**Advanced Materials, Chemical Technology, and Manufacturing (AM
Topic)**

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Proposal Due Date:   June 13, 2007

Rapid advances in new technologies which leverage multidisciplinary
synergies across the boundaries of science and engineering are directly
impacting businesses, consumers and society as a whole, and creating
significant opportunities for small businesses to compete in the global
marketplace. NSF is committed to supporting scientific discoveries that
benefit the marketplace and encourage private sector investment in
commercialization of these technologies. NSF seeks to support high-risk,
high-payoff research aimed at substantially increasing the competitive
capability of our nation's industries. Novel technologies and systems
aimed at achieving increased performance, reductions in cost and/or
improvements in quality are of particular interest. The ultimate goal is
to provide a competitive advantage for the U.S. industries that are
losing their position in today's marketplace due to fierce overseas
competition.

The Advanced Materials, Chemical Technology, and Manufacturing (AM)
topic is subdivided into four areas: (1) Energy Challenge; (2) Advanced
Materials; (3) Chemical Technology; and (4) Manufacturing. The Energy
Challenge is an over-arching area whose main purpose is to cluster all
energy related proposals under one heading. The Advanced Materials,
Chemical Technology and Manufacturing areas follow. **Note that the
selection of the appropriate topic and a specific sub-topic should be
based on where the innovation lies.**

Please direct topic/subtopic inquiries to the specific SBIR/STTR Program
Director listed below:

**Dr. Deepak Bhat** (<dbhat@nsf.gov>), 703-292-8538

Advanced Materials; the Energy Challenge or Chemical Technology

**Dr. Rathindra DasGupta** (<rdasgupt@nsf.gov>), 703-292-8353

Manufacturing; the Energy Challenge or Chemical Technology

**Ms. Cheryl Albus** (<calbus@nsf.gov>), (703) 292-7051

Manufacturing

**The Energy Challenge**

The large projected increases in global population and energy demand
provide unique opportunities for innovative solutions. The Advanced
Materials, Chemical Technology and Manufacturing Topic of the NSF
SBIR/STTR Program seeks to accelerate energy-related industrial
innovation in the US by leveraging high technology capabilities of small
businesses based upon fundamental scientific research and engineering
innovation. The Energy Challenge has been divided into two areas: (1)
Supply, Delivery, and Use; and (2) Transportation and Fuels. The
examples below are representative; however, not all encompassing. Please
contact the appropriate Program Director if you have questions regarding
your proposed topic.

> **A. Energy Supply, Delivery and Use**
>
> Numerous opportunities exist for electricity supply, delivery, and use
> in the areas of advanced materials, chemical technologies, and
> manufacturing.

**A.1. Direct Conversion and Utilization of Thermal Energy**

> The vast majority of energy usage in industrial processes is in the
> form of heat. Much of the heat is released into the environment.
> Proposals are sought in the area of improved energy efficiency of
> thermal systems.

**A.2. Buildings**

> Major steps to reduce energy needs for the built environment are
> essential. Potential solutions could include:

-   New façade systems

-   Insulating materials

-   Lighting innovations

-   Materials

**A.3. Electrochemical energy conversion and storage technologies**

> Large-scale inexpensive storage can significantly change the landscape
> of energy markets. Major advances are needed in the areas of energy
> density, cost, and durability. Potential Advanced Materials, Chemical
> Technology, and Manufacturing Innovation proposals are:

-   Novel processes to produce electrocatalysts

-   Battery storage

-   Hydrogen storage materials

**A.4. Coal and Carbon Sequestration**

> Coal is the most abundant energy resource in the US, China, and India.
> It is also relatively inexpensive and supplies half of the US
> electricity use. The challenges for coal-based power generation are
> environmental. Approximately 80% of US emission from electricity
> production is CO~2~. If CO~2~ is successfully captured, safe and
> economical storage is required. Innovative proposals are sought in the
> area of Carbon Sequestration.

**A.5 Renewables**

> Renewables hold the promise of addressing security and environmental
> concerns. Advanced Materials, Chemical Technology, and Manufacturing
> innovations are sought in the renewable areas of:

-   Solar Energy

-   Wind Energy

**A.6 Energy Efficient Applications**

> Projects aimed at improving energy efficiency applications related to
> manufacturing processes including melting, heat treating, and hot
> working operations.

