the data accuracy.

Parkinson's and Alzheimer's disease are two major neurodegenerative diseases for the elderly, emphasizing the necessity for developing related diagnostic drugs. NARI used the aforementioned AI retrosynthesis to prepare the precursor TRODAT-1 with total yield increased by 4.2% compared with the original process, and purity improved more than 98%. The AI application in chemical retrosynthesis will open up a new direction for NARI in the research and development of nuclear pharmaceutics. (a)

(b)

PET scans of (a) normal brain; (b) brain with Parkinson’s disease

Contributors for NARI’s R&D 100 achievements NZ Bio Forestry: a company creates a unique platform with diverse components and specializes in the integration of using forestry resources with wood engineering and bio-refining with the chemical and petrochemical sectors.

Inspira: a company has expertise in wood processing and integrates forest industries with biotechnology to produce bio-chemical and bio-material that is sustainable and renewable.

mechanical / materials WINNERS

EASE: Ether-based Aqueous Separations and Extractions Idaho National Laboratory EASE uses a commodity chemical to recover valuable dilute minerals from aqueous wastes and other solutions. The EASE research team focuses the technology on three key processes: separating magnesium from seawater, recovering critical minerals from mine tailings, and extracting potassium nitrate from agricultural wastewater.

EASE could provide a more environmentally friendly means to produce magnesium. Critical elements not recovered in primary mineral extraction could also be reclaimed from mine wastewater. Lastly, the domestic supply shortage of fertilizers could be ameliorated by treating agricultural wastewater with EASE technology. In addition to its low energy consumption, EASE recycles the chemicals used in the process, avoiding additional waste production.

FABIA: Fieldable Atomic Beam Isotopic Analyzer

FilmTec Fortilife NF1000 Nanofiltration Membranes

Los Alamos National Laboratory

DuPont

The Fieldable Atomic Beam Isotopic Analyze (FABIA) is a portable instrument for conducting isotopic analysis of nuclear materials in the field. This device is an asset for energy production, global security, and nuclear medicine because of its small size, portability, and simplicity of operation. In the case of nuclear non-proliferation, the International Atomic Energy Agency inspects enrichment plants of signatory nations to ensure that uranium is being enriched only enough for nuclear energy purposes. FABIA can analyze samples right at the plant, immediately revealing whether uranium has been enriched beyond reactor-grade levels. In addition, FABIA is an invaluable tool to determine the purity of individual isotopes used in medicine, where it is important to analyze isotopes rapidly at the point of production.

The NF1000, a spiral-wound nanofiltration membrane, yields high water flux with exceptional high-pH durability while accomplishing challenging separations in high-pressure industrial wastewater applications. It combines the first-of-its-kind compaction-resistant support layer with the ultra-cross-linked polyamide selective layer and an element design for challenging waters.

This combination positions the product to majorly impact the sustainability of coal-tochemical, textiles, petrochemical, industrial power, and the steel and metals industries.

Other wastewater processes, such as landfill leachate and wastewater softening, also benefit from the low energy cost and high productivity of NF1000.

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Gravity-free Brassiere Using Bio-inspired Shock-absorbing Materials Nano and Advanced Materials Institute Co-Developers: Super Rich Moulders Ltd., Four K Knitters Ltd.

NAMI has developed an innovative material that emulates spider silk, offering both flexibility for comfort and resistance to movement.

The material features soft and hard segments, with the soft part providing elasticity and the hard portion delivering energy-absorbing capabilities.

This material can be made into various forms, including sponges for bra cups and elastomer bands for bra straps. The sponge cups provide cushioning that conforms well with the body while offering superior support during high-intensity athletic activities. Bra straps constructed with NAMI’s material can switch between soft and stiff states during rapid motion, improving breast support.

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mechanical / materials WINNERS

Greener, Faster, and Tougher Polyurea Gelcoat

High Transfer Efficiency Commercial Vehicle Coating System

PPG

Axalta Coating Systems

PPG’s Polyurea Gelcoat is a greener, ultra-low VOC, ultra-fast cure, oven-free, styrene-free, and peroxide-free gelcoat technology with environmental, energy-saving, and employee safety benefits.

It’s five times improved impact resistance reduces damage warranty claims, extends product life, and reduces landfill waste. The oven-free production process will save significant energy consumption. Without the use of styrene, peroxides, or other high vapor-pressure monomers, PPG’s Polyurea Gelcoat will enhance employee safety and eliminate styrene odors in plants and nearby communities. Yet the advantages do not sacrifice the product’s aesthetics. Compared to conventional gelcoat technologies, PPG’s Polyurea Gelcoat provides at least 10 units more gloss and three times better abrasion and chemical resistance.

This new vehicle coating system is a major step forward for commercial vehicle manufacturers in meeting their sustainability and productivity targets. It also enhances the coated surface’s appearance and expands color capability for the market. This technology meets several market megatrends in the commercial vehicle and heavy-duty truck market. It reduces solvent emissions through high transfer efficiency application and high solids coating formulations, thus promoting sustainability. It also improves process efficiency and manufacturing capability through a one-pass application process, thereby enhancing productivity. Furthermore, it improves the vehicle’s appearance by offering enhanced color capability with improved flake orientation.

Grid Regulation Delivered by Aggregations of Loads (GRID-BAL) Los Alamos National Laboratory Co-Developers: University of Michigan, Ann Arbor; Pecan Street Inc.; University of California, Berkeley Accommodating the variability of renewable sources requires impractical energy-storage systems, importing power from remote locations with significant losses in transmission, or building additional power generation. GRID-BAL is a unique grid-balancing innovation that exploits the flexibility of residential AC systems, modestly adjusting their on-off timing across large aggregations of ACs without affecting customer comfort. The low incremental hardware cost of about $30 per kW to connect houses is markedly preferable to the roughly $1,000 per kW to deploy battery storage for the same function. The GRID-BAL control method has been thoroughly stress-tested through simulation, laboratory experimentation, and field testing to greatly mitigate the adoption risk for power utilities.

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Highly Thermal Conductive Material for 5G and ADAS Application The Dow Chemical Company Advanced chipsets are crucial in tackling challenges related to 5G telecom, self-driving vehicles, and powering data centers. However, high-power processors often encounter thermal issues, such as overheating, due to their condensed packages and structures. To address this, DOWSIL TC-4083 offers a thermal technology based on patented silicone chemistry, representing a significant step forward compared to existing materials. It offers several benefits, including improved heat dissipation in harsh conditions; long-term retention of properties with patented stabilizers; controlled rheology with automated dispensing processes for high manufacturing efficiency; and low oil bleed and volatiles to avoid contamination with a designed cure network.

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mechanical / materials WINNERS

Hyperspectral X-ray Imaging Detector (HXI) Los Alamos National Laboratory Co-Developers: National Institute of Standards; University of Colorado HXI is a groundbreaking innovation in analytical instrumentation for analyzing electron microscope samples.

Its advanced technology enables detailed mapping of the chemical and elemental composition of matter at the nanoscale — something that has never been possible before. This type of analysis is especially important for samples with varying compositions on very small length scales and where macroscopic material properties depend on microscopic features. HXI is the first microcalorimeter-based detector to be deployed on an SEM with performance directly comparable to EDS detectors in both ease of operation and count rate capabilities.

INFICON Ion Reference Gauge IRG080

Innovative LNP ELCRES Resin: Enables Advancements in Renewable Solar Energy Industry by Achieving the Highest Electrical Tracking Resistance CTI0

INFICON Inc. Vacuum pressure measurement is crucial in advanced production and metrology.

Ionization gauges are versatile but lack standardization. The Ion Reference Gauge with plate number 1 sets a new standard in the ion gauge class.

It’s the first to comply with the new ISO TS 6737 norm, making it a suitable reference standard in the 1e-6 Pa to 1e-2 Pa range. The Ion Reference Gauge offers an unprecedented level of accuracy, repeatability, reproducibility, and long-term stability. It’s suitable for users of demanding processes requiring precise vacuum pressure measurement, particularly in advanced manufacturing, calibration, metrology, and standards transfer.

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SABIC The LNP ELCRES Resin is a breakthrough polycarbonate-based copolymer resin for photovoltaic (PV) connector bodies, meeting stricter performance and regulatory requirements for emerging 1.5 kV solar systems. It has superior properties, such as a high comparative tracking index (CTI) level (UL PLC0) and IEC as Material Group 1 (IEC MG 1). It also delivers low-temperature ductility, heat resistance, durability, weather resistance, and flame retardance. This specialty resin surpasses other materials, such as glass-reinforced nylon, PPE, and standard PC. It meets international standards for 1.5 kV components, making it easier to adopt in modern solar PV systems and offering practical benefits to designers.

MercLok P-640 Amendment for Mercury Remediation Albemarle Amendments Mercury is a highly hazardous element with acute and long-term human toxicity. It exists in elemental, ionic, and organic forms, cycling through air, water, and soil.

Industrial activities, including mining and chemical processes, have led to highly concentrated soil and water contamination. This widespread problem is currently managed by mechanical “dig and haul” methods and chemical treatments that provide temporary mitigation.

MercLok P-640 is a novel amendment poised to disrupt the remediation industry by providing a long-term solution to the mercury problem. The product has been field-tested with traditional remediation methods, such as soil mixing and permeable reactive barriers, and is effective at immobilizing multiple mercury species.

