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 Some R&D Case Studies
Environmental Sensors
Light-Activated Shape Memory Polymer
Syntactic Processing
From Medical Devices to Repair Isolation
New Formulation
IP Portfolio Management
SMP Commercialization
Micro Air Vehicles
The case studies below highlight examples of different
levels of research that CRG has provided for various customers.
These examples demonstrate how we engage in research, inserting
ourselves at any R&D level or combination of levels that the
customer needs. CRG focuses on understanding what a customer really
needs and negotiates to deliver exactly that.
Case
Study 1: Environmental
Sensors
Sensor Development
Our team partnered with the US Navy to design and develop a new
technology that will precisely determine product freshness. The
result was environmental exposure tracking sensors that are shape
memory polymer-based and capable of sensing cumulative exposure
to temperature and humidity. These sensors span a variety of applications
by establishing supply-chain accountability, providing munitions
reliability, ensuring quality consumer goods, and monitoring perishable
goods.
Moving into the Market
In an SBIR Phase I and Phase II effort, we were able to develop
low-cost, no- power
visual and radio frequency identification (RFID) sensors capable
of determining product freshness through continual tracking. As
the sensor is exposed to environments above the customized settings,
the shape memory material transitions from high-performance epoxy
polymer to high-performance elastomer, allowing for the recovery
of stored energy. Tailoring the size, shape, and material of the
sensor allows for monitoring of a variety of temperatures from
<0°C to 260°C (<32°F to 500°F). These sensors
serve multiple markets, with affordable products ranging from
frozen food reliability sensors for consumer confidence to munitions
monitoring for defense customers.
Case
Study 2: Light-Activated
Shape Memory Polymer
Project Goals
In this DARPA-funded project, we teamed with a university partner
to develop light-activated shape memory polymer (SMP). This new
technology offers an alternative to thermal activation of the
material that will enable shape-changing aerostructures and many
more applications. The goals were to develop a material with no
heat signature and no continuous energy source.
 Teamwork
We began by developing a clear understanding of polymer molecular
structure and how it affects the bulk structure. This led to a
new class of polymers that demonstrated the ability to reversibly
switch from flexible to stiff. The university partner embraced
the challenges of developing entirely new characterization methods
and provided real-time testing of the new polymer as well as material
modeling.
Beyond Basic Solutions
Optimization and scale-up in the second phase led to continued
testing, performance improvement, and successful fabrication of
a light-activated composite prototype. Additional prototypes were
designed by both our team and the university partner. Together,
this diverse team of chemists and engineers, university researchers,
and the customer has developed new materials, novel testing methods,
and new research avenues that reach beyond the original work plan.
Case
Study 3: Syntactic
Processing
 Established
Expertise
Our reputation for customized syntactic formulation and part production
interested Varian Semiconductor Equipment*. With completely open
parameters of design, but a specific use in mind, we were challenged
to develop new materials and to design the process and tooling
techniques for a next-generation product. In this highly competitive,
fast-burn project, we were able to deliver quality parts in just
four months, beating the competition in time, performance, and
part quality. This process involved determining material requirements,
developing materials tailored to Varian’s needs, creating
composite tooling in-house, and fabricating finished parts.
Continued Cooperation
Success of this project hinged on making Varian a priority. A
dedicated team worked to meet the delivery schedule and deadline,
proved to be reliable and easy to work with, and ultimately resulted
in a customer extremely pleased with the final results.
Case
Study 4: From
Medical Devices to Military Repair Isolation
Fast Turnaround
The customer approached us with a basic conceptual design for
a medical device. They required quick development of multiple
new prototype devices for surgeon evaluation. This competitive
project called for innovative device design in a complicated,
cluttered IP field. Multiple research  teams, within the customer’s
company as well as outside firms, were tasked to find a novel
approach to the surgical device.
Effective
Prototypes
Through communication with the customer’s engineering team,
we rapidly designed multiple lab-scale prototype devices, some
involving new materials development, in a two-month effort. We
offered a new perspective on the company’s prototype concepts
as well as quick results. Two of the final three designs elected
for surgeon evaluation were our prototypes. In the second phase
of this project, our team delivered more than 80 prototypes for
testing.
Leveraging into New Markets
This same principle was used to design and deliver a prototype
for military field repairs. The Navy presented us with several challenges in designing a repair containment system. The device needed to be effective, simple in design, low in cost, easy to manufacture and use, and deployable under any conditions. It needed to be an innovative, economical approach to composite repairs, offering a reliable, tight seal around the repair site that keeps contaminants out and debris generated from the repair in the contained area, protecting the repair site, the surrounding environment and equipment, and the technician.