**B. Transportation and Fuels**

**B.1. Transportation**

> The global transportation sector is highly dependent on
> petroleum-based liquid fuels. Example areas for which proposals are
> sought include:

-   Improving efficiency and emissions reductions in engines

-   Alternative fuel options (proposals in the area of biofuels should
    be submitted to Biotechnology Topic area (BT))

-   Robust and Efficient Fuel Cell and Battery technologies

-   Vehicle weight reduction through use of new materials

> **B.2 Hydrocarbons**
>
> Enhanced recovery methods from existing reservoirs could significantly
> improve petroleum availability. Advanced materials, chemical
> technology, and/ or manufacturing innovation topics in this area
> include:

-   Innovative approaches to physical and/or chemical stimulation of
    existing reservoirs

-   Emerging coal gasification techniques to produce a wide spectrum of
    products including liquid fuels

**B.3. Transportation Power Trains**

> Potential opportunities exist to improve internal combustion engines
> and hybrid systems. Examples include:

-   The use of onboard fuel reforment technology to maintain or improve
    the fuel economy of diesel engine vehicles, while meeting emission
    regulations

-   NOx reduction

**Advanced Materials**

Advanced Materials area seeks proposals that focus on the development of
new materials that can advance the competitive nature and state of the
art for the U.S. industry. New materials and systems that have potential
for revolutionary changes and paradigm shifts will be given special
consideration.

Proposals must be market-driven and identify the end users of the
proposed technology, and its potential for commercialization.

The focus of the Advanced Materials area is on **Materials Innovation**.
Innovative projects to develop new classes of Materials and/or Material
Systems are solicited. Of interest are materials of high quality and
reproducibility, with superior properties for potential applications,
obtained through chemistry, morphology, and processing variables. If the
focus of the proposed research is on *manufacturing process innovation*,
then please select the Manufacturing Innovation Topic and select
appropriate sub-topics from that list. Materials development proposals
addressing energy related applications should be submitted to the Energy
Challenge sub-topic.

The following topics and sub-topics are addressed under the Advanced
Materials. Please select one appropriate topic and a specific sub-topic
within that broad area for the proposed research.

C.  **High-temperature Materials\
    **

    1.  Refractory metals and alloys

    2.  Metals, Ceramics and Composites for high-temperature
        applications; e.g. materials for advanced gas turbines, metal
        casting molds/dies, materials for dies used in various hot
        working processes (forging, extrusion), furnaces, and severe
        environments; innovative light-metal alloys

    3.  Materials to combat high-temperature erosion, corrosion and
        environmental degradation

    4.  High-temperature polymer materials

D.  **Engineered Structural Materials** - Materials and systems from the
    macro- to the nano-scale *with engineering applications other than
    those listed above\
    *

    1.  Materials, including polymers, with improved mechanical
        properties (strength, toughness, fatigue and fracture resistance
        )

    2.  Advanced composite materials for structural applications

    3.  Novel structural materials using unique processing techniques

    4.  "Smart" Materials; e.g. shape-memory alloys, environmentally
        adaptive materials, excluding coatings (see topic G.4)

    5.  Advanced (metal/polymer/ceramic matrix) composites

    6.  Structural foams and other lightweight

    7.  Novel abrasives, adhesives, pigments, sealants, fillers,
        additives, binders and lubricants

    8.  Advanced materials *engineered at the nanoscale and designed at
        atomistic scale\
        *

    9.  Carbon-based materials (e.g., carbon nanotubes, nanofibers,
        fullerenes)

    10. Multi-functional materials addressing thermal management,
        electronic, optical, structural,and magnetic properties,
        conformability, etc

    11. Functional materials designed to meet specific properties
        (magnetic, rheological, expansion, conductivity,
        thermo-electric, etc)

E.  **Corrosion-resistant Materials\
    **

    1.  Advanced materials to combat aqueous corrosion (e.g., marine
        environment, chemical pollution, etc.)

    2.  Materials to combat aqueous/environmental corrosion (excluding
        high-temperature corrosion; see topic C.3), stress corrosion