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mechanical / materials WINNERS

Micro-Foaming Pellets (MFPs) for Completely Closed-cell Foamed Bottles Nano and Advanced Materials Institute Co-Developer: Ace Plastic Ltd. Plastic pollution is a global crisis, yet it is difficult to replace plastic as a material for packaging bottles due to its low cost, lightweightness, and inertness. NAMI is dedicated to reducing the carbon footprint by developing MFPs. Through collaboration with Ace Plastic Limited, a supplier of packaging bottles worldwide, NAMI has reduced plastic consumption by more than 6,000 tons per year. The newly invented foamed EBM bottles are revolutionizing the industry by providing lightweight yet durable bottles that serve the same purpose. These foamed EBM bottles can also be customized into various shapes and sizes to serve different purposes using fewer plastics. NAMI’s Micro-Foaming Pellets enable the greener and more economical use of plastic packaging bottles.

Sustainable Ion Exchange Resin for Ultrapure Water Treatment DuPont Water Solutions

Solventless Antimisting SYL-OFF SL 184 Release Coating — Innovation Breakthrough Enabling Fast and Sustainable Label Market Growth DOW — Dow Performance Silicones The release coating industry heavily invests in high-speed production to improve productivity, cost, and sustainability.

However, the speed increase creates heavy misting, a major long-standing industrial issue. Combined with Dow’s cutting-edge release coating technology, the breakthrough SYL-OFF SL 184 Coating revolutionizes the PSA industry.

Mist suppression performance is 28 times lower than the industrial threshold, enabling unprecedented highspeed production (up to 1,600 m/min). This solventless coating, produced through an innovative solventless route, establishes a new sustainability benchmark by improving safety, reducing waste generation by over 20%, lowering overall energy consumption by 50%, and achieving 41% CO2 footprint reduction according to Full Life Cycle Analysis. Moreover, SYL-OFF SL 184 Coating complies with FDA/EU food regulations, setting a new benchmark in the release coating market.

A critical component of the chip manufacturing process is the ultrapure water used in a range of process steps, such as wafer cleaning, that are highly sensitive to impurities. H2O2 present in the UPW as a side product of UV treatment of organic impurities can cause problems, such as system components corrosion.

Removing H2O2 can be efficiently accomplished using the new DuPont AmberTec UP4000Pd OH, which enhances performance and improves the application’s sustainability. The significant reduction in palladium usage while maintaining the H2O2 removal performance directly results from the improved nanoparticle synthesis route used for this new resin, demonstrating a real benefit stemming from sustainable design.

Sustainable Low Emission Zero Degassing High Voltage Cable Insulation Compound Dow Inc. Dow Endurance HFDD-4201 is the best-in-class high-voltage insulation compound designed for underground and undersea power cables up to 500 kV. It is a novel, patented cross-linkable polyethylene formulation that provides over 70% reduction in methane byproduct versus incumbent materials.

Patented polyethylene molecular architecture and additive technology breakthroughs enable reduced peroxide levels through improved crosslinking efficiency. This effectively allows for the complete elimination of the degassing process by cable manufacturers, enabling inventory and energy cost savings and reducing byproduct chemical waste and emissions. This is achieved while also enabling a step-change increase in run length without sacrificing the other critical and challenging properties required for high-voltage insulation.

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process / prototyping WINNERS

Electro3D

Electrochemical Machining System for Intelligent Electrode with Three-Dimensional Variable Curvature (EMS)

Sandia National Laboratories (SNL)

Metal Industries Research & Development Centre (MIRDC)

Electro3D was created to enable a new electrochemical metal 3D printing method. It reduce barriers to using water and nonaqueous electrolyte feedstocks and opens the door to a wide range of possibilities from novel material combinations. Previously, metals needed to be printed in extreme environments and often required costly and time-consuming post-processing. With Electro3D, materials can be deposited at room temperature and pressure without post-processing. Without such limitations, Electro3D enables the ability to print materials into existing components without exposing them to harsh requirements. The technology can be used in a wide variety of applications.

As the size of metal components develops towards more precise or highly complex shapes, the processing of difficult-to-machine materials is facing a large demand. The EMS provides an intelligent continuous processing innovation solution for forming difficult-tomachine metal parts in multi-curvature structures. It has the advantages of simultaneous processing of multiple electrodes, optimization of processing paths, intelligent electrode forming technology, and intelligent data management. It also provides intelligent production and systematic services for diverse and customized geometry complex structural parts. In the future, it can be applied to precision components, such as optoelectronic semiconductors, machine tools, aerospace, electric vehicles, medical equipment, food processing, chemicals, fasteners, and valves.

FixCarbon Technology: Carbon-Negative Bioplastics from Afforestation Institute of Nuclear Energy Research (INER), Atomic Energy Council, Executive Yuan, ROC (Taiwan) Co-Developers: NZ Bio Forestry Ltd., Inspira Applied Bio Solutions CO., Ltd. FixCarbon technology revolutionizes the use of forestry waste and enables large-scale bio-plastic production using leftover Pinus Radiata wood processing and forestry waste as feedstock.

The technology uses an acid-catalyzed steam explosion as a pretreatment method that effectively destroys the tough fiber structure of lignocellulose, thereby enhancing its conversion potential. The method also enhances the induction of fermented sugar, enabling efficient and cost-effective production of enzymes necessary for the conversion process. INER has generated highly resilient bacteria strains that can withstand challenging conditions and maximize the production of desired bio-chemicals using high-throughput screening technology.

The innovative processes used by FixCarbon Technology significantly reduce forestry waste and enable bioplastic production on a commercially viable scale.

GRX-810: A 3D Printable Alloy Designed for Extreme Environments NASA’s Glenn Research Center The ODS alloy, called GRX-810 (Glenn Research Center Extreme Temperature above 810° C), leverages laser-based additive manufacturing (AM) to disperse nanoscale Yttrium oxide (Y2O3) particles throughout the microstructure, without resource-intensive mechanical or in-situ alloying processing steps. Current processes for creating ODS alloys are time-consuming, inefficient, and costly. GRX-810 is produced through laser powder bed fusion, a 3-D printing technique for complex geometries, and can resist stress cracking and dendritic segregation. It is not susceptible to damaging phase changes when exposed to extreme temperatures and requires limited post-processing. GRX-810 shows promise for metal components of gas turbines, rocket engines, nuclear reactors, and other high-temperature applications.

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process / prototyping WINNERS

Honeywell’s Ethanol-to-Jet Processing Technology

FUELING THE FUTURE FOR CLEANER SKIES Take off with UOP’s ethanol to jet (ETJ) process technology. The next generation of renewable fuels.

BENEFITS OF ETJ

5. SUSTAINABLE AVIATION FUEL (SAF)

High jet yield output

The resulting biofuel from the fuel blending process (Sustainable Aviation Fuel) is a safe and effective fuel solution that delivers cleaner, higher performance.

Lower CAPEX & OPEX

$

FINN Partners Co-Developer: Honeywell

Reduced GHG emissions

$

Higher profit margins

4. SUSTAINABLE AVIATION FUEL (SAF) BLEND Renewable jet fuel from the ethanol to jet process is blended with conventional jet fuel for use in flight.

3. ETHANOL TO JET Ethanol to jet technology efficiently converts ethanol into high-quality, renewable jet fuel with similar properties to conventional jet fuel.

FUEL

2. ETHANOL PLANT Renewable feedstock supply is refined and processed to produce high-efficiency ethanol.

1. FEEDSTOCK SUPPLY Sources of ethanol, primarily corn, grains and sugar cane, are collected.

Ethanol-to-Jet Processing Technology is a revolutionary solution that provides a cost-efficient, sustainable route to produce sustainable aviation fuel. The technology is built on Honeywell UOP’s experience in Sustainable Aviation Fuel, represented in its Ecofining technology. This product represents critical development in the global drive to meet 2030 sustainable aviation fuel mandates. SAF plants using Honeywell’s technology can be modularized off-site enabling lower installed costs and faster, less labor-intensive installation compared to job site construction. By using Honeywell’s ETJ technology and an integrated, modular construction approach, producers can build new SAF capacity more than a year faster than with traditional construction approaches.

Liquid Medium Entropy Alloy Catalyst (LMEAC) for Production of CO2-free Hydrogen and High-Value Carbon Products Lawrence Berkeley National Laboratory The LMEAC is the only technology that overcomes many long-standing barriers to achieving the goal of rapid societal decarbonization. The LMEAC catalyst used with methane pyrolysis (LMEAC-MP) enables stable methane pyrolysis at low temperatures, producing clean hydrogen at costs lower than any of its competitors. It also exhibits higher activity, selectivity, durability, and energy efficiency than any other product. As a bonus, it co-produces advanced, high-value carbon materials that enhance the process’s economics.

Its low temperatures allow industrial waste heat to be used in the process, reducing energy consumption. Because LMEAC achieves 100% selectivity for hydrogen production, its operational costs are reduced.

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Micrometer-based, Customized Production System Technology Industrial Technology Research Institute (ITRI) The accuracy, stability, and reliability of machine tools are crucial in precision machining.

Adding intelligent capabilities to machine tools, such as online accuracy detection, cutting heat compensation, cutting chatter monitoring, and early warning systems, can be powerful tools to enhance product competitiveness. Safety concerns are paramount when it comes to human life, especially in the aircraft sector, where machine tools are used to manufacture parts. Quality control is critical in the production process since any flaw in a part endangers the lives of passengers. ITRI Micro-CPS technology optimizes machine tool processing, improves processing efficiency, and enhances airplane part production yield while protecting passenger safety. Achieving micron-scale machining accuracy is challenging, but ITRI Micro-CPS technology has successfully overcome these challenges.

Thermo Fisher Scientific Gibco CTS DynaCellect Magnetic Separation System (CTS DynaCellect system) Thermo Fisher Scientific The current cell therapy manufacturing process faces challenges due to open steps that can result in contamination, manual steps that are difficult to scale up and can introduce human errors, and a lack of flexibility. To address these issues, the CTS DynaCellect system has been developed to mitigate some of the major pain points in cell therapy manufacturing, thereby helping manufacturers achieve their target results. For patients and consumers who rely on access to valuable cell therapies, the CTS DynaCellect system is crucial in isolating cells, reducing failures, and preventing contamination in cell therapy manufacturing. This could potentially save more lives and offer additional options for effective new therapies that patients can trust.

