R&D100 Winners - Mechanical/Materials

Fuel cell catalyst with ultralow Pt loading

Argonne’s LP@PF catalyst substantially reduces platinum usage in fuel cell cathodes through a novel synergetic ORR (oxygen reduction reaction) catalysis design. The MEA (membrane electrode assembly) prepared with this catalyst demonstrates higher fuel cell current and power densities than the commercial benchmarks, even at merely 1/10th and 1/6th of the cathodic Pt loading. It also showed excellent durability during the accelerated stress test, far surpassing commercial benchmarks and multiple DOE 2025 performance targets. LP@ PF catalyst lowers the platinum usage in the fuel cell stack. In fact, an 80-kW fuel cell stack in a passenger sedan using this catalyst will have total Pt loading of less than 7 g, about the same amount as currently used in the catalytic converter of a passenger car with an IC (internal combustion) engine. This low platinum usage will smooth the transition from IC engines to fuel cell in vehicle mass production.

High energy density and safe battery system for powering electric vehicles

Microvast — a leading developer and supplier of innovative lithium-ion battery solutions — partnered with Argonne National Laboratory to develop one of the highest-energy-density lithium-ion batteries available for electric vehicles. Microvast and Argonne accomplished this by successfully integrating three advanced battery components while maintaining fast-charging capabilities and critical safety attributes. By designing battery components optimized for performance and safety, Microvast and Argonne developed four state-of-theart products capable of being manufactured in high volume: an improved full gradient cathode with surface doping (invented by Argonne and scaled up by Microvast); an aramid separator that maintains its integrity at very high temperatures (developed by Microvast); a high-capacity silicon anode (developed by Microvast); and a novel pre-lithiation technology that suppresses irreversible losses (invented by Argonne). These breakthrough technologies are key enablers of electric vehicles that can travel long ranges between charges and are safe. These advances also hold significant promise for enabling even higher energy densities — and thus, longer. vehicle range — while maintaining safety and affordability.

Argonne’s fast, high-efficiency Thermal Energy Storage System (TESS)

Thermal energy storage system (TESS) rapidly stores heat and releases it on demand so the heat can be put to productive use, thereby greatly increasing the energy efficiency and cost-effectiveness of many industrial processes. TESS is finding many commercial applications because of this and also because of its unique modular design, which permits TESS units to be configured variously as individual modules of different sizes or as assemblages of large numbers of modules. This would be needed to allow baseload electrical plants to store heat energy for later conversion to electrical power to meet peak load requirements and to enable solar power plants to continue generating levelized electrical power during weather events, cloudy days, and nighttime hours. In TESS, heat is stored as the latent heat of fusion of a phase-change material (PCM), with heat transfer causing the material to either melt or solidify as heat is absorbed or released, respectively. The phase-change process is significantly higher in energy density than sensible heat storage, and latent heat storage systems have exceptionally high exergy efficiencies, as well.

Cobalt-based nanocrystalline alloys for gapless inductor and sensor applications

Patented cobalt-based nanocrystalline alloys, from National Energy Technology Laboratory, show superior mechanical properties, magnetic performance, and responsiveness to advanced manufacturing processes, such as in-line strain annealing. They enable the manufacture of novel electrical devices, including gapless inductors and sensors that offer unprecedented electromagnetic capabilities for next-generation power technologies, improving performance, boosting efficiency and reducing peak temperature. This market-ready product links atomic-level changes to grid-scale impacts by allowing customization of magnetic properties for a broad range of impactful electrical applications. Converging societal trends — such as the evolution of the nation’s energy infrastructure, demand for more efficient electrical machinery and increasing electrification of transportation — require advanced power magnetic components that provide efficient, reliable and power-dense solutions. Finally, the alloys offer the capability to develop advanced magnetic components that meet the technology demands associated with electrification of the nation’s transportation fleet, including automobile, aviation, aerospace, rail, and naval systems.

