Lightweight EMI-Resistant Metal Rubberâ„¢ Wiring for Rotorcraft

NanoSonic’s breakthrough technology of Metal RubberTM lends itself to the Army’s objective of reducing the EMI susceptibility of wiring on advanced helicopters, by 1) improving the performance of current technology wiring harnesses, and 2) using Metal Rubber’s unique characteristics to fundamentally change wire harness design. Metal Rubber offers significant weight reduction over current solid metal wire, RF shielding and electrical grounding materials. Metal Rubber is a self-assembled nanocomposite with an electrical conductivity on the order of that of bulk copper (107 S/m). Its mass density (1 g/cc) is less than that of copper (8.96 g/cc), so replacing copper wiring with Metal Rubber may result in weight savings of up to 90%. Metal Rubber also exhibits broadband EMI shielding behavior for low areal densities, so may be used as lightweight shielding/ground sheath within cable to reduce EMI coupling and improve EMC performance, and as electrically conducting coating or appliqué on composite structure. During Phase I, NanoSonic will fabricate shielded Metal Rubber wire and cable and versions of shielding/ground materials, and evaluate their electromagnetic and environmental performance according to MIL SPEC standards. NanoSonic has a CAI of 40, works with multiple major defense contractors and has specialized materials onboard fielded defense platforms.