April 2021 - Physical Sciences Inc.

Press Release

Physical Sciences Inc. (PSI) has been awarded a program from the U.S. Air Force to demonstrate compatibility of high strength fibers with the PSI’s ceramic matrix composites (CMC) fabrication process.

PSI will use commercially available high strength carbon fiber to optimize the fiber/resin base material (“pre-preg”) system for the manufacturing of carbon fiber reinforced CMC. The high strength system will improve upon baseline materials established throughout the composites industry and be applicable to PSI woven fabric, tow, and tape pre-preg forms suitable for hand lay-up, fiber placement or tape braiding of complex shaped CMC components. PSI will ultimately increase the strength to weight ratio of carbon fiber reinforced CMC, reducing preform production cost by as much as 1/3. Along with increased composite strength, fibers will continue to provide toughening to the CMC structures as a result of interface development.

PSI CMCs are ideal materials for high temperature hypersonic applications, but cost is a limiting factor. Increased CMC strength will allow for reductions in component thickness, increased production rates, and decreased cost. The strength and cost improvements will be realized across PSI’s entire suite of CMC material systems and fabrication routes. Candidate Air Force applications include The High-Speed Strike Weapon (HSSW) Tech Mat program Office (AFFRL/RWPI) and Air Force ManTech (AFRL/RXMS). Additional DOD applications include Army, Navy, and Missile Defense Agency hypersonic applications. Non-defense commercial markets will also benefit from the innovation as the market for pre-preg and composite components continues to rise in both the automotive and aerospace industries.

For more information, contact:

Dr. John Steinbeck
Product Manager, Advanced Composites
steinbeck@psicorp.com
Physical Sciences Inc.
Telephone: (978) 689-0003

Press Release

Physical Sciences Inc. develops and demonstrates key technologies and products for our nation’s defense, homeland security, and health industry. During this period of uncertainty, conforming with federal and state guidelines, Physical Sciences Inc. and its subsidiaries will be operating without interruption. Our company remains open, dedicated and responsive to our customers, helping protect our country and its citizens. We will continue to provide our technologies, products and services while placing great importance on the health and safety of our employee/owners at all locations. Our staff is currently working remotely to the greatest extent possible and is using thoughtful safe practices at our laboratories and facilities.

Press Release

Physical Sciences Inc. (PSI) has been awarded a contract from the Defense Logistics Agency to develop a new process to apply a separator layer as a coating directly to the surface of battery electrodes.

PSI’s directly applied (DA) separator method will simplify the traditional process of “stacking,” in which separator films are woven through stacks of battery electrodes. The DA method will improve manufacturing speeds and reduce the cost of lithium ion batteries in the DLA supply chain, and will also mitigate safety risks associated with traditional stacking and improve cell performance. The separator layer is deposited on the surface using a rapid, low-cost manufacturing process that can readily be inserted into the back end of the electrode coating/calendaring line.

PSI’s DA separator process will be targeted for cell manufacturers producing electric vehicle (EV) battery cells. Conventional separator raw materials contribute to 12-16% of the total of the cost of the EV cell. It is anticipated that the DA separator process will reduce the cost of the separator by 87%. Elimination of separator stacking will also reduce capital equipment costs and direct labor, further reducing the total cost of the cell.

For more information, contact:

Dr. Christopher Lang
Area Manager, Energy Technologies
lang@psicorp.com
Physical Sciences Inc.
Telephone: (978) 689-0003