DeltaMax performance modifiers, masterbatches for polypropylene

Polypropylene (PP) impact copolymers are among the fastest growing plastics in the world as the demand for appliances, cars, and e-commerce goods drive the need for higher impact plastics. Commonly used in injection molding to create automotive and industrial parts, home goods, and lawn and garden products, consumers expect polypropylene impact copolymer products to be tough, durable, feature a certain quality of stiffness, and — especially in today’s environmentally conscious culture — use natural and material resources responsibly when manufactured. This, however, presents additional challenges to manufacturers to maintain the stiff qualities and impact strength of plastic products.

DeltaMax Performance Modifiers, masterbatches for polypropylene, developed by Milliken, address this problem with all-in-one solutions that maximize the flow properties, stiffness, and impact strength of polypropylene through reactive extrusion — altering the polymer structure to more efficiently use the impact modifiers present in the formulation while also enabling more recycled content to be incorporated in products.

High strength binder system for additive manufacturing

Binder jetting is an additive manufacturing technology that can create geometries out of a variety of materials without the need for costly directed-heat apparatuses such as lasers or electron beams. Any material that can be formed into a powder can be processed via binder jetting. Properties of the printed part, which is driven directly by the binder itself, have been a challenge to the binder jet technology. In this work, Oak Ridge National Laboratory has developed a novel binder for use in binder jetting machines that provides superior properties to artifacts printed sand, which is used in foundries (comprising over half of the binder jet industry). The binder also eliminates the need for toxic components of current foundry binders and provides an environmentally friendly option. Finally, the properties of the binder are so unique that many other applications for printed sand are being investigated, such as large wash-out tooling for carbonfiber composite manifolds and metallized artifacts for industrial and consumer goods.

Voltanol: Electrochemical conversion of carbon dioxide to ethanol

The carbon nanospike catalyst Voltanol is a nanotechnology-based catalyst composed of carbon, nitrogen, and copper. With this catalyst, carbon dioxide and water can be converted to ethanol in high yield using renewable electricity.

This electrochemical catalyst for the conversion of CO2 to ethanol is an example of the types of approaches society will need to transition off of fossil fuels. For the purposes of transportation, batteries will work well with low-dutycycle applications such as commuting. For heavy-duty applications such as commercial transport, aircraft and trains, liquid fuels have more than 10 times greater energy density and do not require extended charging times. Carbon-neutral liquid fuels, such as those produced by the Oak Ridge National Laboratory nanospike catalyst, can meet that need without emitting CO2. This catalyst can, in essence, store electricity in the form of a liquid for later use.

FEARCE: Fast, Easy, Accurate, and Robust Continuum Engineering: Improving fuel efficiency and reducing emissions in combustion engines

FEARCE (Fast, Easy, Accurate and Robust Continuum Engineering), multiphysics software from Los Alamos National Laboratory, improves the understanding of turbulence and how it affects combustion efficiency of fuel mixing with gases to create optimum energy and efficient vehicle power. FEARCE runs simulations on how engine components influence and improve the mixing process, adjusting turbulence inside an engine to generate more power with less fuel while releasing fewer pollutants. FEARCE allows researchers to reduce expensive physical experiments, by planning better engines with its improved modeling and prediction software tools. FEARCE could help make it possible to achieve gas mileages greater than 50 mpg. Such improved vehicle gas mileage could save more than 4 million barrels of oil per day, according to Robert Carling, Transportation Energy Center Director, Sandia National Laboratories, significantly decreasing greenhouse emissions.

Novel nanodiamonds for nanosensing and quantum computing

The NV (nitrogen-vacancy) and SiV (silicon-vacancy) color centers in diamonds provide a suitable platform for quantum information processing and nanosensing with roomtemperature functionality. These defects can exhibit long spin relaxation and coherence time and can be manipulated electronically, photonically, and thermally. Currently, NV and SiV nanodiamonds are synthesized by detonation, ball milling, and ion implantation, resulting in impurity contamination and generation of defects, which cause environmental decoherence. In addition, control of position and orientation of NV and SiV centers are well beyond the capabilities of the current methods. Thus, creation of these color centers without other harmful defects and impurities, and deterministic placement of them in right orientation in crystalline diamond lattice have presented major challenges. Enter Q-Carbon’s recent research breakthrough, where carbon can be converted into diamond in the form of nanodots, nanofibers, and thin films by pulsed laser annealing at ambient temperature and pressure. These nanostructures can be grown eptaxially and doped with NV and SiV at concentrations exceeding the thermodynamic solubility limits.

