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 will develop applications for TPF for military air and space systems. As part of Phase I, we will identify and prioritize candidate components that will benefit most from a reduced manufacturing time and costs. We will also evaluate TPF capabilities required for commercial scale production and develop a detailed manufacturing plan and strategies for insertion into DOD’s systems. This project will enable domestic capabilities to fabricate complex, high performance products for DOD’s air and space platforms using TPF rapidly and affordably.