Efficient fabrication of components for air and space systems through thermoplastic forming of bulk metallic glasses

Manufacturing of complex metallic components for air and space systems is fundamentally challenging. Traditional processing requires multiple steps, has a high cost and a long production time. Bulk metallic glasses (BMGs) are the only metals that can be processed through thermoplastic forming (TPF) like plastics. In addition, BMGs have properties that are superior to conventional materials, including exceptional strength, hardness, elasticity and corrosion resistance. Using TPF techniques allows net-shaping of highly precise and complex components in seconds with limited or no post-processing, as opposed to days and weeks for traditional metal processing. Supercool Metals is the only company in the world that has developed expertise and capabilities to realize the TPF technology on a commercial scale. In this project, we are developing applications for TPF for military air and space systems. As part of Phase I, we identified and prioritized candidate components that will benefit most from a reduced manufacturing time and costs. For further development in Phase II, we selected three product areas that are used widely across military air and space systems. These include mechanical components, conformal antennas, and avionics components. In Phase II, we plan to produce prototype products and test them in partnership with defense suppliers. We will also evaluate and start building TPF capabilities required for commercial production and develop strategies for transition of these products into DOD’s systems. This project will enable domestic capabilities for rapid and affordable manufacturing of complex, high-performance products for DOD’s air and space applications.