Lotus Superhydrophobic Compositions and Coating Process (LotusFlo)

In the oil industry, the drilling process faces myriad challenges in extracting petroleum from beneath the ocean floor, including asphaltenes, which are sticky and tar-like molecular substances found in crude oil; paraffins, soft waxy materials that are derived from petroleum; and inorganic scales, which are mineral deposits that form from the mixing of water with different types of salty liquids. All of these substances adhere to pipes, accumulate and occlude the oil flow and are very costly to remediate. The Lotus Researchers at Southwest Research Institute have developed the Superhydrophobic Compositions and Coating Process (LotusFlo) technology, which is aimed at solving two specific problems: preventing these materials from adhering to pipe surfaces and creating an effective, efficient application process for the coating that is scalable to large production volumes of coated pipe. The technology combines the chemistry of the coating as well as the process by which it is applied, specifically to long tubular structures.

Enhanced performance anodic epoxy electrocoat

PPG researchers developed the enhanced performance anodic epoxy electrocoat POWERCRON160 to deliver the superior corrosion protection of electrocoat to products with rough metal surfaces for the first time. Electrocoat has been used in the automotive industry for more than 50 years and is one of the key reasons that vehicles no longer rust like they used to. However, electrocoat has always been limited to a thickness of about 50 microns — too thin to protect the peaks of metal on a rough surface such as a cast iron pipe. Through a combination of innovative polymer design, crosslinker, and additive technologies, quality films of Powercron160 can be applied at previously impossible thicknesses up to 200 microns. It provides outstanding corrosion protection to cars, appliances, airplanes, and any other electrically conductive object that can be immersed in water and baked in a cure oven. These coatings are environmentally friendly in that they are water-based and are applied with nearly 100% efficiency (no overspray), which minimizes material waste.

Nano-functionalized alloys for additive manufacturing

HRL’s nano-functionalized alloys address a longfelt need to reduce cost and increase strength in powder bed metal additive manufacturing. Metal AM processes have significant potential to circumvent the limitations of traditional manufacturing routes and enable optimized free-form geometries with arbitrary complexity. Because AM approaches are agnostic to the component being produced, they are ideal for limited production runs (e.g. customization) or for immediate spare parts or platform sustainment. In order to realize these benefits, AM materials must be competitive with incumbent structural alloys employed in the aerospace, automotive, medical, and consumer product industries. HRL’s nano-functionalization approach enables AM materials produced to be performance and composition comparable with their wrought counterparts, a significant leap forward in both functional and cost competitiveness of metal AM. The impact of this disruptive approach and its rapid transformation into an industrially viable product has been recognized by the world’s most impactful scientific journal (Nature) as well as numerous respected trade associations.

SolarEdge: World’s 1st EV charging solar inverter with solar boost mode for up to 6X faster charging

SolarEdge wanted to combine the PV and EV markets in order to accelerate the adoption of both. SolarEdge’s R&D developed the world’s first EV charging solar inverter, which enables solar energy to power EVs, reducing dependence on fossil fuel and shrinking carbon footprints. By supplementing the grid with PV power, the SolarEdge EV charging solar inverter uses its innovative solar boost mode to offer ≤6X faster charging than a standard Level 1 charger. If PV is not available, the EV charger uses grid power for charging ≤5X faster charging than a standard Level 1 charger. This integrated solution offers users reduced total cost of ownership. Management and monitoring of PV and EV is all from a single app. This one elegant solution also helps to decrease stress on the electric grid by helping to use the intermittent supply of solar energy to support the unprecedented energy demand patterns from EVs.

