This Small Business Technology Transfer (STTR) Phase II project aims to develop a Modulation-Assisted Machining (MAM) system with novel capabilities for micro/meso-scale deep-hole drilling of biomedical components. The system is structured around a new device; an accessory developed for computer numerically controlled (CNC) machine tools. This new device superimposes a low-frequency sinusoidal modulation onto machining processes enabling controlled chip formation and easy disposal, enhanced lubrication of tool-chip contact, reduces energy consumption, and, potentially, a reduction in tool wear. When implemented in the appropriate system framework, unprecedented increases in productivity and efficiency of deep-hole drilling processes are envisaged.
The broader impact/commercial potential of this project will be commercialize MAM technology in manufacturing of biomedical components and related applications in automotive and aerospace fluid systems manufacturing. Complemented by a strong education and training program. By driving the development of a class of clean machining processes with reduced effluent streams and energy consumption, and improved efficiency, this project will impact sustainable manufacturing for the discrete products sector, with broad societal benefits.
The NSF STTR award enabled M4 Sciences to complete key research objectives that became critical components in the design and development of a new commercial product for industrial machining. This product, called the TriboMAM drilling system, is designed to improve mechanical drilling of small diameter holes. Many high-performance products require mechanical drilling of small dimaeter holes. Examples inlcude orthopedic fixation devices, industrial hudraulics components, and automotive fuel systems components. The TriboMAM drilling system enables a new technology – Modulation-Assisted Machining (MAM) – in the form of a machine tool accessory that can be directly retrofitted on new or existing computer controlled machine tools. MAM technology offers productivity gains up to 500% over current drilling process technology. The STTR research objectives included analysis of MAM process control algorithms, as well as an extensive suite of experimental investigations that quantified the fundamental physics of Modulation-Assisted Machining. M4 Sciences’ pursuit of these objectives in the STTR program defined commercial product specifications and data needed to guide engineering analysis and product development. Our partnership with Purdue University (School of Industrial Engineering) explored basic and applied research and strengthened our fundamental understanding of the MAM process, while also enabling M4 Sciences to build relationships with expert faculty. Simultaneously, the STTR served as a pathway for undergraduate and graduate students to participate in activities with a start-up company. As a direct result of the STTR program, M4 Sciences received the 2010 R&D 100 Award jointly with Purdue University. In 2011, M4 Sciences received the SBA Tibbetts Award for demonstrating exemplary performance in research and commercialization through the NSF STTR program. Equally important to the scientific research and discovery, the STTR provided M4 Sciences a framework for executing a plan and schedule for innovation and business development. The identification of key objectives and related steps for technology and commercialization throughout the NSF STTR program (Phase I/IB, Phase II/IIB) were essential components of our successful introduction of this new product which enables a disruptive technology in the well-established machining industry. M4 Sciences has forged commercial relationships and partnerships with businesses ranging from third generation privately held companies to fortune 500 companies with headquarters in the United States and abroad. M4 Sciences distributor relationships extend from the United States, to the United Kingdom, Germany, South America, and Japan – all key product markets for machining technology. These relationships are accessing the market for TriboMAM and M4 Sciences future products. Today, as a direct result of the NSF STTR program, manufacturers around the world are benefiting from MAM technology for mechanical drilling applications. In less than two years, sales of M4 Sciences’ TriboMAM drilling system have already reached commercial implementation in nine countries, with end-users benefiting from increased productivity and quality – the hallmarks of sustainable manufacturing. Customer applications include the drilling of titanium alloy cannulated orthopedic bone screws where, in some cases, customers are realizing economic benefits amounting to more than $1,000 per day compared to their conventional processing methods. The growing catalog of customer successes continues to expand along with M4 Sciences’ product offerings for MAM technology. In summary, the outcomes of the NSF STTR project include a growing machining technology company, M4 Sciences, with a range of commercial products that are enabling industry users to access MAM technology and achieve increased productivity and quality in mechanical drilling