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process / prototyping WINNERS

Precise, Continuous, & High-Speed Manufacturing of Thermoplastic Composites Using Additive Manufacturing- Compression Molding (AM-CM) Oak Ridge National Laboratory (ORNL) The AM-CM process could revolutionize the manufacturing of polymers and composites. It is a hybrid process that combines the best features of traditional polymer manufacturing (CM) and advanced additive manufacturing (AM). This process provides the benefit of less material waste, advanced geometries, and significantly reduced lead times while maintaining a high-quality surface finish and fast cycle times. The AM-CM process produces composite parts that are fabricated using AM to deposit uniformly dispersed fibers oriented in the optimal direction. CM then removes voids and imparts a smooth finish to the completed part. This process offers a promising solution for lowcost, high-volume applications.

Rapid Response Steel Tooling using Additive Manufacturing

Solution-processed Perovskite Crystalline Films (SPeC)

Los Alamos National Laboratory

Los Alamos National Laboratory

Additive manufacturing is revolutionizing steel tooling production. By streamlining conventional mass production methods such as forming, forging, and stamping, it has the potential to make a significant impact.

Additive technology is Rapid Response Steel Tooling most effective in forming small batch parts and highly complex, exotic materials. This is particularly relevant in tooling manufacturing, where the work environment is extreme and complex geometries such as internal channels are often required. Printing tooling reduces waste, improves recyclability, and minimizes wasted energy and material. Developing AM methods will make formed tooling stronger and more reliable while reducing the number of steps required to create tools and lowering the risk of human error.

2 0 2 3 R & D 10 0 E N T R Y

FPO SAFE AREA R&D 100 Award Sticker

U S I N G A D D I T I V E M A N U FA C T U R I N G

EASILY CUSTOMIZABLE for optimized usage FASTER time-to-market for increased efficiency

Los Alamos National Laboratory has developed a nextgeneration, solution-processable semiconductor made from earth-abundant materials. Its SPeC technology combines molecular engineering with a thin-film coating method, readily adaptable to existing industry massproduction techniques, to produce near-single crystal layer perovskite films of virtually any size and with dramatically fewer crystal-grain boundaries and defects than other semiconductor fabrication methods. With SPeC, developers demonstrate exceptionally highperformance devices at far lower cost — including more efficient solar cells, much brighter and fully color-tunable LEDs, and much more sensitive X-ray detectors — compared to those in use today. Moreover, Perovskite semiconductors can be recycled easily, inexpensively, and completely.

DECREASED COSTS from fewer manufacturing steps

DURABLE OUTPUTS improve tooling longevity and performance REDUCED ENERGY consumption and recyclable byproducts

Titanium Production — a Transformative and Sustainable Process University of Utah Co-Developer: IperionX Steel was too expensive compared to iron for 3,000 years until Henry Bessemer created a new process in 1856 that reduced the production costs. Steel holds the position of being the most significant metal in today’s world. Although titanium is superior to steel and aluminum, its high cost limits its use. The University of Utah’s team discovered that hydrogen can weaken the bond between titanium and oxygen, leading to the development of the HAMR process. This process can significantly reduce the cost of producing titanium, contributing to the lightweighting of electric vehicles and the growth of green hydrogen. With the HAMR process, titanium is having its “Bessemer moment.”

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software / services WINNERS

Annotated Translated Disassembled Code (@DisCo) Idaho National Laboratory Annotated Translated Disassembled Code (@DisCo) was created to give cybersecurity researchers the ability to reverse engineer binary code. Using machine learning techniques to identify firmware components and flag changes that might indicate the presence of malware enables engineers to capture, preserve, and share information from their analyses, overcoming the problem of siloed and missing knowledge about firmware binaries in existing energy systems. It comes with a sophisticated visualization suite that depicts how binaries interact, dramatically simplifying the analysis process. @DisCo can also assist engineers in code quality analysis to ensure new vulnerabilities aren’t being introduced to systems and supply chain analysis to determine what binaries are present in a system.

CANDLE (CANcer Distributed Learning Environment) Argonne National Laboratory Co-Developers: Oak Ridge National Laboratory, Lawrence Livermore National Laboratory, Los Alamos National Laboratory, Fredrick National Laboratory for Cancer Research The CANDLE software suite offers unparalleled deep learning benchmarks to evaluate the performance of new deep learning accelerator hardware.

It also advances solutions for cancer researchers and other scientific applications. Moreover, complex workflows using CANDLE’s deep learning cancer models are currently operational on the most advanced exascale systems. Combining molecular simulation and AI on leadershipscale supercomputers is yielding promising new insights into future COVID-19 therapeutics. Overall, the CANDLE software is a unique and powerful platform that combines machine learning, deep learning, and cancer research. It accelerates the discovery of new cancer therapies and treatments while providing benchmarks to the hardware industry to aid in developing novel hardware solutions.

Cardinal: Accelerating Discovery in Fusion and Fission Energy Argonne National Laboratory Co-Developer: Idaho National Laboratory Cardinal is an open-source simulation software package that accelerates scientific discovery in fusion and fission energy using advanced computing. Cardinal features state-of-the-art, scalable, and high-order algorithms for achieving multiphysics solutions on platforms ranging from laptops to extreme-scale computers. An extremely flexible CAD geometry with an innovative on-the-fly re-meshing algorithm tackles complex geometries and unsteady turbulent flows. Integration with advanced physics models for thermal shock, solid mechanics, material science, dynamic power systems, and fluid-structure interaction allows scientists to harness exascale computing resources to accelerate engineering innovation and discovery. Cardinal’s extreme scalability and interfaces to AI, machine learning, and uncertainty quantification, bridge the gap between fundamental supercomputing research and scientific problem-solving on real-world problems of importance to nuclear engineering.

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Climate Risk & Resilience Portal (ClimRR) Argonne National Laboratory Co-Developer: AT&T Federal Emergency Management Agency (FEMA) ClimRR is a free and innovative tool that provides scientists with advanced climate science. It can generate more than 100 visualizations of projected climate conditions at a neighborhood-scale resolution. This feature enables people of all backgrounds to plan for the climate hazards that they may face in the future. ClimRR has a multitude of benefits that can aid every aspect of the community, from public health to infrastructure, culture, and commerce. It has the potential to revolutionize applied climate science and improve the lives of millions, if not billions, of people in the coming years.

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software / services WINNERS

Deep Resolve — MRI faster than ever before Siemens Healthineers

FEVER: Fast Evaluation of Viral Emerging Risks 2 0 2 3 R&D 10 0 E N T R Y

Los Alamos National Laboratory

To address the critical gap in pathogen detection, Los Alamos National Laboratory created a new method to develop futureproof diagnostics bolstered against viral mutation.

Fast Evaluation of Viral Emerging Risks (FEVER) is an open-source technology that designs optimized primers and probes to be used in concert for multilevel biosurveillance — monitoring entire classes of viruses, outbreak strains, and variants simultaneously.

FEVER-designed probes are compatible with both traditional and cutting-edge diagnostic platforms, supporting fieldable diagnostics and offering broader accessibility without the need for a clinical laboratory. FEVER enables rapid and accurate results to support early warnings and guide outbreak mitigation efforts, providing the foundational capability necessary to mitigate future pandemics and directly support global pandemic preparedness.

Fast Evaluation of Viral Emerging Risks

■ Enables biosurveillance of entire classes of viral pathogens

■ Supports monitoring of outbreak strains and variants ■ Reduces false negatives from rapid viral mutation

■ Delivers optimized probes for a variety of detection technologies

■ Provides rapid and accurate results to mitigate future pandemics

MRI scans face the challenge of balancing acquisition speed, image quality, and signalto-noise ratio. Deep Resolve’s AI-powered reconstruction technology improves all three factors simultaneously, making scans faster and maintaining image quality. This technology generates actionable diagnostic insights that can save lives. With Deep Resolve, scan times can be shortened by up to 60%, resulting in up to 60% energy savings per scan and up to 13% average energy savings per year. The technology also improves patient experience and extends MRI benefits to demographics previously considered challenging or ineligible for scanning. Deep Resolve is a game-changing technology that takes one more step towards building a healthier and more sustainable world for everyone.

High Efficiency Aspect Ratio Deposition/Matrix ALD Industrial Technology Research Institute (ITRI) Semiconductor device manufacturing requires atomic-level precision. HEADMatrix ALD+ meets the high-quality and high-reliability coating system needs of major manufacturers such as Intel and TSMC. It uses a dual-mode atomic layer deposition system with pulsed discrete feed method (DFM) and bidirectional flow (cross-over) deposition technology to improve uniformity and reduce transmission and pumping time. The technology leads the industry in innovative product research and development, improving process throughput and film quality yield while also reducing equipment footprint and cost. It can help lead the way to net-zero carbon reduction and sustainable development.

Industrial Control System Cybersecurity Analytic Platform Institute for Information Industry Using AI technology, ICSentry detects and analyzes potential threats in OT networks, providing a promising solution to protect critical infrastructure.

It has been successfully implemented in real-life infrastructures, such as a natural gas company’s production. Moreover, ICSentry also conducts POC verification at Taiwan Water Supply Company, which provides good performance and competitiveness for ICS network security in its OT environment. Its advanced algorithms enable real-time monitoring and detection of anomalies, making it a powerful tool for safeguarding against malicious threats. The goal of ICSentry is to remain vigilant and prevent threats by continuously analyzing and monitoring OT network traffic, thus ensuring reliable and secure operation.