Dow Release Modifier for high efficiency label manufacturing

Controlling release force properties is the greatest challenge in release-coating technology. Dow SYL-OFF SL 25 Release Modifier enables high-speed converting and minimizes the risk of web break during label converting processes, representing a new standard in pressure-sensitive labels. As processing and converting conditions become more challenging, performance requirements also increase. SYL-OFF SL25 is designed to meet these demands offering a flatter release profile. In addition to its benefits during processing, SYL- OFF SL25 Release Modifier is a solventless and olefin-free formulation. The performance profile of the pressure-sensitive construction can be tuned to meet the low release forces that enable high-speed matrix stripping operations, while simultaneously delivering the higher release forces needed at end use applications such as hand-peel.

GREAT STUFF Smart Dispenser

The GREAT STUFF Smart Dispenser, from Dupont, is an innovative solution to make air sealing easier, more precise, and with less product waste. The dispenser is reusable for up to 30 days, provides no drip, less mess and greater control. Consumers can worry less about wasting a nearly full can of GREAT STUFF after one use, as this new technology and dispenser design will give end users the flexibility to move from project to project seamlessly, with the option to come back to their air sealing job at a later time. Listening to customer feedback and going back to the drawing board, the new patent-pending dispenser was developed answering the two biggest complaints: messiness and the lack of reuse. GREAT STUFF provides a simple, cost-effective solution to improve energy efficiency and indoor air quality.

Eshmuno CP-FT resin

Removing aggregates during the downstream purification of monoclonal antibody (mAb) therapeutics is imperative since these impurities increase the risk of an immunogenic response and can reduce efficacy. Aggregates are the most challenging impurity to remove in the downstream purification of mAbs, as they are not removed by protein A chromatography and they have very similar isoelectric points and hydrophobicities to the monomeric protein. MilliporeSigma’s Eshmuno CP-FT resin is the first CEX resin designed to efficiently remove aggregates using flow-through frontal chromatography. It has a novel tentacle ligand technology composed of both negatively charged ligands and neutral spacers that was optimized for the efficient removal of mAb aggregates. The unique tentacle structure facilitates displacement of the bound monomer by aggregates, which is the key process in a flow-through frontal chromatography mechanism.

DIFA (Distance Fabric) — New dimension of weaving machine

By integrating weaving, mechanical and electrical engineering, and electromagnetic, optical, pneumatic, and artificial algorithm technologies, the Taiwan Textile Research Institute and the VUTS research team in the Czech Republic have collaborated to produce a unique machine that can weave 3D fabrics with variable heights to produce distance fabrics with an interlaced structure. The air-jet weaving machine, called the DIFA, produces innovative composite materials that can be used to improve the durability of airbags and produce rigid, lightweight panels. The DIFA has instigated a departure from the traditional techniques that have been used for more than 30 years in the creation of sandwich and spacer fabrics. It enables the production of reinforced composite materials in various fields, such as those of aerospace technology, transportation, boat construction, architecture, sports, rescue technology, water activities, and energy generation, and thus might inspire further developments in these fields.

Bionic Intelligent AGV Fleet System

The Bionic Intelligent AGV (BI-AGV) Fleet System, from the Metal Industrial Research & Development Centre, imitates the agility and mobility that ants exhibit when carrying objects, which means all of the Centre’s power wheel models can move autonomously, as well as form into an optimal arrangement to carry an object collaboratively according to the shape and weight of the object. The flexibility they show in response to the size, shape, and the weight of objects being carried can cut down costs spent in purchasing different models of AGVs. Simply put, they have unified different AGV specifications. The BI-AGV System not only changes the manufacturing chain, sales, and application of AGVs but brings forth a new way of thinking for smart factories and automatic warehousing systems.

High impact polymer resin

Polypropylene is among the fastest-growing plastics in the world, injection-molded to make automotive and industrial parts, home goods, and lawn and garden products. There are, however, inherent tradeoffs between melt flow properties, stiffness, impact strength, and use of recycled content when manufacturing products. Milliken & Company has developed DeltaMax Performance Modifiers masterbatches for polypropylene, representing a breakthrough in this long-standing struggle in the plastics industry. These easyto-use additives increase the polymer melt flow rate of polypropylene without sacrificing durability — in fact the recycled resin mirrors or even surpasses the properties of virgin polypropylene in strength and application. It enables the use of up to 100% post-consumer and post-industrial recycled resins, improving manufacturers’ energy savings and environmental impacts, and simplifying the formulation process for polymer processors through an all-in-one solution. DeltaMax Performance also enables lower operating temperatures, saving energy and increasing the efficiency through reduced injection-molding equipment cycle times.

