Microscopic carbon nanotubes (CNTs) have been a huge R&D focus because they can impart strength and weight reduction – and other needed materials characteristics – to polymers. But it’s still big news when a nanocomposite product makes a big spash entering the realm of commercialized products. Columbus (OH)-based Zyvex Performance Materials has literally made such a big splash recently by introducing its Piranha unmanned surface vessel (USV).

By incorporating Arovex™, Zyvex’s proprietary CNT-reinforced carbon fiber prepreg in the design of the Piranha, Zyvex has created the largest boat ever built from CNT-enhanced materials. “This 54-foot USV weighs only about 8,000 pounds,” says Lance Criscuolo, Zyvex president.”Yet it has the ability to cruise at 45 knots for 2800 nautical miles on 1400 gallons [amount of fuel], which is ten-fold increase over traditional USVs. And it weighs half as much and is approximately twice as large as the existing generation of USVs.” This is no small feat.

“In designing Piranha, we took advantage of the unique properties of Aerovex, including the 40 to 50 percent stiffer modulus and its 20 to 30 percent increase in strength compared to traditional materials,” said Criscuolo. “Piranha was designed entirely by Zyvex and prototyped using our materials processing supply chain partners within Ohio,” he said. “The electronics and systems were outfitted through a partnering agreement with a defense contractor.”

Initially, Zyvex had begun work on this project before setting up the defense partnership because Zyvex leaders felt that the availability of a prototype would be an outstanding way to market the properties and potential that Arovex provides. “We also had solid support from Ohio Third Frontier funding, and we used this to leverage the prototype development,” said Criscuolo. “We had worked with Arovex enough to have great confidence in what it could do, and we also had a lot of help from the Center for Multifunctional Polymer Nanomaterials and Devices (CMPND) and PolymerOhio in networking us to Ohio vendors and tapping into the strength and convenience of working with the local supply chain,” he said. “All the intermediates/prepregs we used – resins and epoxies – were made in Ohio.”

Prepregs are uncured epoxy materials that are semi-rigid, somewhat sticky, and can be molded, moved to another location, then assembled and oven-cured. These inherent qualities made a huge structure like the Piranha possible. “We made Piranha in two pieces, hull and deck, that would ‘pop’ together,” said Criscuolo. “That aspect of the design makes transportation of the parts much more feasible and reduces the labor required for assembly.” Both of these advantages were attractive for commercialization.

“What’s interesting is that we did all this during the economic slowdown. It turned out to be an excellent time to develop the Piranha concept and it also helped keep our suppliers busy when their business was slow,” said Criscuolo. “It also brought a lot of positive attention to Ohio’s advanced technology businesses and gave them a share of the limelight.”

USVs are used by military and governmental agencies to patrol open waters for piracy, participate in search and rescue missions, and provide on-sea surveillance, such as within harbors. They have the potential to be armed, but that depends on the intended use. While this Zyvex product is intended for a military-type application, vessels like the Piranha certainly could have commercial applications.

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Zyvex Performance Materials is the leader in unlocking the power of the carbon nanotube (CNT), the strongest material in the world, to make composite products the strongest, lightest, toughest, and stiffest on the market. Zyvex offers the world’s highest performing prepregs, epoxy resins, and adhesives that are drop-in replacements to existing manufacturing processes. For more than five years, Zyvex has been providing the materials and technology behind commercially available CNT-enhanced products. Their customer base includes partnerships with world leaders in materials and production from defense technology to specialty chemicals. The Zyvex vision is to provide breakthrough results using its technology in next-generation resins, composites, and dispersions.

The Center for Multifunctional Polymer Nanomaterials and Devices (CMPND) leads a research and commercialization partnership in polymer nanotechnology. This multi-institutional, interdisciplinary organization is centered at The Ohio State University in conjunction with research university partners, University of Akron, University of Dayton, University of Toledo, Kent State University, and Wright State University. CMPND puts Ohio at the forefront of nanotechnology research and commercialization opportunities. Other partners include three additional Ohio universities, and more than 60 large and small companies in Ohio. CMPND helps target markets that build on the research strengths of the participating universities and national labs, and develops manufacturing protocols and nanostructures for near-term industrial polymeric nanocomposites, emerging polymer photonic components and devices, and more futuristic biomedical devices and systems with nanoscale functions.

PolymerOhio, Inc. is a polymer industry-specific Ohio Edison Technology Center, which is funded by the Ohio Department of Development.  PolymerOhio focuses on enhancing the global competitiveness of the polymer industry, including companies from the plastics, rubber, bioproducts, and advanced materials segments. For more information, polymerohio.org

The Ohio Third Frontier was initiated in February 2002. This project is the state's largest-ever commitment to expanding Ohio's high-tech research capabilities and promoting innovation and company formation that will create high-paying jobs for generations to come. The 10-year, $1.6 billion initiative is designed to: Build world-class research capacity; support early stage capital formation and the development of new products; and finance advanced manufacturing technologies to help existing industries become more productive. Through the Ohio Third Frontier Project, additional Federal and private sector support can boost the total investment to more than $6 billion.