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R&D WORLD | FALL 2023

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software / services WINNERS

MALA: Materials Learning Algorithms Sandia National Labs (SNL) Co-Developer: Center for Advanced Systems Understanding (CASUS) at the Helmholtz-Zentrum Dresden-Rossendorf (Germany) The Materials Learning Algorithms (MALA) method significantly accelerates electronic structure calculations and provides a more efficient time-to-answer turnaround. This is demonstrated by an impressive speedup of up to 1000 times or more compared to state-of-the-art approaches, making it possible to predict the electronic structure of systems containing several thousand atoms.

Moreover, MALA can compute the electronic structure of systems with up to 100,000 atoms using only a few GPUs, surpassing the capabilities of traditional methods while maintaining accuracy in the quantities of interest. This unprecedented scale and speedup are due to the innovative methods used in MALA, which enable linear scaling with system size, unlike density functional theory, which has cubic scaling.

Materials Data Driven Design (MAD3) Sandia National Laboratories (SNL) MAD3 software uses the power of machine learning to improve metalforming processes by incorporating a material’s microstructural information — allowing manufacturers to obtain microstructure-aware material properties for the first time. This advance is particularly important for the recent emergence of novel materials with complex microstructural features. MAD3 provides accurate plastic anisotropy information three orders of magnitude faster than any existing framework and is deployed with a user-friendly GUI that can be easily adopted by nonexperts using an ordinary laptop. This software reduces the need for forming/stamping trials, which can cost between $2 to $5 million per year per manufacturing plant. It is revolutionizing the manufacturing industry and advancing the design and manufacturing of lighter structures, optimized military vehicles, and alloys for energy applications.

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Medium- and Heavy-Duty Electric Vehicle Infrastructure - Load Operation and Deployment (HEVI-LOAD) Lawrence Berkeley National Laboratory There is currently a lack of a comprehensive planning tool for zero-emission vehicles (ZEV) infrastructure for medium- and heavy-duty vehicles. The HEVILOAD tool is an advanced software with unique modeling capabilities that allow stakeholders to model regional ZEV adoption scenarios and customize charging simulations with greater temporal and spatial granularity. It accurately projects the number, type, and location of charging stations required at various levels, including the site, traffic analysis zone, county, and state levels. This makes it a versatile decisionsupport tool for stakeholders, including government agencies, industry, and utility companies in North America and potentially Europe. HEVILOAD is the most comprehensive and advanced software tool for planning ZEV infrastructure for medium- and heavy-duty vehicles.

Meta Optics Studio Sandia National Laboratories (SNL) Co-Developer: Stellar Science Ltd. Co. Meta Optics Studio (MOS) is a software package specifically designed to create, simulate, and optimize flat meta-surfaces. These artificial structures enhance light wavefront engineering, resulting in better focusing, phase correction, and removal of aberrations. MOS has a unique multi-platform capability and a novel patch-and-stitch approach, which enables designers to simulate a meta-optic that is 55,000 times the wavelength of light in diameter, using modest high-performance computing resources, all within a week’s time.

The software can also perform real-time shape and topology optimization on the full-sized meta-optic, optimizing for target performance.

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software / services WINNERS

PowerModelsONM: Optimizing Operations of Networked Microgrids for Resilience Los Alamos National Laboratory Co-Developers: National Renewable Energy Laboratory, Sandia National Laboratories, National Rural Electric Cooperative Association Both natural disasters and physical/cyber-attacks have prompted utilities to adopt microgrids to enhance resilience, meet reliability standards, and reduce dependence on the bulk electric system.

Although current techniques allow for the evaluation PowerModelsONM of the resilience benefits of individual microgrids, they do not facilitate the coordination of multiple microgrids to achieve benefits greater than the sum of their parts. PowerModelsONM represents the first development and deployment of a new method for planning and optimizing operational choices for multiple microgrids in response to extreme events.

By using real-world data from utilities and being tested on HIL, this integrated modeling and simulation system allows for resilience scenarios to be validated without risking the real system.

2 0 2 3 R & D 10 0 J O I N T E N T R Y

Optimizing Operations of Networked Microgrids for Resilience

EVALUATES resilience benefits of networking microgrids with high confidence

USES high-fidelity, multi-phase power flow models to ensure voltage stability

INTRODUCES advanced engineering requirements for safety and regulatory compliance

PRODUCES outputs for automated hardwarein-the-loop validation

ALLOWS users to validate and customize the opensource code

Puckboard

py4DSTEM — an open-source software package for electron microscopy data analysis Lawrence Berkeley National Laboratory py4DSTEM is a recently introduced product that has become the dominant product in 4D-STEM data analysis. It has active and growing developer and user communities. py4DSTEM provides researchers with cutting-edge analysis tools in an intuitive interface, unlocking atomic structure across multiple length scales, large-scale strain mapping, super-resolution imaging, and crystallographic orientation mapping. Furthermore, py4DSTEM provides more and better analyses with greater ease of use than the competing open-source Python toolkits; performs each of its many supported analyses more easily and effectively than competing single-purpose targeted software; and even outperforms the expensive, integrated commercial alternatives in versatility, robustness, accuracy, and accessibility.

Qnovo’s SpectralX: Intelligent lithium-ion battery management software

MIT Lincoln Laboratory Co-Developers: RevaComm Department of the Air Force, MIT AI Accelerator, MIT, U.S. Air Force 15th Wing, U.S. Air Force 60th Air Mobility Wing, U.S. Air Force 437th Airlift Wing, Headquarters Air Mobility Command, Air Force Research Laboratory, Assistant Secretary of the Air Force (Installations, Environment, and Energy), Raytheon BBN Puckboard, a collaborative crew scheduling application, has several key features that make it stand out among other applications. It boasts highsecurity standards since it ties into the Department of Defense’s Platform One infrastructure and it’s highly accessible, requiring only an internet connection to use.

Puckboard is responsive — able to adjust schedules swiftly to fit last-minute changes while ensuring that schedules comply with rest times and crew qualifications. It uses optimization algorithms to consider various metrics such as training needs, flight hour distributions, and assignment fragility to provide decision support. Finally, the app is human-centered, meaning that crew members’ desires are considered as the app’s recommendations are generated. These benefits are why more than 24,000 personnel and 87 squadrons now rely on Puckboard for scheduling.

WWW.RDWORLDONLINE.COM

Qnovo Inc. SpectralX makes it possible to deploy electric vehicles quickly and safely for both passenger and commercial use in developed and developing markets. Once deployed, cars, trucks, and buses can be driven for longer distances and kept on the road for more extended periods of time, thanks to fast-charging and extended-life batteries. Also, by improving battery performance, SpectralX contributes to reducing CO2 emissions. As interest and opportunities in vehicle-to-grid (V2G) grow, concerns about battery degradation become more critical. However, with Qnovo, battery health, safety, and vehicle warranty concerns are no longer obstacles to using electric vehicles as power-generating sources. This brings us one step closer to accelerating the transition to low-carbon technologies for the planet.

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software / services WINNERS

RAVEN- Computational Platform Performing Stochastic Analyses Idaho National Laboratory A model of a complex system typically requires inputs from many standalone codes, each like a dial that can be tuned to determine how it affects other aspects of the system. Increasing the number of input codes makes a simulation more realistic, but it also increases the complexity of the analysis. Researchers at Idaho National Laboratory built RAVEN to solve this problem. RAVEN acts as a dynamic digital glue to bind the inputs of simulation models. Analysts can easily adjust inputs to a simulation model on the fly without reconstructing the entire model, allowing for faster, cheaper, and more accurate complex systems analysis.

Simulation and Emulation for Advanced Systems (SEAS): Bridging the Gap Between Energy Transition Planning and Implementation National Renewable Energy Laboratory As we move towards a future that relies heavily on clean energy solutions, utilities, local governments, and planners face the daunting task of managing these new systems. Fortunately, SEAS provides the necessary tools to model all the energy system management variables in the context of communities and their existing infrastructure. This allows users to test-drive different software and hardware configurations to understand future “what if” scenarios. It gives planners the confidence to implement reliable solutions rapidly, keeping pace with growing energy demands and devices without risking trial and error. With ambitious national and global decarbonization goals, clean energy adoption, and a growing population, there is a tidal wave of energy demands that are complex and interconnected. SEAS helps to manage these demands efficiently and sustainably.

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Smart Energy for a Sustainable Ecosystem Industrial Technology Research Institute (ITRI) Co-Developer: Taiwan CPC Corp.

Smart Energy for a Sustainable Ecosystem has three features. Firstly, expansibility allows power sources from different sources to be treated as power storage units of varying sizes. This system reduces energy conversion loss by 35%, increases energy transfer efficiency to 98%, extends system cycle life by 223%, and reduces construction costs by 30%. Secondly, the system recycles retired batteries to store electricity, enabling CPC to achieve a net-zero transformation by 2050.

Finally, the system has the first software-defined power management system, which uses AI technologies to monitor, anticipate, control, and manage batteries. This maximizes their service life and performance while lowering failure rates and maintenance costs.

SuperNeuro: An Accelerated Neuromorphic Computing Simulator Oak Ridge National Laboratory Neural simulations at a large scale often suffer from computational inefficiencies that limit their scalability and their ability to improve neural structures for specific applications.

SuperNeuro is a Python-based neural simulator that addresses these limitations and provides AI practitioners with a fast and scalable solution. It also allows users to simulate their own spiking mechanisms in a human-interpretable manner. SuperNeuro provides superior computing performance compared to existing simulation platforms by leveraging GPU computing. This simulator is versatile enough to handle different types of workloads, including neuroscience, deep learning (SNN), and general-purpose computing workloads such as graph algorithms, neuromorphic data structures, and μ-recursive functions.

SuperNeuro easily integrates with other learning tools for SNN optimization and facilitates large-scale AI experimentation on accelerated computing infrastructures.