Marvite Materials

(These products are named in honor of the key inventor, Marvis White, who is suffering from Amyotrophic Lateral Sclerosis (ALS) and is now retired from Engi-Mat Co.)

Marvite Materials provide improved heat dissipation in motors and similar machines by providing a high thermal conductivity flow path from the windings to the motor housing while providing the necessary electrical insulation. Marvite Coated Wire and Marvite Motor Resin (or motor varnish) each provide a dramatic increase in thermal conductivity relative to conventional materials. Together, these two distinctly formulated materials — which are collectively referred to as Marvite Materials — provide a highly effective heat flow path in a motor. Incorporation of Marvite Materials in the build of a motor, in place of conventional coated wire and motor resin, results in lower motor temperatures, improved operating efficiency and increased motor power density. Relative to a motor with conventional materials, a motor with Marvite Materials can either provide the same power with a smaller size, or increased power at the same size. Additionally, Marvite Coated Wire offers a thermal index of 281° C, offering extended operating lifetimes as well as enabling increased motor life at elevated temperatures.

Capacitor-assisted high-power battery

GM has invented a disruptive capacitor-Assisted Battery (CAB) technology in which a hybrid electrostatic and electrochemical capacitor is implemented and co-exists within the same cell of virtually any Li-Ion intercalation electrochemistry. CAB products have demonstrated superior cold cranking to -30° C and outstanding high temperature (up to 55° C) durability compared to base Li-Ion alternatives. The technology has also demonstrated reduced discharge voltage droop, which is crucial for high-powered automotive motors, as well as greater charge acceptance for regen within system voltage limits. The longer life and superior performance enable reduced pack volume, weight, and cost for low-voltage systems. The new CAB battery simultaneously provides superior benefits for meeting peak power demands and fast charging needs of ultra-high energy density chemistries in higher voltage systems, as well as nonautomotive market applications.

A green battery printed on LoRa-IoT devices

NAMI’s Printed Battery-HP was engineered to meet demands from thin and flexible LoRa-IoT devices and applications that will soon face the market. Printed Battery-HP provides unprecedented power performance for any flexible printed batteries, characterized by the ability for this battery to reliably supply pulse currents of 45 mA and also maintain performance at a low temperature of -20˚ C. Such performance was previously not possible for other flexible printed batteries. The significant improvements were made into every battery component, i.e. the printed carbon current collector, cathode, anode, and electrolyte. As a result of improvement in all these areas, Printed Battery- HP achieved a quadruple reduction of internal impedance, with four times higher peak current capability compared to available printed batteries on the market. Also, the battery only reaches the cut-off voltage after the active materials become exhausted. Full utilization of the battery capacity for carrying out high current pulses adds cost effectiveness for the LoRa-IoT devices that will be powered by NAMI’s Printed Battery-HP.

SILASTIC MS-4007 moldable optical silicone for Eaton’s Ephesus LumAdapt 8 LED Sport’s Stadium Light

SILASTIC MS-4007 is a versatile new optical material that enables innovation for advanced LED lighting systems with unprecedented design freedom and photothermal stability relative to traditional injection-moldable optical plastics. This innovation allows optical designers and manufacturers to produce complex lenses with more efficient integration of modern LEDs, improving both form and function. The Ephesus LumAdapt 8 LED luminaire, with secondary optics fabricated from SILASTIC MS-4007, is an excellent example of how new material innovations can lead to product innovations. The LumAdapt system delivers 50,000 lumens through a customized optical system that allows for dynamic beam tuning to enhance the viewing of indoor and outdoor sporting events for athletes, spectators, and at-home television viewers. The hydrothermal and mechanical stability of SILASTIC MS-4007 allows the optical elements in the LumAdapt system to withstand demanding environmental conditions.

