Lightweight Metal Rubber Wire and Cable for Space Power Systems

The objective of this NASA STTR program is to produce ultra-lightweight electrical wire and cable harnesses to reduce the liftoff weight of future space flight vehicles. In cooperation with materials scientists at Texas A&M, NanoSonic would develop and manufacture ultra-lightweight Metal Rubber- and carbon nanotube-based rubber (CNT Rubber) wire and cables with performance equivalent to that of conventional copper cables but with only 10% the weight. Wiring harnesses contribute significant weight load to the spacecraft structure. Ultra-lightweight Metal Rubber and CNT Rubber wires and cables can reduce that weight while offering comparable or superior electrical power and data transmission performance and EMI resistance. During Phase I, NanoSonic would design, fabricate and test lightweight Metal Rubber and CNT Rubber wire and cable prototypes. Texas A&M's nanotechnology laboratory would co-develop methods for CNT Rubber production and evaluate resulting material properties. The conducting core and outer shielding layers would be fabricated by molecular-level self-assembly. Electrically-conducting cable shielding tape layers would be dimensioned using CAD-driven templating equipment at NanoSonic. Wire and cable would be manufactured using wire feed, dielectric extrusion and shielding tape winding steps. NanoSonic is working with a major U.S. cable manufacturer and a major U.S. spacecraft prime contractor on this program.

Non-NASA applications of Metal Rubber and CNT Rubber materials include 1) EMI resistant and EMC shielding materials for electronic enclosures, 2) direct replacements for conventional solder forming metals in flip-chip bonding systems, 3) highly flexible interconnects in medical prostheses that require high deformation, and 4) in lightweight wires for portable personal electronic equipment.

Ultra-lightweight wires, cables and instrumentation harnesses have application on all future NASA spacecraft, research aircraft, and upper altitude instrumentation surveillance missions. Mechanically flexible Metal Rubber and CNT Rubber wire has potential applications as a replacement of conventional lead-tin solder in electronic assemblies, and as sensors and interconnects in crew diagnostic sensor systems for measurement of EKG, and heart and respiration rate. Ultra-lightweight sheet forms of Metal Rubber and CNT Rubber materials offer direct replacements for conventional shielding materials for spacecraft systems.

This is early/mid-stage (TRL 2) — the most realistic path in is NASA SBIR/STTR, which funds small businesses and research institutions to develop technology aligned with NASA's needs (equity-free, phased funding). Check whether a current SBIR/STTR solicitation topic overlaps with this project's technology area, or contact the project directly (above) to ask.

None of these are guaranteed paths for this specific project — TechPort itself doesn't have an "apply" button. Reaching out to the contact(s) above with a specific question is usually the fastest way to find out what's actually open.