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software / services WINNERS

The O-RAN energy-efficient private network management technology

The reV Model: Unmatched Wind and Solar Generation Detail at Scale

Industrial Technology Research Institute (ITRI) Co-Developer: PEGATRON Corp.

National Renewable Energy Laboratory

The O-RAN energy-efficient private network management technology is the world’s first 5G O-RAN low-carbon private network solution. The technology has three key features, including “high deployment efficiency,” which can simulate the number of base stations required with a single click to aid in the planning of private network deployment. It also has “high energy-saving efficiency,” which can intelligently allocate resources through AI and machine learning algorithms combined with traffic monitoring and diversion technology, so that idle base stations rest. Even the base station can be plug-and-play, automatically optimized, monitored, managed, and repaired, thereby reducing maintenance and operation costs. Lastly, it offers a “highly flexible application,” making it suitable for a range of 5G vertical applications, such as smart factories, hospitals, entertainment, warehousing logistics, and drones.

The reV tool uses advanced modeling techniques and detailed data to accurately capture the many local factors involved in realworld wind and solar energy deployments. It scales these factors to provide a national perspective. In the past, modeling wind and solar supply has been challenging due to computational and data issues. Each site is unique and requires a detailed analysis of where and how to place equipment for optimal generation at the lowest cost and environmental impact. With millions of potential sites to assess, reV overcomes these challenges by providing spatially explicit, robust simulations of wind and solar plants. By using reV, users can assess resource potential based on their specific circumstances. This level of detailed analysis was previously only available to project developers for individual sites. reV scales the site-level detail to millions of potential sites.

Variorum: Vendor-Agnostic Computing Power Management

Vitro Architectural Glass — VitroSphere Digital Glass Simulator

Lawrence Livermore National Laboratory

Vitro Architectural Glass

Variorum is an opensource software library that enables users to access the power, energy, and performance metrics of low-level hardware dials across different architectures through vendor-neutral APIs. It is a key component of the U.S. Department of Energy’s Exascale Computing Project (ECP) and the Argo Project, which focuses on node-level power management in the high-performance computing (HPC) PowerStack Initiative. Variorum supports all three upcoming U.S. exascale supercomputers and many other HPC systems. It provides ease of use and reduced integration burden in scientific applications and workflows and is widely accessible to diverse users of supercomputers, bare-metal cloud infrastructure, and researchers studying power and energy management.

Vitro identified a need for a digital simulator tool after evaluating the digital rendering industry in glass and other commercial building products.

Glass is challenging to depict accurately due to its changing visual characteristics. Vitro invested several months in outlining the programming requirements and parameters, and several more in developing the algorithm. With one click, users can watch a building transform, compare different products, and visualize different aesthetics. Additionally, there’s a zoom feature to examine the glass closely and see what it would look like from inside the building.

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software / services WINNERS

Viz Employs AI to Detect Unruptured Aneurysms and Coordinate Patient Care Viz.ai Viz Aneurysm is an AIpowered tool that aims to identify potential brain aneurysms in patients before they become life-threatening.

This platform operates round-the-clock, analyzing computed tomography angiography (CTA) scans across a hospital network. If a possible aneurysm is detected, Viz.ai highlights the case for a specialist to review. Using Viz.ai’s secure app, the clinician can then analyze 3D images and collaborate with colleagues. If the clinician confirms the diagnosis, they can use the Viz platform to share the patient’s imaging data with the care team. Clinical data shows that Viz Aneurysm has successfully identified aneurysms that hadn’t been referred for review before.

ZFP: Fast, Accurate Data Compression for Modern Supercomputing Applications Lawrence Livermore National Laboratory ZFP is a new compressed number format for floating-point and integer arrays intended to reduce in-memory and offline storage and transfer time of large data sets that arise in high-performance computing (HPC). ZFP effectively expands available CPU and GPU memory by as much as 10 times; reduces offline storage by one to two orders of magnitude; and — by reducing data volumes — speeds up data movement between memory and disk, distributed compute nodes, CPU and GPU memory, and even main memory and CPU registers. Such reductions in data movement are critical to today’s HPC applications, whose performance is largely limited by data movement rather than compute power.

Congratulations TO THE 2023 R&D AWARD

WINNERS FOR MORE INFORMATION & TO SEE THE FULL LIST OF CURRENT & PAST WINNERS, GO TO:

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special recognition SPECIAL RECOGNITION

Special Recognition: Battling COVID-19 2 0 2 3 R&D 10 0 E N T R Y

Fast Evaluation of Viral Emerging Risks

GOLD FEVER: Fast Evaluation of Viral Emerging Risks Los Alamos National Laboratory

■ Enables biosurveillance of entire classes of viral pathogens ■ Supports monitoring of outbreak strains and variants ■ Reduces false negatives from rapid viral mutation ■ Delivers optimized probes for a variety of detection technologies ■ Provides rapid and accurate results to mitigate future pandemics

The Fast Evaluation of Viral Emerging Risks (FEVER) open-source technology designs optimized primers and probes for multilevel biosurveillance — monitoring entire classes of viruses, outbreak strains, and variants simultaneously. FEVERdesigned probes are bolstered against viral mutation, providing the foundational capability to mitigate future outbreaks and support global pandemic preparedness.

Special Recognition: Corporate Social Responsibility GOLD FEVER: Fast Evaluation of Viral Emerging Risks Los Alamos National Laboratory The Fast Evaluation of Viral Emerging Risks (FEVER) opensource technology designs optimized primers and probes for multilevel biosurveillance — monitoring entire classes of viruses, outbreak strains, and variants simultaneously. FEVERdesigned probes are bolstered against viral mutation, providing the foundational capability to mitigate future outbreaks and support global pandemic preparedness.

2 0 2 3 R&D 10 0 E N T R Y

Fast Evaluation of Viral Emerging Risks

■ Enables biosurveillance of entire classes of viral pathogens

■ Supports monitoring of outbreak strains and variants ■ Reduces false negatives from rapid viral mutation

■ Delivers optimized probes for a variety of detection technologies

■ Provides rapid and accurate results to mitigate future pandemics

SILVER Grid Regulation Delivered

by Aggregations of Loads (GRID-BAL) Los Alamos National Laboratory University of Michigan, Ann Arbor; Pecan Street Inc.; University of California, Berkeley An integrated system of control algorithms, software, an experimental testbed, and residential field studies enhances the reliability of the electrical grid by making loads able to adjust to fluctuations in supply. Experiments and field testing evaluate and compare the controllers and bring them from theory to practice without inconveniencing customers.

BRONZE Combating Geographic Inequality in Remote Areas by Erecting HighStandard Basketball Courts from Waste Bicycle Tires Dow Chemical (China) Investment Co., Ltd. Meituan, the YAO Foundation Since June 2022, Dow has joined hands with value chains to combat geographic inequality in China’s remote areas by creating numerous brand-new, highly resilient, low volatile and sustainable basketball courts, enabled by Dow’s unique upcycled SPECFLEX bicycle tire granules and VORAMER solvent-less binder. This program aids more than 5,000 rural teenagers.

DOW

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她基⾦ 美 YAOFoundation

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special recognition SPECIAL RECOGNITION

Special Recognition: Green Tech GOLD Deep Resolve — MRI Faster than ever before Siemens Healthineers Deep Resolve is the Siemens Healthineers revolutionary AI-powered image reconstruction technology comprising Deep Resolve Sharp, Gain, and Boost. Deep Resolve can simultaneously increase signal-to-noise ratio and boost image resolution while enabling faster acquisition time. Faster image acquisition leads to improved patient comfort, workflow efficiency, and energy efficiency.

SILVER Sustainable Ion Exchange Resin for Ultrapure Water Treatment

BRONZE A continuous hot-roll process to manufacture nanograin Neo magnet

DuPont

Ames National Laboratory

DuPont AmberTec UP4000Pd OH Ion Exchange Resin is a strong base anion exchange resin doped with highly active palladium nanoparticles useful for removing hydrogen peroxide (H2O2) from the ultrapure water (UPW) used for semiconductor manufacturing processes.

The Hot-roll Nano-NeoMagnet addresses two major issues in magnet production today. First, it eliminates the use of dysprosium, a critical material for green energy applications. Second, it addresses the high cost of traditional nanograin magnets by simplifying the energy-intensive two-step batch process to a single continuous hot-roll process.

Special Recognition: Market Disruptor — Products GOLD Rapid Response Steel Tooling using Additive Manufacturing Los Alamos National Laboratory Rapid response steel tooling uses additive manufacturing (AM) to produce tooling for forming, drawing, and stamping.

AM’s unique capabilities can produce geometrically complex parts from exotic materials with the properties of hardened steel. The rapid build process tailors tools for individual applications in fewer steps and less time.

2 0 2 3 R & D 10 0 E N T R Y

FPO SAFE AREA

SILVER Noncontact Laser Ultrasound (NCLUS) for Medical Imaging MIT Lincoln Laboratory Massachusetts General Hospital (MGH) Center for Ultrasound Research Translation (CURT) and Sound & Bright, LLC

R&D 100 Award Sticker

Rapid Response Steel Tooling U S I N G A D D I T I V E M A N U FA C T U R I N G

EASILY CUSTOMIZABLE for optimized usage FASTER time-to-market for increased efficiency

DECREASED COSTS from fewer manufacturing steps

DURABLE OUTPUTS improve tooling longevity and performance REDUCED ENERGY consumption and recyclable byproducts

WWW.RDWORLDONLINE.COM

NCLUS is a versatile novel laser system that acquires ultrasound images of human tissue without touching a patient. NCLUS enables new low-variability ultrasound imaging concepts that have the potential to offer capabilities comparable to MRI and CT at vastly lower cost and in a portable and automated system.