    3.  Corrosion-resistant coatings and surface modifications

F.  **Tribological and Wear-resistant Coatings\
    **

    1.  Coatings and surface modifications to combat erosion and wear

    2.  Coatings and surface modifications to reduce friction

    3.  Materials improvements in tribological applications

G.  **Surface Modifications and Thin Film Technologies\
    **

    1.  Novel materials, coatings and surface engineering via vapor
        deposition techniques

    2.  Novel materials, coatings and surface engineering via laser
        deposition, infrared (IR) processing, ion implantation, ion-beam
        assisted deposition (IBAD) techniques

    3.  Materials and treatments using hybrid deposition techniques

    4.  "Smart" coatings for sensor applications

    5.  Surface modification of powders

H.  **Powdered Materials\
    **

    1.  Metals and alloys, including refractory materials

    2.  Ceramics

    3.  Mechanically alloyed materials

    4.  Composite materials

I.  **Biomaterials\
    **

    1.  Biopolymers

    2.  Implants

    3.  Coatings

## Medical devices 

> I.5 Biomaterials for pollution mitigation, including air, water, soil
> and marine environments

### Geomaterials 

> Innovative use of geomaterials to build products including
> electronics, structures, etc

### Materials for Sustainability 

> K1. Biodegradable materials (not necessarily biomaterial)
>
> K2. Designing for recyclability, including separation techniques

K3. Novel material systems that use significant levels of recycled
materials

**Chemical Technology**

Innovative techniques that involve the transformation and transport of
matter and energy with the focus of contributing the knowledge base of
industrial manufacturing, as well as natural processes are of interest.
The Chemical --based Technologies (CT) Topic supports research that
involves the development and commercialization of processes and/or
products based upon fundamental engineering principles, mathematical
models, and experimental techniques, with an emphasis on projects that
have the potential for innovation and broad application in areas such as
the environment and chemical processing.

The CT Topic seeks proposals in the areas of separations, catalysis,
photochemical and electrochemical systems, fluid flow, combustion
related processes, thermal analysis, and molecular design. Applications
of these technologies in the marketplace can range widely in the areas
gas and liquid separation processes; single and multiphase processes and
computation fluid dynamics; reactor and heat exchanger design; molecular
modeling; and chemical characterization. Energy related proposals should
be submitted to the Energy Challenge.

> **L. Separations Applications**
>
> Research is needed to develop highly selective, energy-efficient, and
> economic processes and effective mass-separating agents (e.g.
> membranes, adsorbents, extractants) for the separation and
> purification of all types of substances. Examples areas include

-   environmentally benign liquid and gas separations of organics (e.g.,
    olefins), inorganics (e.g., minerals), and

-   critical and strategic metals.

> Membranes used in separation applications for fuel cell are of
> interest. Please see the Energy Challenge within the AM Topic
>
> **M. Novel Catalytic Systems**
>
> Areas of interest include preparation of new catalysts or catalytic
> systems and of new uses for known catalysts. Applications may include

-   consumer products,

-   chemical production.

> Proposals for developing improved techniques for integrating catalysts
> into fuel cells should be submitted to the Energy Challenge within the
> AM Topic.

NOTE: For pharmaceutical innovations, see Biotechnology (BT) topic.

**N. Photochemical or Electrochemical Applications**

-   Novel applications of radiation to affect chemical reactions

-   Innovative electric current applications to affect chemical
    reactions

> Battery, fuel cell and solar energy related proposals should be
> submitted to the Energy Challenge within the AM Topic.

**O. Fluid Flow Applications**

> Proposals are solicited that aim at improving the commercial
> applications of fluid engineering or particle technology processes or
> phenomena leading to advances with significant industrial impact.

-   Improved systems related to single phase and multi-phase fluid flow

-   Novel spraying applications

-   Innovative particle technology applications

-   Computational software related to the modeling of industrially
    applicable processes (non-IT related)

**P. Combustion-Related Processes**

> Proposals are solicited on uses of combustion in industrial
> applications. For example, proposals might address innovative concepts
> for combustion to synthesize a specific product of economic value; and
> diagnostic techniques that can function in a high-temperature or
> high-field environment.