 Addressing the Need
We pulled together a team of researchers with extensive experience with structural composite repairs and by working closely with Navy technicians. By employing a hand port design from the previous work with medical devices and providing a clear exterior to the system, the new deployable isolation repair technology (DIRT) Bag™ offers technicians easy access to the repair site and an unobstructed view of the area. The DIRT Bag is collapsible, making it ideal for use in the field. This product has the added benefit of decreasing costs through reducing reworking and maximizing flight readiness since it eliminates the need for a hangar or clean room.
The bag adheres to unusual surfaces and allows
on-site composite repair. We were able to leverage experience and investment
from the medical device program to develop this military repair
system.
Moving into Testing and Production
The success of the DIRT Bag has moved the technology from the research phase into testing and production. The DIRT Bag is now transitioning into a product for multiple
commercial markets. The first round of production has been completed, and units are currently being tested by military and commercial aerospace customers. Units are available for sale and testing. Patents are pending.
Case
Study 5: New Formulation
Customer Requirements
The customer brought us a material for a precise manufacturing
process with strict materials requirements: specific compression,
modulus, abrasion resistance, hardness, and processability in
their current manufacturing line. They also sought the added benefit
of smart material functionality.
The Challenges
After evaluation and testing of the material was complete, it
became apparent that the customer’s material would not function
with all of the desired characteristics. Our team
of scientists with expertise in formulation and characterization
of smart materials presented new possibilities for polymer properties
and kept in regular contact with the customer throughout the new
formulation process.
 Our
Solution
A custom-formulated smart material was created that would meet
all of the customer’s specific needs. Testing proved the
feasibility of the material and its ability to work in the customer’s
current manufacturing line.
The Benefits
In this instance, the customer was able to leverage years of our
polymer research and smart material expertise. The new formulation
fulfilled the customer’s needs and provided them with the
possibility of new intellectual property.
Case
Study 6: IP Portfolio
Management
Creating a Competitive Stance
The customer’s R&D division was understaffed and required
cutting-edge solutions to maintain industry dominance. Their day-to-day
issues were consuming internal personnel, leaving them fewer resources
for technical development activities. The original plan for outsourcing
R&D to our team was expanded to include more than 15 ongoing
projects across their company. The programs ranged from manufacturing
process and material development to IP portfolio management with
both near-term  and
long-term payoffs.
Real Results
Our team strives to maintain a balance of “high payoff/high
risk” development with technical approaches that include
risk mitigation pathways to ensure success. Our developments were
so viable to the customer that they are currently implementing
the results into their direct production line.
IP Protection
We assist with this customer’s IP, creating a strategy to
protect their rights in a manner they describe as “exceptional.”
We continually feed this customer technical reports and identify
patentable inventions as they are discovered and developed. Our
legal and technical teams work in conjunction with this customer’s
legal department to determine trade secrets, publishable material,
and possible patent opportunities. The result has been a multi-year
strategic alliance that reaches over the next decade.
The Benefits
When this customer teamed with us, they appreciated our culture
and approach, infusing that same energy into their own R&D
division, which is part of the overall goal of this strategic
alliance.
Case
Study 7: Shape
Memory Polymer Commercialization
 Shape
Memory Polymer Development
In 2000, we emerged as a leader in shape memory polymer (SMP)
development and design. Beginning with preliminary research in
thermoplastic SMP and then later in the unique field of thermoset
SMP, our work has resulted in multiple patents and patents pending.
The unique properties of these materials continue to drive innovations
in a wide range of applications. A branded family of shape memory polymers, Veriflex®, has emerged after years of preliminary research funded by both government and commercial entities.
From Molecule to Manufacturing
Our ground-breaking SMP design has led to commercialization of
products from reconfigurable composite structures such as aerospace
systems to the manufacture of consumer products including high-performance
auto racing repair materials. We have secured a broad intellectual
property position covering many classes of thermoset, thermoplastic,
and other types of SMPs, as well as applications and devices.
Case
Study 8: Micro
Air Vehicles
Breakthrough Technology
Our micro air vehicle (MAV) was originally designed and developed
for an application in military support. After completing an SBIR
Phase I, we acquired Phase II funding to develop a functioning
MAV. This vehicle has been highlighted at the Association for
Unmanned Vehicle Systems International (AUVSI) North American
trade show and other venues, generating strong customer pull.
 Customer
Pull
Commercial, homeland security, and military industry leaders encouraged
the further development of the technology. The working prototype
system generated significant interest in several Department of
Defense and civil protection agencies. Early prototypes were sold
to a major defense aerospace company for integration into the
Future Force Warrior system.
Market Leadership
Based on this customer pull, we are launching a new business,
Sentinel Aerosystems, specifically to bring this MAV technology
to a larger customer base, using private equity to fund the new
business. The spin-off is dedicated to being the market leader
in the design and manufacturing of low-cost MAVs based on ducted
fan technology.
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