BRONZE Solution-processed Perovskite Crystalline Films (SPeC) Los Alamos National Laboratory SPeC is a perovskite thinfilm fabrication method used to produce uniform crystalline semiconductors from earthabundant materials for high-performance optoelectronics.

The solution-based methodology is very inexpensive, fully scalable, and suitable for existing mass manufacturing techniques. SPeC has been demonstrated to produce low-cost, highperformance solar cells, x-ray detectors, and color-tunable LEDs.

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special recognition SPECIAL RECOGNITION

Special Recognition: Market Disruptor — Services GOLD Grid Regulation Delivered by Aggregations of Loads (GRID-BAL) Los Alamos National Laboratory University of Michigan, Ann Arbor; Pecan Street Inc.; University of California, Berkeley An integrated system of control algorithms, software, an experimental testbed, and residential field studies enhances the reliability of the electrical grid by making loads able to adjust to fluctuations in supply. Experiments and field testing evaluate and compare the controllers and bring them from theory to practice without inconveniencing customers.

SILVER Materials Data Driven Design (MAD3) Sandia National Labs MAD3 is an innovative software that leverages the power of machine learning to modernize the forming/stamping processes of sheet metals by predicting the parameters that characterize the directional mechanical behavior of a metal alloy 1,000 times faster than existing solutions. As a result, MAD3 significantly reduces expensive and time-consuming forming/ stamping trials.

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Our entire product line is built with the same All-Carbon Microbead surface chemistry, opening new avenues for extraction,separation & purification outside the current state-of-art.

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finalists FINALISTS Analytical/Test category

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30X MWIR continuous zoom lens with folded structure, Viettel High Tech Autonomous Sparse — Aperture Multibeam Echo Sounder, MIT Lincoln Laboratory, MIT FreeStyle Libre 3, Abbott Galleon™ Microbiome Analysis–Cargill’s First-and-only Microbiome Assessment Platform for Gaining Intelligence into and Supporting Improved Health in Chicken Flocks, Cargill Grid Impedance Scan Tool (GIST): Finding and Preventing Power Grid Instabilities, National Renewable Energy Laboratory Rapid Droplet Sampling Interface for Ultrahigh-Throughput Mass Spectrometry Analysis, Oak Ridge National Laboratory (ORNL) SCHOTT® LightView, SCHOTT SwRI Engine for Automatic Biomechanical Evaluation (ENABLE™), Southwest Research Institute Thermo Scientific AccelerOme™ Automated Sample Preparation Platform, Thermo Fisher Scientific Thermographic Phosphor Digital Image Correlation (TP+DIC), Sandia National Laboratories (SNL)

IT/Electrical category • •

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Bat Tags, Pacific Northwest National Laboratory Digital Buoy System: The First Cost-Efficient, Scalable Solution for Tracking Buoys in Real Time to Improve Marine Safety, U.S. Army Corps of Engineers (USACE) Engineer Research and Development Center (ERDC), USACE Army Geospatial Center Doppler Cloak, MIT Lincoln Laboratory Epitaxial Drift Step Recovery Diode, Lawrence Livemrore National Laboratory, United States Army Space and Missile Defense Command, BAE Systems, Lawrence Semiconductor Research Laboratory.

Honeywell Safety Watch, Honeywell Process Solutions Miniaturized and Low-Aerodynamic-Noise Shinkansen Antenna for Overhead Line Voltage Detection and Wireless Communication, Mitsubishi Electric Corp., Central Japan Railway Co. Portable Aircraft Derived Weather Observation System (PADWOS), MIT Lincoln Laboratory Privacy enhancing platform for alternative credit scoring, Hong Kong Applied Science and Technology Research Institute Co. Ltd. Prometheus/Euclid/Seagull Suite of Algorithms for Analysis of MultiModal Data, The Johns Hopkins Applied Physics Laboratory Pulse Based Ultra High Frequency (PB-UHF) Communication System, Lawrence Livermore National Laboratory, Dirac Solutions, Inc. SynSteg: Synesthesia+Steganography–Based Encryption Systems, Oak Ridge National Laboratory WARHAWK MTD, Sandia National Labs (SNL)

Mechanical/Materials category • •

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3M™ Performance Spray Gun with Fine Finish Nozzle Technology, 3M BioLAN™ Lignin Based Composites, Prisma Renewable Composite, Inc., Oak Ridge National Laboratory; Physical Science Directorate, Carbon and Composites Group Closing the loop on HDSS polyethylene packaging bags through PCR Incorporation, Dow Packaging and Specialty Plastics, a business unit of Dow Inc., Plastar Buenos Aires S.A. Celsur S.A Amiplast S.A. Decolorization Plus: Dye Removal Technology for garment-to-garment PET Textile recycling, Industrial Technology Research Institute (ITRI).

Depolymerization Agent for Carbon Fiber Reinforced composites Circularity, Industrial Technology Research Institute (ITRI)

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DEXCARE™ CD-1 Polymer, Dow Consumer Solutions Dow Coating Materials, Dow Coating Materials Dow LDPE 91003 HEALTH+™ Resin for High Purity and Transparent Medical Packaging, Dow Packaging and Specialty Plastics, a business unit of Dow DuPont™ Nomex® Comfort with Ecoforce™ Fabric, Dupont Eco-designed ingredient PURESIL ORG 03 for improved performance at lower carbon footprint, ELKEM Eco-friendly Materials for Garment Heat Transfer Printing, Nano and Advanced Materials Institute, SEC Accessories Ltd. Electrified Fiber Sorbents for Energy-Efficient Direct Air Capture, Korea Advanced Institute of Science and Technology, Saudi Aramco Research and Development Center Elkem Silicone Elastomers as Modifiable Excipient for Drug Delivery Devices, Elkem Silicones Corp.

Hytrel® TPC ECO-B, a sustainable product offering from bio circular feedstock through a mass-balance approach, Celanese INNATE™ ST100 Precision Packaging Resin, Dow LiZ Armored Polyaramid Separator, General Motors, Microvast Holdings, Inc. Pacific Industrial Development Corp.

On-Demand, Pressure-Triggered Sealant for Prefab Building Construction, Oak Ridge National Laboratory, CertainTeed, Saint Gobain, Bensonwood One-stop solution of vacuum metallized PE enabling recyclable high barrier packaging, Dow Inc PPG Pitt-Therm 909 High Performance Spray-On Insulation Coating, PPG Recycled Waste-gas Based Polyester Fiber, Far Eastern New Century Corp. (FENC), LanzaTech SolarFlow, Zendure USA Inc ULTEM™ DT1820EV resin, innovation material solution enabling costeffective metallization to uplift consumer electronics designs, SABIC

Other category •

E Ink Gallery™ 3, E Ink

Process/Prototyping category • • • •

A low-cost and scalable strategy to microencapsulate salt hydrate phase change materials, Oak Ridge National Laboratory ELECPURE™ Technology for Electronic Processing, Dow Innovative Solution Provider for 3D-IC Packaging Inspection, Industrial Technology Research Institute (ITRI) Novel Underwater Transducer Structures Using Additive, Manufacturing, MITRE, Lithoz America LLC MSI Transducers Inc.

Software/Services category • • • • • • •

Acoustic Resonance Spectroscopy (ARS) Mechanical Condition Monitoring, Los Alamos National Laboratory ActivO, Argonne National Laboratory Chaff Detection, Lincoln Laboratory Green Computing Toolbox, MIT Lincoln Laboratory OpenMxP — Open-Source Mixed Precision Computing, Oak Ridge National Laboratory Simcyp™ Discovery Simulator Reduces the Risk of Failure in the Early Stages of Drug Development, Certara ThreatHunter — HoneyNet with Machine-Learning Based Network Flow Analysis for Cyber-Crime Threat Intelligence, Hong Kong Applied Science and Technology Research Institute Co. Ltd.

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ADVERTORIAL

ULTRA-STRONG ALUMINUM ALLOYS FOR ADDITIVE MANUFACTURING NEW ALUMINUM ALLOYS FOR HIGHTEMPERATURE APPLICATIONS

Dr. Amir Farkoosh is a research associate at NUCAPT and the Materials Science and Engineering department at Northwestern University, working with Prof. David N. Seidman. His current research focuses on designing advanced heat-resistant aluminum alloys and high-strength steels for additive manufacturing, using a combination of experimental and theoretical methods. Prior to joining Northwestern in 2017, he performed his doctoral research at McGill University in Quebec, Canada, where he studied the physics of creep resistance in high-temperature aluminum alloys.

A conversation with Dr. Amir Farkoosh Additive manufacturing (AM), or 3D printing, is an emerging technology used to create 3-D mechanical parts, layer-by-layer, utilizing geometry as the only input.

Although not at full technological maturity, rapid prototyping using AM has already reduced design cycle time and manufacturing development costs. Obviating some of the traditional manufacturing and alloy design barriers, AM makes possible complicated geometries that cannot be conventionally manufactured.

At NUCAPT, Dr. Farkoosh uses Atom Probe Tomography (APT) mainly in a correlative manner or in combination with other characterization techniques,

analytical theory, and computer simulations. In the case of aluminum alloys, for instance, these alloys are generally strengthened with nanoprecipitates with different compositions and crystal structures. To elucidate the precipitates’ nucleation, growth, transformation, and coarsening kinetics as a function of time and temperature, he relies principally on 3-D APT, which provides structural and chemical information at the sub-nanoscale.

AM enables significantly higher cooling rates than conventional manufacturing methods, resulting in microstructure development at a drastically smaller length scale. Consequently, AM alloys

(a)

45 o

90 o

(b)

(c) 30 nm

001

20 μm 101

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1 μm

45 o

are particularly well-suited for examination using APT in comparison to conventionally produced alloys. In additively manufactured materials, most of the microstructural features are orders of magnitude smaller, several of which can be imaged in a single APT specimen. For instance, a single APT reconstruction in Fig 1 reveals the nature of a complex intertwined eutectic structure with four different phases directly solidified from the liquid state in one of my newly designed NUAdd alloys [1], which remain ultra-strong at both ambient and high temperatures.

