| NSF Org: |
TI Translational Impacts |
| Recipient: |
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| Initial Amendment Date: | April 17, 2020 |
| Latest Amendment Date: | August 4, 2023 |
| Award Number: | 1951193 |
| Award Instrument: | Standard Grant |
| Program Manager: |
Rajesh Mehta
rmehta@nsf.gov (703)292-2174 TI Translational Impacts TIP Directorate for Technology, Innovation, and Partnerships |
| Start Date: | May 1, 2020 |
| End Date: | March 31, 2024 (Estimated) |
| Total Intended Award Amount: | $750,000.00 |
| Total Awarded Amount to Date: | $892,957.00 |
| Funds Obligated to Date: |
FY 2021 = $50,000.00 FY 2023 = $92,957.00 |
| History of Investigator: |
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| Recipient Sponsored Research Office: |
401 11TH AVE S HOPKINS MN US 55343-7838 (612)308-8740 |
| Sponsor Congressional District: |
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| Primary Place of Performance: |
2400 N 2nd St, STE 301 Minneapolis MN US 55411-2256 |
| Primary Place of
Performance Congressional District: |
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| Unique Entity Identifier (UEI): |
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| Parent UEI: |
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| NSF Program(s): | SBIR Phase II |
| Primary Program Source: |
01002021DB NSF RESEARCH & RELATED ACTIVIT 01002122DB NSF RESEARCH & RELATED ACTIVIT |
| Program Reference Code(s): |
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| Program Element Code(s): |
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| Award Agency Code: | 4900 |
| Fund Agency Code: | 4900 |
| Assistance Listing Number(s): | 47.084 |
ABSTRACT
The broader impact/commercial potential of this Small Business Innovation Research (SBIR) Phase II project is the replacement of steel with synthetic materials that are stronger and lighter. The beachhead market for this technology is the performance bicycle spoke market, which is a $180M global market. The potential benefits of this technology go beyond cycling because the polymer-to-metal interface has other potential applications. Cable assemblies are used in a wide variety of applications and industries such as industrial, aerospace, construction, and consumer goods. Advances in the termination of synthetic cable assemblies will enable the creation of higher strength-to-weight ratio cables and thereby increase efficiencies in transportation applications and improve the safety of tension based systems. An application of particular societal benefit is wheelchair wheels, where weight reduction increases portability for those with physical disabilities. Investment in termination technologies for high performance polymers will also help bridge the gap between polymer research and industry, helping society benefit from developments in polymer science occurring in academia. Finally, the ability to produce low-cost rope terminations will increase US manufacturing competitiveness because the majority of high-volume production is outsourced to low-cost labor markets.
This Small Business Innovation Research (SBIR) Phase II project will develop an advanced manufacturing process for ultra high molecular weight polyethylene (UHMWPE) and metal hybrid structures for bicycle spokes. UHMWPE has a strength-to-weight ratio of fifteen times that of steel, but it cannot be utilized in many applications because of the difficulty in manufacturing high-strength bonds to metal. The primary objectives of this research are to automate the insertion and bonding of stainless steel rods inside the hollow cavity of braided fibers, and to automate the creation of eye splices. These operations require delicate manipulation of fibers in a confined space, and are typically performed manually. Instead, we will develop novel automatic machinery that will create these bonds, inspect the final product, and validate the strength with 100% in-process inspection. Another objective of this research is to develop a black surface coating process for braided UHMWPE fibers. To achieve this, we will identify a surface pretreatment procedure to add functionality to the non-polar backbone of UHMWPE, develop the coating chemistry, and create an in-line coating system that integrates with our manufacturing process.
This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.
PROJECT OUTCOMES REPORT
Disclaimer
This Project Outcomes Report for the General Public is displayed verbatim as submitted by the Principal Investigator (PI) for this award. Any opinions, findings, and conclusions or recommendations expressed in this Report are those of the PI and do not necessarily reflect the views of the National Science Foundation; NSF has not approved or endorsed its content.
Berd LLC was enabled by the NSF SBIR research program to develop the world's lightest bicycle spokes made from a flexible material, ultra high molecular weight polyethylene (UHMWPE) that has 15 times the strength-to-weight ratio of steel. These innovative spokes are replacing metal spokes which have been state-of-the-art for more than 150 years. Now, cycling enthusiasts to world champions are riding Berd PolyLight spokes because they are lighter weight, more durable, and produce an extremely smooth ride that allows cyclists to ride further and faster.
The technologies and innovative concepts developed through this multi-year NSF research program include the patented connection between braided UHMWPE and stainless steel. This connection relies on the "finger trap" effect to achieve its strength and durability. More importantly, the NSF SBIR research program provided funding to develop an advanced semi-automated manufacturing process to produce spokes both reliably and economically in Hopkins, MN.
Berd spokes are now available from over 500 retailers in over 20 countries worldwide. They have been ridden to win multiple World Cup Cross Country Mountain Bike Championships and will be ridden by athletes from five nations at the 2024 Olympics. This technology developed under the NSF SBIR research program is enabling the long-term adoption of a more sustainable high performance material in bicycle wheels worldwide.
Last Modified: 06/27/2024
Modified by: Charles S Spanjers
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