Materials and Advanced Manufacturing

Assurance; Chemistry, Materials & Coatings; Manufacturing & • Hafnia gate dielectrics for energy conversion offer a novel solution for enhanced performance in wide bandgap semiconductor device applications today and beyond​ Business Problem The electrical grid is facing increasing pressure...

Chemistry, Materials & Coatings • LEAP-L technology offers a cost-effective, energy-efficient, and sustainable solution for gas capture and separation via the use of environmentally friendly materials The reliance on energy sources like biogases, natural gas,...

Chemistry, Materials & Coatings • Summary Traditionally, organic polar substance separations, especially chemically related polar substance separations, have been very difficult to achieve. Description Sandia has developed a novel separations media using a crystalline manganese...

Manufacturing & Assurance • Rigid Polyurethane Foam Absorbs Energy, Worker Safe, and Environment Friendly TufFoam is a toluene diisocyanate (TDI)-free, CFC-free water-blown, closed-cell, rigid polyurethane foam available in densities from 2 to 40 pounds...

Assurance; Chemistry, Materials & Coatings; Manufacturing & • By addressing thermal expansion mismatch, this innovative molecular system can enhance polymer durability for a wide range of applications. Business Problem Polymers are lightweight, cost-effective, easily molded, and have good...

Assurance; Chemistry, Materials & Coatings; Manufacturing & • Materials Data Driven Design, or MAD3, is an award-winning software enables accurate simulations of complex material deformation for a wide range of applications. The Sandia team behind the development of...

Manufacturing & Assurance • An additive manufacturing method using new resin chemistries and dual wavelength photocuring to rapidly create high-resolution parts with improved strength and durability This technique of vat-based 3D printing for robust...

Manufacturing & Assurance • A new method of additive manufacturing that leverages fluidics and electrochemistry to rapidly produce high-quality parts with engineering materials. Existing methods of metal 3D printing are ineffective in creating micro-resolution...

Chemistry, Materials & Coatings • An alternative to high-pressure hydrogen compression that can isolate thousands of new metal hydride compositions for hydrogen storage applications Hydrogen compression is one of the key components of a hydrogen-based...

Assurance; Chemistry, Materials & Coatings; Manufacturing & • A compact, high-throughput diagnostic tool for characterizing laser-based processes Characterizing the laser absorptivity and efficiency compensation of laser-based processes can provide useful avenues for defect characterization and mitigation; however, laser-metal...

Chemistry, Materials & Coatings • A process to prevent delamination failure and increase the long-term safety and performance of composite structures while reducing costs and adverse impacts. Delamination is a common failure in laminate composite...

Chemistry, Materials & Coatings • Highly localized, site-specific additive manufacturing of high power conversion efficiency (PCE) crystalline materials for semiconductors and functional devices Semiconductors are foundational materials that underpin all modern electronic devices ranging from...

Chemistry, Materials & Coatings • An architected porous stamp fabricated using multiphoton lithography (MPL) can achieve very fine tunable features and exceptional control in liquid transfer printing Mass production roll-to-roll printing techniques such as flexography,...

Chemistry, Materials & Coatings • Sandia’s electromechanical grip tester allows for simultaneous electrical and mechanical testing, resulting in reduced testing time and decreased costs. The increasing demand for products to meet industry accepted performance standards...

Chemistry, Materials & Coatings • Recent breakthroughs in hybrid advanced manufacturing and advanced alloys can significantly extend the temperature and pressure operational range of heat exchangers Description When it comes to their material properties, high-efficiency...

Chemistry, Materials & Coatings • A technique for tailoring the mechanical properties of traditionally low-strength and low ductility alloys using laser beam powder bed fusion (LB-PBF) additive manufacturing Additive manufacturing (AM) offers unprecedented design freedom...

Assurance; Chemistry, Materials & Coatings; Manufacturing & • A two-step additive manufacturing approach for forming highly conductive, high-resolution electrical traces and components with properties suited for flexible and hybrid electronics Electrical traces and conductive components are essential features...

Manufacturing & Assurance • A micronozzle adapter capable of printing line widths and thicknesses 10x finer than existing 3D plasma jet printers Heightened interest in next-generation printable and flexible electronics is accelerating research and...

Manufacturing & Assurance • An easy-to-install wire rivet for making electrical connections to multiple substrates in less time with fewer parts There is a need to provide a simple and quick electrical connection to...

Chemistry, Materials & Coatings • Elastomers are polymeric materials with elastic properties used in gaskets, seals, tubing, and other products that provide critical sealing functions in diverse settings Elastomers are polymeric materials with elastic properties...

Chemistry, Materials & Coatings • Lower-cost strengthened glass substrates for smart phones, smart watches, tablets, and other durable, impact-resistant applications Glass substrates with enhanced strength and durability are in high demand for use in handheld...

Manufacturing & Assurance • An apparatus that uses load frames to conduct Mode I Fracture Testing of bonded structures without surface prep, adhesive mixing, alignment jigs, or prolonged wait times Fracture testing drives material...