APT data are ideal for direct comparison with atomistic computer simulations and

modeling, to understand the microstructures and their dynamics on an atomic scale. Hence, my APT results are often complemented with density functional theory calculations and integrated to correlate processing, micro/ nanostructures, and properties.

Fig. 1 (a) 3D-APT reconstructions displaying the as-printed nano-structure of a heat-resistant ultrahigh strength NUAdd alloy produced via selective laser melting (SLM). This aluminum alloy is developed specifically for additive manufacturing at NUCAPT. The reconstructions reveal the nature of a complex intertwined eutectic structure made of four different phases, directly solidified from the liquid state. The two intermetallic phases and the Si phase are delineated with isoconcentration surfaces with concentration values indicated in the figure; ΣTM1 denotes a mixture of transition metals and ΣTM2+REE denotes a mixture of transition metals and rare-earth elements. (b) EBSD inverse pole figure (IPF) map displaying the grain structure of the as-printed alloy. Grains are reinforced with the eutectic phase as shown in the SEM micrograph in (c).

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ADVERTORIAL This integration follows the fundamental paradigm of materials science and engineering, specifically focusing on the relationships between micro-/nanostructures and physical and mechanical properties.

Why research aluminum alloys in relation to AM? AF: Compared to steels, titanium alloys, and superalloys, aluminum alloys have experienced a slower adoption in AM despite attractive properties such as low density, high strength, and good corrosion resistance. To date, only a limited number of aluminum powders suitable for demanding, high-stress, or high-temperature applications are commercially available for AM. There are a few reasons for this: current commercial aluminum alloys are much more difficult to process with the common AM techniques when compared to, for example, low-carbon steels or stainless steels. Hot-cracking susceptibility is a major issue. Commercial alloys, except for some cast alloys, crack during printing and should be modified significantly in order to enhance printability; or new alloys should be designed from scratch with good inherent printability, which by itself is an extremely challenging but rewarding endeavor.

Another major problem with aluminum alloys, specifically those produced additively, is that existing commercial aluminum alloys are unusable above ~250 oC, due mainly to the rapid coarsening/dissolution of their fine scale strengthening precipitates [2]. To overcome this problem, in the past, we have utilized coarsening-resistant L12nanoprecipiates, Fig. 2, to increase the operation temperature of conventional aluminum alloys up to 400 oC. I employ a similar approach in designing heatresistant aluminum alloys for AM.

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(a)

(b)

~ 1.0 Billion atoms ~3300 nanoprecipitates Isochronally aged to 425 oC

~0.5 Billion atoms ~ 500 nanoprecipitates Isochronally aged to 475 oC

200 nm

170 nm

Fig. 2 3D-APT reconstructions of an Al-0.5Mn-0.09Zr-0.05Er-0.05Si alloy after isochronal aging from the as-cast state to 425 °C (peak hardness) and to 475 °C (slightly overaged), showing the core-shell L12-nanoprecipitates delineated with 2.5 at.% (Zr+Er) iso-concentration surfaces. Only 1% of the Al atoms are displayed for clarity. (b) Proximity histogram [3] of the same alloy after isochronal aging from the as-cast state to 475 °C, computed from the datasets displayed in (a), utilizing the 2.5 at.% (Zr+Er) isoconcentration surfaces. The detection limits (DL), defined as one atom per proxigram bin, are too small to be visible on the proximity histograms. The matrix/L12 interface (vertical dot-dash red lines) is defined as the inflection point of the Al concentration profile [4].

What can you share about your research on ultra-strong aluminum alloys?

AF: The long-term goal of my research is designing and studying fundamentally a series of lowcost, high-strength precipitationhardened aluminum alloys that are usable at both ambient and temperatures as high as 427° C. Over the last few years, I have embarked on developing novel aluminum alloys for additive manufacturing, NUAdd Alloy Series, which are strengthened with multiple populations of precipitates, utilizing similar alloy design principles. My interest lies in: 1) exploiting the unique characteristics of AM to develop advanced high-strength aluminum alloys tailor-made for AM, with mechanical and physical properties exceeding those of their

conventional counterparts, and 2) overcoming the generic challenges associated with the AM of existing aluminum powders.

I take a materials-by-design, or first-principles, approach to alloy design for AM, utilizing integrated computational materials engineering combined with experiments and physical simulations of the AM processes.

Some of my design considerations for AM alloys are printability, cost, ductility, and strength at ambient and high temperatures.

Additive manufacturing of ultrastrong precipitation-hardened aluminum alloys refers to the use of AM in creating aluminumbased materials that possess exceptional strength and are reinforced through a process called precipitation hardening.

These advanced aluminum alloys are engineered for use in applications that involve elevated temperatures, making them suitable for both high-temperature and standard (ambient) temperature environments.

Does hydrogen embrittlement impact this process?

AF: Hydrogen embrittlement, HE, is of concern in many applications, such as hydrogen energy systems, automotive, aircraft, marine, bridges, and nuclear reactors. Exposure of metals and alloys to hydrogen during manufacturing, storage, or service – even a relatively small average concentration of a few atomic parts-per-million – can embrittle structural materials. Aluminum is more resistant to HE compared to, for instance, stainless steels or high-chromium martensitic

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ADVERTORIAL steels. In fact, the susceptibility of steels to embrittlement increases as their strength increases, and can potentially be a bigger problem in the case of additivelymanufactured steels as they possess a high number density of defects. In a separate study on AM of steels, I utilize APT to understand how atomic-scale structures relate to brittleness when exposed to hydrogen by observing individual hydrogen atom distributions within the nanostructure of AM stainless steels as illustrated in Fig. 3. I intend to conduct similar studies on my NUAdd alloys.

How might your research be used in aerospace/defense applications?

AF: I anticipate that our NUAdd Alloy series will be suitable for a wide range of lightweight applications that experience varying service temperatures, stresses, and corrosive conditions. There are many practical examples where materials are required to survive for long periods under load at high temperatures – a classic example is in the turbine blades of jet engines. In the interest of improved efficiency and performance, it is desirable to maximize the operating temperatures while minimizing overall weight. A heat-resistant aluminum alloy, therefore, is an attractive alternative to the titanium-based components currently used in the frontal sections of jet engines.

Additively manufactured alloys can be used to create lightweight yet durable components for weapons, vehicles, and equipment. In the energy sector, AM can be used to create parts for gas turbines, nuclear reactors, and renewable energy systems. This transformative technology also allows for real-time production of components in the field, enabling swift and efficient

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repairs and replacements. This capability is invaluable when it comes to crafting mission-critical components as it ultimately diminishes reliance on expensive or time-consuming resupply missions onboard a battleship, inside a spacecraft, or even (one day) on distant celestial bodies like Mars.

Carbon Deuterium

For more information on Dr. Farkoosh’s study, Enhanced age-hardening response and creep resistance of an Al-0.5Mn-0.3Si (at.%) alloy by Sn inoculation [6], visit: DOI:10.1016/j. actamat.2022.118344.

Do you anticipate commercial and industrial applications as well?

AF: Yes, definitely! The application of new additively-manufactured alloys continues to expand as materials science and 3D printing technology advance. These alloys offer the advantage of design flexibility, reduced material waste, and the ability to create complex geometries with unprecedented mechanical and physical properties that were previously impossible or cost-prohibitive with traditional manufacturing methods. As a result, many industries are increasingly adopting AM to improve efficiency, reduce costs, and enhance product performance.

Our NUAdd alloys can be used in high-performance automotive engines and exhaust systems, which experience elevated temperatures. Because these alloys enable the on-demand production directly from digital files, they can also serve as versatile generalpurpose materials that streamline product maintenance and support in the field, diminishing the requirement for extensive spare-parts inventories, as in my aerospace examples. For instance, Mercedes-Benz has embraced additive manufacturing to fabricate spare parts for their vehicles.

50 nm Fig. 3 A 3D atom-probe tomographic (APT) reconstruction of an additively manufactured QT17-4+ stainless steel provides convincing evidence for deuterium atoms being trapped within carbon-rich regions (i.e., austenite/ martensite interfaces, lath martensite boundaries and perhaps epsilon carbides). The APT analyses are conducted at 60 K in the voltage pulsing mode after electrochemically charging the specimen with deuterium.

Electrochemical deuteration was employed instead of hydrogenation to enhance the accuracy of compositional analyses with APT. Deuterium is a stable isotope of hydrogen, also known as heavy hydrogen [5].

The consumer electronics industry utilizes additive manufacturing for producing intricate electronic housings and components. Various alloys, including aluminum, are used to create lightweight, customized electronic enclosures for products, including laptops, smartphones, digital watches, and gaming consoles.

What’s next for you and your team?

AF: Materials are at the center of any major challenge we face.

To build a future of clean energy, we need more efficient engines,

solar panels, wind turbines, and batteries. Manufacturers need new materials to create more advanced products and replace materials subject to supply disruptions, such as rare earth elements. APT and AM technologies will enable the development of electric, fuel cell, and hybrid-powered vehicles, supporting the global movement towards environmental sustainability.

Expertise and a technology base in lightweight, high-strength AM alloys is an important part of reaching these goals.

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ADVERTORIAL

The Northwestern University Center for Atom-Probe Tomography (NUCAPT) is an educational research facility at Northwestern University in Evanston, Illinois. Founded in 2004 by David Seidman, NUCAPT provides instrumentation, expertise, and services for materials characterization at the atomic scale, in 3D, via APT and related techniques.