-   Use of combustion to synthesize a specific product

-   Applications for combustion of gaseous, liquid or solid fuels

**Q. Reactor Engineering Applications**

> Commercialization of research in the areas of chemical reaction
> engineering encompassing the interaction of transport phenomena and
> kinetics in reactive systems and the use of this knowledge to design
> complex chemical reactors is of interest. Research areas of interest
> include, but are not limited to

-   Membrane reactor systems

-   Supercritical fluid applications

**R. Chemical Design and Synthesis**

> Research is needed for the design and synthesis of new organic and
> inorganic substances that enable the testing of theoretical,
> mechanistic, or structural hypotheses with commercial promise. For
> example, proposals might address:

-   Molecular-level design

-   Synthesis of novel molecules

-   Characterization techniques for chemical systems, surfaces or
    interfaces

**[Manufacturing Innovation]{.underline}**

Projects that make the country's manufacturing base more competitive
through innovation and response to changing needs are encouraged.
Innovation in this context is fostered by research and development (R&D)
of technologies that are aimed at increasing the competitive capability
of manufacturing firms. In a broad context, manufacturing-related R&D
encompasses innovation in existing methods or processes; improved
education and training of competent work force with the aim of getting
maximum benefit from existing or new methods or processes; or wholly new
processes, machines or systems. The overall goal is to support new and
emerging manufacturing innovation that will advance the competitiveness
of the nation's manufacturing sector.

Manufacturing Innovation topics are grouped into **five broad areas of
interest**:

S. Unit Process Level Technologies

T. Machine Level Technologies

U. Systems Level Technologies

V. Workforce Capability and Environmental Protection

W. Manufacturing Simulation Technologies

Please select **one specific sub-topic** within that broad area for the
proposed research.

**S. Unit Process Level Technologies: Projects that Create or Improve
Manufacturing Processes, including:**

> S1. Additive Processes -- projects aimed at advancing rapid
> prototyping/solid preform fabrication for material and process
> improvements
>
> S2. Deformation Processes -- projects aimed at advancing forging,
> extrusion, rolling, and sheet metal processing and punching for
> material property
>
> improvements based on the advances in the processes
>
> S3. Joining and Assembly Processes -- projects aimed at joining
> similar and/or dissimilar material combinations including welding,
> soldering, brazing, diffusion bonding, and adhesive processes
>
> S4. Surface Engineering Processes -- projects aimed at CVD, PVD,
> laser, thermal spray, electrochemical methods, innovative plasma or
> other diffusion treatment processes for surface property enhancement
> (ex: cleaning and surface preparation), duplex coating and hybrid
> processes
>
> S5. Powder Material Processes -- projects aimed at advancing
> powder-based materials/processes that include powder metals, powder
> ceramics and hybrid materials; processes include powder consolidation
> methods (sintering, injection molding, mechanical milling, lased
> cladding, near net shape manufacturing techniques, die compaction,
> field assisted electromagnetic consolidation of powders) and similar
> hybrid methods
>
> S6. Casting/Molding Processes -- projects aimed at improved
> efficiency/control in processing for high pressure, high velocity die
> casting, low pressure permanent mold, gravity permanent mold casting,
> semi-solid metal casting, investment casting and hybrid processes (ex:
> casting and forging)
>
> S7. Polymer Processing -- projects aimed at creating or improving
> manufacturing processes for various types of polymers including
> polymer matrix composites (PMC), surface engineering including polymer
> treatments for polymers
>
> S8. Ceramic Processing -- projects aimed at creating or improving
> manufacturing processes for various types of ceramics including
> ceramic matrix composites (CMC)
>
> S9: Metal Matrix Composite Manufacturing -- projects aimed at creating
> or improving manufacturing processes for metal matrix composites (MMC)
>
> S10. Sensor Manufacturing -- projects aimed at creating or improving
> manufacturing processes for various types of sensors including gas
> combustion sensors, accelerometers/gyroscopes and low-cost
> micro-sensors particularly for applications in energy and power
> management
>
> S11. Electro Mechanical Systems at Micro and Nano-Scales (MEMS & NEMS)
> -- projects aimed at manufacturing systems with applications to
> accelerometers, shock resistant devices, wide temperature range
> devices, actuators, and communication devices involving high levels of
> integration and hermetic packaging
>
> S12. Micro/Meso Scale Components -- projects aimed at minitiarization
> of manufacturing systems, manufacturing equipment and processes for
> manufacturing micro/meso-scale components and products, handling and
> assembly of micro/meso-scale components
>
> S13. Passive Nanotechnology Applications -- projects aimed at creating
> or improving manufacturing processes for nanoparticles, nanofibers,
> nanocomposites, nanocoatings and carbon nanotubes
>
> S14. Heat Treat Processes -- projects aimed at **[novel]{.underline}**
> heat treat processes including hardening techniques
>
> S15. Non Destructive Inspection -- projects aimed at creating new
> non-destructive inspection techniques for various materials
>
> S16. Machining and Material Removal -- projects aimed at process
> improvements for milling, grinding, drilling and cutting tools;
> non-traditional material removal processes (ex: EDM, plasma, water
> jet, laser-based micromachining, electrochemical machining and
> combinatorial techniques); high speed machining, dry machining and MQL

