Periodic Reporting for period 2 - TiPlate (Industrial Titanium-Plating Process for the Manufacturing of Light-Weight Composite Parts)
Reporting period: 2021-11-01 to 2023-07-31
Polymertal Ltd. is revolutionizing the world of materials engineering with its groundbreaking TiPlate technology, bridging the gap between titanium's exceptional properties and the versatility of polymers. Titanium is prized for its lightweight strength and corrosion resistance, ideal for aerospace, medical implants, and tough industries. However, its high production costs and processing complexities have posed challenges. TiPlate by Polymertal solves this, enabling low-temperature titanium plating on sensitive substrates, especially polymers.
The TiPlate solution empowers the creation of lightweight, high-performance, corrosion-resistant, and biocompatible titanium-plated polymer components and parts. TiPlate delivers outstanding advantages: 70% less titanium, significant cost savings, 60% less weight, and 30-50% stronger polymer parts. This transformative process enables cost-effective, reliable manufacturing through 3D printing, minimizes Ti material volume costs, and eliminates energy-intensive production processes like forging and machining. Crucially, all products produced with TiPlate are recyclable, including end-of-life components, contributing to sustainability.
Strategic Objectives:
Polymertal has set its sights on becoming the global leader in metal plating of 3D printed polymers, explicitly focusing on titanium plating. Strategically, the company aims to penetrate the high-end niche market of titanium parts, offering the medical, aerospace, and other industries an economical alternative to costly machined or 3D printed titanium metal parts. TiPlate will establish Polymertal as a unique player in European markets, with no competitors offering comparable services or products.
Program Development Goals:
In program development, Polymertal defined several vital objectives. These involved testing the TiPlate process to ensure high titanium plating quality. Furthermore, the company conducted multiple case studies using the TiPlate process with polymers for medical devices. Creating a fully controlled, cost-effective TiPlate process was another critical milestone. Lastly, Polymertal collaborated with medical device partners who could navigate the regulatory requirements aligned with their novel TiPlate process. These objectives embodied the company's commitment to advancing material science and delivering global industry transformations.
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The TiPlate solution empowers the creation of lightweight, high-performance, corrosion-resistant, and biocompatible titanium-plated polymer components and parts. TiPlate delivers outstanding advantages: 70% less titanium, significant cost savings, 60% less weight, and 30-50% stronger polymer parts. This transformative process enables cost-effective, reliable manufacturing through 3D printing, minimizes Ti material volume costs, and eliminates energy-intensive production processes like forging and machining. Crucially, all products produced with TiPlate are recyclable, including end-of-life components, contributing to sustainability.
Strategic Objectives:
Polymertal has set its sights on becoming the global leader in metal plating of 3D printed polymers, explicitly focusing on titanium plating. Strategically, the company aims to penetrate the high-end niche market of titanium parts, offering the medical, aerospace, and other industries an economical alternative to costly machined or 3D printed titanium metal parts. TiPlate will establish Polymertal as a unique player in European markets, with no competitors offering comparable services or products.
Program Development Goals:
In program development, Polymertal defined several vital objectives. These involved testing the TiPlate process to ensure high titanium plating quality. Furthermore, the company conducted multiple case studies using the TiPlate process with polymers for medical devices. Creating a fully controlled, cost-effective TiPlate process was another critical milestone. Lastly, Polymertal collaborated with medical device partners who could navigate the regulatory requirements aligned with their novel TiPlate process. These objectives embodied the company's commitment to advancing material science and delivering global industry transformations.
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Several technological achievements have been made in the development of the TiPlate process:
1. Testing and Optimization of the Original Formulation of the TiPlate Process
Traditional titanium electroplating challenges, like hydrogen gas and titanium oxide formation, were addressed through collaboration with Prof. Daniel Mandler's academic group at the Hebrew University of Jerusalem. Extensive testing used techniques like cyclic voltammetry and morphological assessments. Initially, denatured ethanol was the plating medium in a nitrogen-rich environment. However, as experiments progressed, it became clear that the original TiPlate process wasn't cost-effective, prompting the search for an alternative approach.
2. Development of the Alternative TiPlate Process
Three distinct approaches were investigated to discover an alternative technology for the TiPlate process. The chosen final process offered advantages like the capability to plate diverse metals and function under ambient conditions using an aqueous solution.
3. TiPlate by EPD Development Stages
Stabilizing the electrolyte was a crucial step in the TiPlate process. We optimized various factors, including dispersion solvent, agents, mixing, and additives. Polymertal achieved a durable electrolyte solution.
Other parameters were refined, such as anode materials, current density, electrode spacing, plating time, and temperature. Experiments on copper foil and 3D polymer substrates yielded promising results. Polymertal identified the suitable electrolyte composition, resulting in uniform titanium particle plating.
4. Pilot Studies
Pilot studies were initiated to explore the feasibility of using TiPlate technology for various applications. In Pilot 1, thin layers of titanium plating were substituted with nickel to assess their impact on plated polymers' mechanical, thermal, and electrical properties. The study demonstrated improved electrical conductivity, mechanical and thermal properties, flame resistance, and enhanced chemical stability.
In Pilot 2, the biocompatibility of TiPlate was intended to be tested on a PEEK substrate plated with a thin evaporated layer of titanium. Unfortunately, this pilot did not yield favorable results due to the low conductivity of the initial titanium layer. In future endeavors, the first titanium layer will be replaced with gold, which offers significantly higher conductivity.
