Bio-inspired Energy Dissipating Structures for Enhanced Airdrop Capabilities

Physical Sciences Inc. and George Mason University developed a biomimetic approach to produce novel energy dissipating biopolymer foams produced from upcycled cellulosic waste feedstocks. After the completion of a successful Phase I SBIR program, the team proposes a subsequent Phase II program to mature and demonstrate the technology validated in Phase I. The team has successfully demonstrated the feasibility of the developed foam materials in a 6-month Phase I SBIR program. This 100% bioderived biopolymer foam made from cellulosic waste feedstocks was integrated into novel, bio-mimetic form factors and demonstrated high energy dissipation characteristics. The Phase I results achieved a >7.5X improvement in SEA from state-of-the-art (SOA) paper honeycomb. The team performed a preliminary techno-economic analysis that shows PSI’s technology has a 1.1-5.3X reduction in material cost compared to commercially available paper honeycomb. The Phase II Base program seeks to enhance material properties to achieve a specific energy absorption (SEA) of > 40 J/g EDS at normal impacts, and > 20 J/g EDS when impacted at a 30° incline. The team will incrementally scale-up the material production, creating 6” x 6” test coupons to demonstrate mechanical properties. In the Phase II Option, the team will further scale up the Energy Dissipating Structure (EDS) production to create a proof-of-concept full size (36”x96”) foam panel and demonstrate its mechanical properties at scales relevant to airdrop applications. Additionally, PSI will produce a detailed design and plan for constructing and operating a pilot plant capable of producing one full size EDS panel per hour. The team will build the pilot plant and operate it to generate at least 10 full-sized EDS panels over a fabrication campaign. This SBIR program will enable a scalable, domestically produced enhanced material for U.S. air drop capabilities across the world. PSI’s foam material will increase air drop mission success rates, providing efficient airborne and airlift operations to resupply missions, unit deployments, and humanitarian aid.