Chemistry, Materials & Coatings • A process for generating polymeric replicas of biological cells and soft tissues that retain the structure and mechanical properties of their natural counterparts Novel and more sophisticated three-dimensional (3D) soft...

Manufacturing & Assurance • An integrated tool with the ability to lift, rotate, and lock a suspended work piece at any angle — eliminating the need for manual operators or additional custom fixtures to...

Chemistry, Materials & Coatings • Metal hydride nano-inks for printing electrically conductive, metal-based patterns under ambient conditions that broaden the scope of printable electronic conductors Metallic inks are useful for flexible displays, smart packaging, environmental...

Chemistry, Materials & Coatings • A low-cost, environmentally-friendly thin film coating with demonstrated atmospheric corrosion resistance that meets or exceeds conventional coatings 10x as thick Metals across nearly every industry have a need for high...

Chemistry, Materials & Coatings • A rapid electropulsing method to reduce chemical microsegregation in metallic additively manufactured (AM) parts comparable to conventional heat-treatment techniques in a fraction of the processing time For many applications, the...

Chemistry, Materials & Coatings • A simple, rapid, and volume-scalable method to produce high quality coinage metals for nanoinks Printed and flexible electronics are a fast-growing area of interest with commercial applications ranging from wearables,...

Manufacturing & Assurance • Design and manufacturing companies specializing in valves, tubes, and other gas and fluid system components continue to battle the age-old problem of fitting pipes and tubing together quickly and reliably....

Manufacturing & Assurance • A linearized joint interface that delivers greater predictability and reduced variation in the structural response of complex assemblies Predicting the dynamic properties of a structural system is particularly valuable for...

Manufacturing & Assurance • A compliant flexure design with highly tunable features to reduce error and over-constraint in sophisticated manufacturing and assembly environments Conventional fasteners like nails, bolts, and welds are subject to manufacturing...

Chemistry, Materials & Coatings • Multifunctional organic optically re-writeable (ORW) materials with enhanced tunability, micron scale accuracy, compatibility with diverse substrates, and self-healing properties Since the rise of liquid crystal displays (LCDs), organic liquid crystals...

Chemistry, Materials & Coatings • Chemical warfare agents (CWAs) present a threat to national security at home and abroad. Current methods to neutralize CWAs and organophosphates rely largely upon reactions in water-based conditions. Though broadly...

Manufacturing & Assurance • All objects with temperatures above 0 K emit electromagnetic waves or radiation. In theory, the temperature of an object can be calculated by measuring the intensity of this emitted radiation....

Chemistry, Materials & Coatings • After decades of utilizing nuclear energy, the United States and countries abroad have been seeking effective methods to store radioactive waste from spent nuclear fuel. Conventionally, the international community has...

Manufacturing & Assurance • There is a need for high volume material testing/qualification, but industry and researchers are currently limited by commercially available testing devices. Most wear testers can only handle one sample at...

Chemistry, Materials & Coatings • From cell phones to satellites, industry spends millions on traditional gold alloy electrical contact coatings While gold and other metal alloys have been an industry standard to protect metal components...

Chemistry, Materials & Coatings • The ability to track underground fluid flows in oil and geothermal wells is critical to allow operators to extract energy as efficiently as possible. This information will allow operators to...

Manufacturing & Assurance • A high-sensitivity X-ray Phase Contrast Imaging system for non-destructive 2D radiography and 3D tomography of low-density composite materials Sandia National Laboratories has developed a high-sensitivity X-ray Phase Contrast Imaging (XPCI)...

Chemistry, Materials & Coatings • Sandia National Laboratories developed an organic glass scintillator that will improve safety and security at our nation’s ports and borders. Current radiation monitors typically utilize plastic scintillators, which are unable...

Chemistry, Materials & Coatings • Due to current manufacturing methods, nanomaterials suffer from a lack of uniformity resulting in efficiency and reliability issues. Sandia National Laboratories developed an innovative crystallization method that produces well-defined multi-functional...

Manufacturing & Assurance • There are many examples of surface modifications that reduce resistance to flow and improve performance. For instance, a dimpled golf ball can travel twice as far as a smooth ball...

Manufacturing & Assurance • Many systems require miniature coil-wound springs, such as firing devices, medical, and precision instruments. In order to qualify miniature springs, manufacturers of these systems rely on commercially available testers that...

Manufacturing & Assurance • Additive manufacturing (AM) material assurance has relied upon traditional test coupons and testing methods which work well for wrought materials, but fail to address the unique and not as well-known...

Manufacturing & Assurance • Sandia National Laboratories has developed an experimental apparatus that is capable of obtaining intermediate-rate stress-strain data of materials that have previously been unavailable due to a lack of instrument precision....

Chemistry, Materials & Coatings • Nanosolders allow for increased capabilities in the formation of soldered interconnections for heat sensitive electronic packages. The desired characteristic of nanosolder is to have a low process temperature that does...