Research applications include local composition at surfaces, buried interfaces, and precipitates, compositional gradations, dopant profiles, and nanostructures in metallic materials, nanowires and semiconductor devices, quantum wells,

thin-film, fuel cell barrier layers, biominerals and hybrid materials, nanomaterials for catalysis and environmental remediation, nuclear, geology, and planetary sciences, as well cultural heritage materials such as ancient glass and paint pigment.

NUCAPT is open to researchers at all levels, including high-school interns, undergraduate, graduate, and post-graduate students from Northwestern University, as well as external users from other universities, industry, non–profits, and government laboratories. For more information, visit nucapt.northwestern.edu/NUCAPT.

“MY INTEREST LIES IN EXPLOITING THE UNIQUE CHARACTERISTICS OF AM TO DEVELOP ADVANCED HIGH-STRENGTH ALUMINUM ALLOYS TAILOR-MADE FOR AM, WITH MECHANICAL AND PHYSICAL PROPERTIES EXCEEDING THOSE OF THEIR CONVENTIONAL COUNTERPARTS.” — DR. FARKOOSH

References • A[1] A.R. Farkoosh, D.N. Seidman, “Additive manufacturing of ultra-strong precipitation-hardened aluminum alloys for high and ambient temperature applications,” Office of Naval Research, annual report (2023).

• [2] K.E. Knipling, D.C. Dunand, D.N. Seidman, “Criteria for developing castable, creep-resistant aluminum-based alloys - A review,” Z. Metallk. 97(3) (2006) 246-265. https://doi.org/10.1515/ijmr-2006-0042 • [3] O.C. Hellman, J.A. Vandenbroucke, J. Rüsing, D. Isheim, D.N. Seidman, “Analysis of Three-dimensional Atom-probe Data by the Proximity Histogram,” Microsc. microanal. 6(5) (2000) 437-444. https://doi.org/10.1007/S100050010051 • [4] A.R. Farkoosh, D.C. Dunand, D.N. Seidman, “Solute-induced strengthening during creep of an aged-hardened Al-Mn-Zr alloy”, Acta Materialia 219 (2021) 117268. https://doi.org/10.1016/j.actamat.2021.117268 • [5] A.R. Farkoosh, N. Eliaz, D.N. Seidman, “Influences of cohesion enhancing elements, impurities and hydrogen/deuterium at grain boundaries and heterophase interfaces on embrittlement of additively manufactured steels,” NSF-BSF, annual report (2023).

• [6] A.R. Farkoosh, D.C. Dunand, D.N. Seidman, “Enhanced age-hardening response and creep resistance of an Al-0.5Mn-0.3Si (at.%) alloy by Sn inoculation,” Acta Materialia 240 (2022) 118344. https://doi.org/10.1016/j.actamat.2022.118344

CAMECA is a global supplier of microanalytical and metrology instrumentation for research and process control. As a business unit of AMETEK, the company provides a diverse range of advanced characterization technologies that measure elemental and isotropic composition in materials down to atomic resolution, as well as equipping government, academic, and high-tech industry labs around the world.

www.cameca.com

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• cameca.info@ametek.com

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professional awards PROFESSIONAL AWARD WINNERS

R&D Leader of the Year

R&D Sustainability Innovator of the Year

Distinguished Professor Ashok Gadgil, Lawrence Berkeley National Laboratory

Bob Robinson Maughon, SABIC

Professor Ashok Gadgil is an exceptional R&D leader who has devoted more than 30 years to creating technological innovations for safe drinking water, clean air, sustainable energy, and reduced infant mortality, profoundly benefiting the health and dignity of low-resource communities. He has mentored numerous researchers pursuing impactful R&D careers, directed a national laboratory research division, directed a binational clean water-energy technologies research organization, directed a university development impact lab addressing global poverty, and developed and taught courses in development engineering at UC Berkeley.

Fueled by a deeply rooted passion to uplift hundreds of millions of people suffering from environmental, economic, and sociopolitical hardships, Gadgil tirelessly works beyond expectations to ensure his innovations reach target communities quickly. He has gained international recognition as a champion of R&D innovation and received numerous awards for developing technological solutions and blueprints for action to ensure those solutions reach people in need.

R&D Researcher of the Year Bharat Indu Chaudhary, Dow Dr. Chaudhary started his professional career with Dow R&D in Germany in 1990. He played a leading role in developing and implementing a proprietary global process technology for ETHAFOAM Extruded Polyethylene Foam made with a highly flammable blowing agent of zero ozone depletion potential. This successful initiative had a significant economic impact and set a sustainability theme that persists in his contributions. In 1994, Chaudhary transferred to the U.S., where he has worked in Dow’s different R&D departments. In his present role at Dow Wire & Cable, Chaudhary continues developing novel polymers and polymer compositions. His research and development activities have revolved around creating value by coaching individuals and teams based on his in-depth technical expertise, partnering with others within Dow, and collaborating closely with leading universities and institutes worldwide. The results from these collaborations were used in support of process/product development, 12 patent applications, 19 journal papers, and five conference presentations.

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Dr. Bob Robinson Maughon is the EVP and chief sustainability and technology officer at SABIC. He oversees a global organization with 19 research centers worldwide and a talented team focused on driving innovation to bring sustainable material solutions and products to the marketplace. Before joining SABIC in 2019, he served as the R&D vice president for Packaging & Specialty Plastics and Hydrocarbons at Dow. He is also actively engaged in developing bold sustainability initiatives through the World Economic Forum and the Alliance to End Plastic Waste, focusing on decarbonization, circularity, and enabling the energy transition to a sustainable future. Maughon is a visionary and thought leader in sustainability to drive change and transformation in the chemical industry.

R&D Team of the Year Energy Management System (EnMS), Lawrence Berkeley National Laboratory The EnMS team’s groundbreaking work has profoundly impacted global efforts to promote energy management business practices in the commercial, manufacturing, and institutional sectors. The team includes diverse academic and personal backgrounds with a wealth of experience and expertise. They have developed measurement and verification protocols and international standards, delivered technical assistance to organizations globally, developed professional workforce certification programs, and partnered with private and public sector organizations to accelerate the deployment of energy management business practices. The EnMS Team provides technical leadership to the International Standards Organization Technical Committee responsible for ISO 50001. It engages with representatives from more than 60 countries to advance energy management system standards.

R&D Technician of the Year Olena Palasyuk, Ames National Laboratory Olena Palasyuk has been a key team member of numerous research groups at Ames National Laboratory and contributing institutions that are members of its Critical Materials Institute (CMI). Her expertise in materials synthesis, magnetic measurements, scanning electron microscopy, thermal analysis, and X-ray diffraction have been crucial enabling techniques in understanding and controlling materials processing in a wide range of materials. Palasyuk oversees the X-ray diffraction equipment and trains new users in safe operations and how best to collect data for sample chemistries and morphologies. She is engaged in a multi-pronged science-based approach, looking for new, environmentally sound materials for energy, electronic, and transportation applications.

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DESIGN WORLD ONLINE EVENTS AND WEBINARS WEBINAR SERIES

DESIGN WORLD WEBINAR SERIES:

FOR UPCOMING AND ON-DEMAND WEBINARS, GO TO: www.designworldonline.com/designworld-online-events-and-webinars

Where manufacturers share their experiences and expertise to help design engineers better understand technology, product related issues and challenges.

AD INDEX Axalta Coating Systems........................................................................... 17 Industrial Technology Research Institute .......................................... 27 Institute for Information Industry ............................................................3 Lawrence Livermore National Laboratory .................................... IFC, 1 Los Alamos National Laboratory...................................................... 10, 11 Millennial Scientific ................................................................................... 44 Nano and Advanced Materials Institute (NAMI) ..............................IBC National Atomic Research Institute (NARI) ........................................ 22 Pacific Bio Sciences .................................................................................. 13 Pfeiffer Vacuum, Inc. ..................................................................................2 Pittcon .......................................................................................................... 41 Southwest Research Institute................................................................BC Tata Steel ......................................................................................................5 TESCAN ORSAY Group, a.s. ........................................................... 34, 35 The Hong Kong Research Institute of Textile and Apparels .......... 19 University of Arkansas - School of Engineering ................................ 31

Stay tuned to the latest research & development news The R&D World website is constantly updated with industry news, technology developments, case history stories, and all of the most current data about research budgets and future forecasts. From corporate to academic to government laboratories, the website — along with R&D World’s Twitter, Facebook, and LinkedIn pages — are your need-to-know information source for this industry!

SALES

LEADERSHIP TEAM

U.S. Sales Director Jim Dempsey 216.387.1916 jdempsey@wtwhmedia.com

Co-Founder, VP Sales Mike Emich 508.446.1823 memich@wtwhmedia.com @wtwh_memic

Jami Brownlee 224.760.1055 jbrownlee@wtwhmedia.com Mary Ann Cooke 781.710.4659 mcooke@wtwhmedia.com Mike Francesconi 630.488.9029 mfrancesconi@wtwhmedia.com Courtney Nagle 440.523.1685 cseel@wtwhmedia.com @wtwh_CSeel

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Co-Founder, Managing Partner Scott McCafferty 310.279.3844 smccafferty@wtwhmedia.com @SMMcCafferty EVP Marshall Matheson 805.895.3609 mmatheson@wtwhmedia.com @mmatheson

WINNER

Southwest Research Institute’s

WIDEBAND CONFORMAL CONTINUOUS-SLOT ANTENNA ARRAY

WINNER

recognized as one of the 100 most significant innovations for 2023.

State-of-the-art technology features: • high-performance direction-finding & signal acquisition across the UHF/SHF bands • a low profile, designed to conform around shipboard masts without requiring the mast top • durability necessary for shipboard environments • adaptability for other low-profile, restricted-space applications

Learn more about Southwest Research Institute’s Signals Intelligence Solutions: https://sigint.swri.org

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