Polartec Power Air

Polartec Power Air is the first fabric technology engineered to reduce fiber shedding. By encapsulating lofted fibers within a multilayer, continuous yarn fabric construction, this revolutionary new platform offers advanced thermal efficiency that is proven to shed five times less than other premium ‘mid-layer’ weight fabrics. Insulation that effectively regulates core body temperature has traditionally been achieved via lofted or high pile knit structures that hold warm air. Although Polartec is a leader in making resilient materials, it has recognized that any exposed fiber is susceptible to shedding as a function of normal wear. The Polartec Power Air construction process mitigates this by encasing the insulating lofted fibers within the knitting process. As such, Polartec Power Air will enable more responsible, durable and versatile apparel design by the world’s leading apparel brands, which rely on Polartec for textile innovation.

First polyethylene-based build material in 3D printing: EVOLV3D OBC

EVOLV3D Olefin Block Copolymer (OBC) is a unique build material designed for 3D printing by both Fused Filament Fabrication (FFF), one of the most common methods for 3D printing, and direct pellet printing. It is produced by a Dow proprietary process resulting in unique performance properties useful in applications where low-density, chemically resistant, durable, recyclable polymers are required. The unique property set empowers designers and engineers seeking to develop prototypes and functional parts for a wide variety of applications. It’s best described as a rigid elastomer, different from most 3D printable polymers that are rigid, brittle materials. It brings a totally unique set of material properties to the design palette. Dow’s EVOLV3DTM printing technology platform revolutionizes 3D-printing by providing novel, high-performance, and more sustainable material solutions. Acceptance of 3D-printing beyond prototyping applications is limited by the availability of materials with a performance window beyond high modulus, low elongation, rigid materials.

Phononic’s F200 Merchandising Freezer

The Phononic F200 Merchandising Freezer disrupts the food & beverage category through the use of solid-state technology. Built on a small thermoelectric chip about the size of a thumbnail, Phononic’s solid-state cooling approach integrates the phases of pumping, moving, and controlling heat to create a powerful thermoelectric cooler (TEC) — known as the Phononic Thermal Engine — that is flexible, sustainable, and commercially viable. Notably, the Phononic F200 is unique among freezers in that heat is dispersed across the entire surface of the freezer unit as opposed to being focused at one point like traditional systems. This eliminates the excessive heat output common of today’s refrigerators and freezers, which rely on CFCs, hydrocarbons, and other toxic refrigerants to operate their compressors. By eliminating the use of these chemicals and leveraging a more sophisticated form of heat displacement, the Phononic F200 can be placed in locations never before considered for freezer units, such as right at checkout near temperature-sensitive goods, such as candy bars, gum, and other snacks.

High thermal conductivity impregnating resin — Voltatex 4224

By using Axalta’s new Voltatex 4224 as an impregnating resin the performance of electric motors can be increased significantly, by conducting the thermal energy as fast as possible from inside to outside of the electric device. That enables the motor manufacturer to increase the performance of the electrical machine while keeping the temperature of the motor at an acceptable level. Voltatex 4224 also allows the reduction of size and weight of the electrical device. When using standard impregnating resins, the size is dictated by the ability to manage the thermal energy inside the motor. By using Voltatex 4224 thermal energy can be better transferred out from the motor allowing for smaller motor sizes at equivalent performance levels. Application of this unique material can also be used for generators and transformers. Voltatex 4224 is based on a specially designed unsaturated Polyester resin, which is patent protected.

Thermally conductive and emissive PBT resin for heatsink applications

Crastin FR1301TC BK350 was developed by Dupont Transportation & Industrial as a thermally conductive resin to replace aluminum heatsink for lightweighting and high heat emissivity in highpower LED housing. Electric applications such as LED and ECU need both thermal management and light weighting broadly. Highly flowable thermally conductive resin, Crastin FR1301TC BK350, can expand the applicable range from small to large applications with injection molding across all industries. Furthermore, the feature of NMT compatibility can accelerate the light weighting in both existing and new applications based on the concept of thermally conductive resin. Crastin FR1301TC BK350 can drive a new design of every application and usage which has been limited by the increasing power of electronic devices.