Research & Development Advanced Materials

Foster-Miller's research & development advanced materials laboratories and staff of over 65 scientists and engineers cover a broad spectrum of materials including polymers, metals, ceramics, high-performance films and fibers, composites, specialty coatings; electronic, optical and medical materials. We routinely provide fully integrated, cost-effective solutions for both government and commercial customers. In addition, we have a portfolio of more than 100 patents that can help our customers establish a unique competitive advantage in their market sector.

Foster-Miller scientists, chemists and engineers, experts in research & development of advanced materials and polymer processing,  have the experience and expertise to solve difficult materials related problems and provide integrated solutions. We provide a variety of services to government and commercial sectors, including the following:

• Identification, evaluation and validation of specific materials for challenging applications.
• Development of equipment and systems for converting difficult to process polymers into intermediate forms and/or end products.
• Development and/or modification of polymer systems for property enhancement and/or reduction in manufacturing cost.

We are also a world leader in processing thermotropic and lyotropic liquid crystal polymers (LCPs) into thin films and net shape parts. Our exceptionally high strength and very low permeability LCP films/extruded components are used in a variety of programs and applications including printed circuit boards, biomedical devices and probes, substrates for solar cells, microelectronics packages, and fuel cell membranes. Programs have been carried out focusing on demonstrating commercially viable PCB and package fabrication processes using LCP. Successful process techniques should enable LCP materials to be used for the next generation of high-performance electronics. Based on this work, Foster-Miller is able to provide LCP film samples for test and evaluation for applications, and can develop processes and equipment for converting LCPs into high value products.

Foster-Miller has more than 20 years of experience working with advanced composite materials. Braided 2D and 3D fiber preforms, ultrasonic lamination and densification, multi-functional composites, and part design and fabrication are core competencies. Our facilities can handle most composite fabrication methods including hand lay-up, autoclave molding, filament winding, braiding and resin transfer molding (RTM). Customers include all three armed services, aerospace primes and biomedical device companies.

Successful composite implementations require fully integrated design solutions that concurrently address application requirements, material properties and manufacturing processes. We work with our customers to define the design, then fabricate proptotypes for customer test and evaluation. Finally, we transition the developed manufacturing processes to the customer for production. An example of one of our innovations that has had widespread industry impact can be found in Projects under the title, "Z-Direction Tape Reinforcement of Composite Laminates."

Foster-Miller has numerous scientists and engineers working on cutting-edge technologies within this discipline, focusing on high-temperature and structural materials applications. We hold solid intellectual property positions in ceramic oxide preforms, pre-ceramic polymers, co-continuous metal matrix composites, and brazing and joining of dissimilar materials.

One recent project in this area involves alternative filaments for incandescent light bulbs; DOE is sponsoring this project in hopes of promoting a dramatic increase in energy efficiency. Foster-Miller's technology provides a ceramic material of appropriate morphology that emits light efficiently in the visible spectrum without also emitting in the (non-visible) infrared spectrum, thus having the potential to double efficiency of today's bulbs. We fabricated ceramic structures that demonstrate good visible emission and are robust to the thermal shock of switching lamps on and off. Current work is aimed at optimizing structures that minimize emission in non-visible regions.

Foster-Miller has leveraged its advanced materials expertise to create breakthrough innovations and applications for high performance electronic and optical (visible and infrared) materials.

We have a long history with liquid crystal polymers (LCPs), evolving from initial research & development of the world's first viable (biaxially oriented) LCP films to application areas including electronic packaging and interconnection, long-life food and beverage packaging and cryogenic liners. Of particular impact and significance is the application of LCPs as an electronic substrate and packaging platform. LCPs have a unique combination of properties that make them ideally suited for MEMS and high density electronic substrate applications. Programs have been carried out focusing on demonstrating commercially viable PCB and package fabrication processes using LCP. Successful process techniques should enable LCP materials to be used for the next generation of high-performance electronics. Based on this work, Foster-Miller is able to provide LCP film samples for test and evaluation for applications, and can develop processes and equipment for converting LCPs into high value products.

In addition we have expertise in formulation and processing methodologies to enable use of polymer dispersed liquid crystals for holographic and diffractive optics. Foster-Miller has been a leader in demonstrating an extensive array of applications using optically or electronically switchable Bragg gratings for laser beam steering, multilayer arrays, switchable lenses, and fiber optic wavelength control devices for optical data storage and filtering of communication signals.

Over the past decade, Foster-Miller has developed considerable expertise in infrared materials, including sapphire, silver halides, ZnSe, ZnS and chalcogenides with applications ranging from net shape infrared windows to development of evanescent sensors and functional devices for chemical and biological sensing, EMI shielding for infrared seekers, to tunable emissivity for a variety of military platforms and spacecraft, to novel infrared detectors.

Nanostructured Materials

As a nanotechnology company, Foster-Miller has worked for more than five years on advanced materials that incorporate nanometer size fillers into organic matrix materials to enhance both mechanical and electrical performance. A range of fillers has been employed, including nanostructured clays and polyoligomeric silsequioxanes, but particular emphasis has been placed on carbon nanotubes. Foster-Miller has worked with Carbon Nanotechnologies, Inc. (CNI) to explore the use of single-walled carbon nanotubes for a range of commercial and government applications.

One project in this area focused on conductive gap sealants on Navy aircraft. We developed conductive compounds by preparing and dispersing single walled carbon nanotubes in a way that optimized their conductivity. The compounds had equivalent conductivity to those used in practice while being 40 percent lighter. In addition to developing the formulation and process details on the prototype level, full-scale production materials, machinery, processes, and quality determinations were defined.

We are also developing processes and equipment to electrospin nanofiber based woven mats that are porous and breathable, yet provide excellent barrier protection against chemical and biological agents. These nonwoven mats also possess extremely high specific surface areas, making them an excellent material for biological applications involving cell adhesion and drug encapsulation/delivery. A 48-nozzle prototype manufacturing system is being developed for producing 10 to 18 inch wide continuous lengths of nonwoven nanofiber based fabrics.

Foster-Miller encompasses a wide range of technical capabilities and expertise, including structural materials design, textile processing, electronics packaging, and sensors. Thus, we are ideally suited to carry out multidisciplinary research and development programs related to materials that can perform multiple functions at the same time.

In an Army program, for example, we investigated fully integrating antennas into soldier uniforms so they can transmit information while maintaining full antenna performance, ergonomic functionality and weight of an existing uniform. The program first determined suitable body placement for antennas, then evaluated antenna design, developed the embedded antenna prototype, and measured performance. Antenna performance measurement was possible mainly due to Foster-Miller's experience in electro-textile fabrication. The program established feasibility of the concept while determining some specific design trade-offs and optimizations necessary for field implementation.

Foster-Miller has developed ultraviolet (UV) curable resins for coatings applications, environmentally compliant resins with low to no volatile organic compounds (VOCs), and environmentally compliant controlled-release gel additives for corrosion resistant coatings. We work with coatings companies and end users to develop coatings to protect metal parts from corrosion. Foster-Miller's technology for UV-curing resins provides outstanding adhesion, better than conventional UV cured resins, which show poor adhesion.

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