Chemistry, Materials & Coatings • Sandia has expanded upon research into microstructured semiconductor neutron detectors and created a silicon-based device with greater sensitivity than the current state-of-the-art with adaptability for detection of general particles/radiation. Sandia’s...

Manufacturing & Assurance • Extreme temperatures are vital to scientific and industrial processes such as cryogenics, metallurgy, tempering, and tribology. However, sciences and processes such as these are inherently dangerous. Furthermore, experimenting with extreme...

Manufacturing & Assurance • Sandia National Laboratories has developed a novel tool that allows users to qualify small diameter bearings before incorporating them into components. Sandia’s High Sensitivity, Environmentally Isolated Bearing Tester was developed...

Manufacturing & Assurance • SummaryLocal Exhaust Ventilations (LEV) are vital engineering control systems used to prevent exposure to harmful airborne contaminants in the workplace. When fumes are produced, LEV systems produce enough suction to...

Chemistry, Materials & Coatings • A composite coating with enhanced resistance to whisker penetration and improved thermal conductivity and dielectric properties In order to comply with the Restriction of Hazardous Substances (RoHS) directive, pure tin...

Manufacturing & Assurance • Ultrasonic testing is a nondestructive inspection (NDI) technique that uses ultra-high frequency sound to detect flaws within a part of interest Ultrasonic testing is a nondestructive inspection (NDI) technique that...

Chemistry, Materials & Coatings • Nanocrystalline iron nitride is an important soft magnetic material; however, conventional methods of production don’t exist. Synthesis of dense nanocrystalline iron nitrides is not possible by simply annealing elemental iron...

Chemistry, Materials & Coatings • Sandia National Laboratories has developed a class of hybrid liquid or gel scintillators for the efficient detection of neutron radiation from nuclear threat materials. Scintillators have proven very useful in...

Chemistry, Materials & Coatings • The LED market is one of the fastest growing markets worldwide, driven by demand for clean solid state lighting, LED displays and mobile devices. GaN-based materials are essential components of...

Chemistry, Materials & Coatings • Safety is often a major concern in high voltage electronics and energy applications containing capacitors. In the event of a fire or overheating, disabling the capacitor becomes extremely important in...

Chemistry, Materials & Coatings • Highly uniform magnetic nanoparticles are highly desirable for numerous applications including medical imaging, chemical manufacturing, and development of drugs in the pharmaceutical industry. Currently, achieving nanoparticles with a small size...

Chemistry, Materials & Coatings • Sandia National Laboratories has developed a class of plastic scintillators capable of detecting fission neutrons, while discriminating against interfering gamma rays, enabling their use as a replacement for liquid scintillator...

Chemistry, Materials & Coatings • Sandia National Laboratories has created a new class of scintillators with novel properties enabling use in a wide range of particle detection schemes, including pulse-shape discrimination methods for detecting fast...

Manufacturing & Assurance • This novel invention relates to a portable, pneumatically -controlled instrument capable of generating a vacuum (less than 10 Torr), calibrating volumes, and performing quantitative leak tests, all without the use...

Manufacturing & Assurance • Many communication systems employ multi-channels that transmit and receive a common signal. In these systems, the common signal is combined at thereceiver to achieve maximum channel capacity. During the combining...

Chemistry, Materials & Coatings • There is a need for improved active infrared optical elements such as modulators. Extraordinary optical transmission (EOT) through subwavelength apertures allows for tailored filtering based on plasmon resonance. Until now...

Manufacturing & Assurance • A powder dispersion system that outputs up to 60 grams per syringe and achieves dispersion rates of at least 170 mg per minute Research and development settings sometimes require large-scale...

Chemistry, Materials & Coatings • Versatile polymer membrane separator technologies with improved long-term stability, performance in high temperatures, and suitability for acidic and alkaline environments Fuel cells are hailed as clean, quiet, and efficient technologies...

Chemistry, Materials & Coatings • Direct methanol fuel cells have an advantage over hydrogen fuel cells because the liquid methanol has high energy density and is easily transportable. However, one of the challenges with this...

Chemistry, Materials & Coatings • Sandia has developed a heat transfer fluid (HTF) for use at elevated temperatures that has a lower freezing point than any molten salt mixture available commercially. This allows the HTF...

Chemistry, Materials & Coatings • NanoCoralTM produces platinum nanomaterials which can significantly reduce costs and improve the efficiency and durability of hydrogen fuel cells and other renewable energy technologies. NanoCoralTM is an innovative nanotechnology for...

Chemistry, Materials & Coatings • Sandia has developed red-emitting phosphors that will help to transform the cold blue of many current light-emitting diodes (LEDs) into the warm white that is preferred for general lighting. This...

Manufacturing & Assurance • Sandia has developed an advanced electrical wiring diagnostic capable of detecting insulation defects in complex wiring systems. The portable diagnostic system detects and accurately locates hard to find insulation defects...

Chemistry, Materials & Coatings • Sandia National Laboratories has developed a disruptive new crystal growth technology, called Electrochemical Solution Growth (ESG). This technology has a high potential for producing the high-quality, large-area, and economical bulk...