Biomimetic Microstructure Formation of High Performance Silk Films and Fibers

The complex biological processing used by the silkworm and spider to create silk fibers yields exceptionally high strength, stiffness, and extensibility. In this proposed program, Foster-Miller will again join with Prof. David Kaplan and theBiotechnology Center at Tufts University to develop fibers and films based on reconstituted silkworm silk that possess unique and tailorable properties for emerging Air Force applications. Prof. Kaplan is an acknowledged expert in the biology andcharacterization of silk. Foster-Miller will also work with Mr. John O'Brien at Dupont Central Research and Development to assess the commercial potential of this novel biomimetic material, and to identify potential markets. In the Phase I program,Foster-Miller utilized our experience in liquid crystal polymer processing, to show that the processing characteristics of silk biological liquid crystal polymers are analogous to those of synthetic liquid crystal polymers. Building on these results, wewill continue our development of spinning dopes, extrusion parameters and orientation processing to produce films and fibers with properties which approach those found in native dragline spider silks. Scale-up will be demonstrated to levels capable ofproducing cost-effective biomimetic fibers and films from easily obtainable stocks of silkworm silk for a range of commercial and military applications. (P-030012) This program pursues broad materials technology development toward general implementationrather than an application-specific development. It is initially envisioned that bulletproof vests and parachute cords present military applications with good near term pull. Ultimately, the material is likely well suited for highly optimized large spacestructures such as solar sails or space telescopes, applications where Foster-Miller is currently working on large deployable structures for the Air Force and NASA. In the commercial marketplace, preliminary target applications certainly includebulletproof vests as well as high strength cords and straps, prosthetic devices, and highly abrasion resistant textiles. Foster-Miller will work with Dupont Central Research and Development to assess and develop these markets.