**T. Machine Level Technologies: Projects that Create or Improve
Manufacturing Equipment**

> T1. Machine Design -- projects aimed at improving design of existing
> machines and equipment in order to improve efficiency and/or cost;
> modular design of machine component
>
> T2. Machining and Material Removal -- projects aimed at advances in
> machine tool design (ex: improved tool holder and part holder design)
>
> T3. Metrology -- projects aimed at improving machine tool calibration,
> and part inspection equipment
>
> T4. Material Processing -- projects aimed at innovation in processing
> equipment for MMC, PMC and CMC
>
> T5. Deposition Equipment -- projects aimed at developing new hardware
> or improving hardware component for deposition (ex: cathodic arc
> evaporation process, CVD, equipment for electrical insulating coating
> material, and "continuous" vs "batch" processing equipment
>
> T6. Disassembly and Sorting Equipment -- projects aimed at development
> of new and innovated machinery to disassemble end of life products and
> sort components in material groups
>
> T7. Process Control -- projects aimed at in-process sensing technology
> and sensor technology integration

**U. Systems Level Technologies: Projects that Create Innovation in the
Manufacturing Enterprise**

> U1. Intelligent Process Control -- projects aimed at development of
> manufacturing system control methodologies using artificial neural
> logic network
>
> U2. Manufacturing Enterprise Systems -- projects aimed at decision
> tools for supply chains, planning, scheduling, distribution, and risk
> optimization for the extended and spatially distributed enterprises
>
> U3. Six Sigma -- projects aimed at developing new methods and/or
> equipment for implementation of lean manufacturing

**V. Workforce Capability and Environmental Protection: Projects that
Improve Workforce Capabilities and Manufacturing**

> V1. Workforce Capability -- projects aimed at improving the
> manufacturing work environment (including reducing worker exposure to
> hazardous environment) by incorporating ergonomics and interactive
> computing systems
>
> V2. Environmental Cleanup -- novel systems that use significant levels
> of recycled materials and projects aimed at improving techniques for
> recycling of materials
>
> V3. Plastics Scrap Sorting Process -- projects aimed at developing
> innovative methods and processes to separate many different grades of
> plastics obtained from household and consumer level waste
>
> V4. Virtual Manufacturing -- projects aimed at technology to run
> machines remotely

**W. Manufacturing Simulation Technologies**

> W1. Residual Stress Prediction -- projects aimed at accurately
> predicting residual stress introduced in many manufacturing methods
> such as casting, forging, machining, and heat treatment
>
> W2. Distortion Prediction -- projects aimed at predicting an actual
> shape (not the theoretical shape) formed during and after various
> manufacturing methods
>
> W3. Physical/Mechanical Properties Prediction -- projects aimed at
> accurately predicting local mechanical properties in components made
> using various manufacturing processes
>
> W4. Initial/Boundary Condition Definition - projects aimed at
> obtaining appropriate initial and boundary conditions necessary for
> manufacturing simulation experimentally and numerically