5. Establishment of Technical and Business Infrastructure
Polymertal has actively penetrated global markets, with initial sales efforts in EU markets. The company is engaged in the automotive, semiconductor, and medical industries, with notable collaborations with companies like Porsche, BMW, ASML, and J&J. A global expansion plan for 2025 includes establishing a production line in the EU region, enhancing the company's international presence. These achievements underscore Polymertal's commitment to advancing TiPlate technology for diverse industries.
1. Testing and Optimization of the Original Formulation of the TiPlate Process
Traditional titanium electroplating challenges, like hydrogen gas and titanium oxide formation, were addressed through collaboration with Prof. Daniel Mandler's academic group at the Hebrew University of Jerusalem. Extensive testing used techniques like cyclic voltammetry and morphological assessments. Initially, denatured ethanol was the plating medium in a nitrogen-rich environment. However, as experiments progressed, it became clear that the original TiPlate process wasn't cost-effective, prompting the search for an alternative approach.
2. Development of the Alternative TiPlate Process
Three distinct approaches were investigated to discover an alternative technology for the TiPlate process. The chosen final process offered advantages like the capability to plate diverse metals and function under ambient conditions using an aqueous solution.
3. TiPlate by EPD Development Stages
Stabilizing the electrolyte was a crucial step in the TiPlate process. We optimized various factors, including dispersion solvent, agents, mixing, and additives. Polymertal achieved a durable electrolyte solution.
Other parameters were refined, such as anode materials, current density, electrode spacing, plating time, and temperature. Experiments on copper foil and 3D polymer substrates yielded promising results. Polymertal identified the suitable electrolyte composition, resulting in uniform titanium particle plating.
4. Pilot Studies
Pilot studies were initiated to explore the feasibility of using TiPlate technology for various applications. In Pilot 1, thin layers of titanium plating were substituted with nickel to assess their impact on plated polymers' mechanical, thermal, and electrical properties. The study demonstrated improved electrical conductivity, mechanical and thermal properties, flame resistance, and enhanced chemical stability.
In Pilot 2, the biocompatibility of TiPlate was intended to be tested on a PEEK substrate plated with a thin evaporated layer of titanium. Unfortunately, this pilot did not yield favorable results due to the low conductivity of the initial titanium layer. In future endeavors, the first titanium layer will be replaced with gold, which offers significantly higher conductivity.
5. Establishment of Technical and Business Infrastructure
Polymertal has actively penetrated global markets, with initial sales efforts in EU markets. The company is engaged in the automotive, semiconductor, and medical industries, with notable collaborations with companies like Porsche, BMW, ASML, and J&J. A global expansion plan for 2025 includes establishing a production line in the EU region, enhancing the company's international presence. These achievements underscore Polymertal's commitment to advancing TiPlate technology for diverse industries.
Project Achievements and Future Directions:
During the project, substantial knowledge was gained in titanium plating, additives for electrolyte conductivity, particle charge manipulation, and plating adhesion improvement. Extensive research covered diverse material properties, including mechanical, thermal, electrical, chemical resistance, flame retardancy, and permeability to vapors and gases. To safeguard this intellectual property, Polymertal is in the process of patenting crucial stages of the TiPlate process, with expected completion by mid-2024, including filings in Israel and Europe. Future endeavors involve further optimization of the TiPlate process, completion of biocompatibility testing using gold as an initial layer, and business development strategies, including enhanced marketing and focused research and development efforts to expand market presence and diversify applications across industries.
Economic and social impact of the project:
The TiPlate project has significant economic and social implications. From a financial perspective, TiPlate provides cost-effective solutions and competitive advantages, benefiting manufacturers and end-users. Additionally, introducing the novel electrophoretic particle deposition plating process opens up opportunities to plate other challenging yet attractive metals, such as aluminum. This expansion into new materials can potentially disrupt markets and drive innovation.
On the socio-economic front, it creates jobs, saves costs, and fosters technological advancements. Quantitative analysis reveals revenue projections, gross margin improvements, break-even expectations by 2025, and positive net present value, highlighting its economic significance.
During the project, substantial knowledge was gained in titanium plating, additives for electrolyte conductivity, particle charge manipulation, and plating adhesion improvement. Extensive research covered diverse material properties, including mechanical, thermal, electrical, chemical resistance, flame retardancy, and permeability to vapors and gases. To safeguard this intellectual property, Polymertal is in the process of patenting crucial stages of the TiPlate process, with expected completion by mid-2024, including filings in Israel and Europe. Future endeavors involve further optimization of the TiPlate process, completion of biocompatibility testing using gold as an initial layer, and business development strategies, including enhanced marketing and focused research and development efforts to expand market presence and diversify applications across industries.
Economic and social impact of the project:
The TiPlate project has significant economic and social implications. From a financial perspective, TiPlate provides cost-effective solutions and competitive advantages, benefiting manufacturers and end-users. Additionally, introducing the novel electrophoretic particle deposition plating process opens up opportunities to plate other challenging yet attractive metals, such as aluminum. This expansion into new materials can potentially disrupt markets and drive innovation.
On the socio-economic front, it creates jobs, saves costs, and fosters technological advancements. Quantitative analysis reveals revenue projections, gross margin improvements, break-even expectations by 2025, and positive net present value, highlighting its economic significance.