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The generalized ultrasonic inspection method harnesses piezoelectric transducers and ultrasonic resonance spectroscopy to detect sub-500-micron defects in batteries. By analyzing the resonance behavior of high-frequency sound waves and employing novel data processing techniques, subtle structural changes in batteries can be identified. Two hardware setups were developed: one employing direct transducer contact and another utilizing ultrasonic measurements through a captured water column. Both configurations incorporate a scanning technique that captures spatial degradation data – rather than a single point measurement – enabling structural insights even in layers too thin for time-domain c-scan resolution. Processing of the data includes converting the measurements and reference time domain signals to the frequency domain, then normalizing the measurement signal in the frequency domain to determine the frequency dependent reflection coefficient. As a result, resonance behavior between the test specimen and apparatus can be isolated. This resonance-based approach is ideal for delicate materials unsuitable for high-powered laser excitation or full immersion testing, and the associated data-analysis allows the battery defects to be detected more efficiently. This NASA invention offers significant potential for highly sensitive, nondestructive enhancements of battery safety and quality control in industries such as automotive, aerospace, additive manufacturing, and composites.

The SABERS innovators developed novel lithium-sulfur designs, including sulfur-selenium on graphene cathodes, and lightweight bipolar plate stacking and packaging designs. SABERS is unique in several aspects, in particular, it deploys graphene-based manufacturing processes for the cathode and bipolar plates, and it uses a solid-state electrolyte in place of the liquid electrolyte found in other lithium-sulfur battery designs. The team has achieved energy densities over 500 W-hr/kg, with ongoing development targeting further improvements. Coin cell and pouch prototype demonstrations have been successful and are ongoing. Major component technologies in SABERS include the following: • S/Se Cathode – Sulfur/Selenium on graphene scaffold (LEW-20228-1) • Solid Electrolyte – Solid-state electrolyte composites (LEW-20445-1) • Bipolar Stack – Graphene plates (LAR-20257-1) Robust computational models have been developed to support the battery materials design and are available to licensees to evaluate and optimize different materials combinations and performance targets. Further developments in catholyte formulations, anode interlayering, and packaging optimization are presented in SABERS 2.0 (LEW-TOPS-188). Individual technologies can be licensed from either suite, or entire portfolios can be licensed to support solid-state battery development programs.

The interlayer consists of lithiophilic metallic or metal-containing nanoparticles supported on holey graphene, a special carbon material perforated by small holes that enables dry processing. The composite interlayer guides uniform lithium deposition and maintain stability during cycling. The result is a thin, film-like material that can be integrated (via dry processes) into battery cells as standalone interlayers or combined with solid electrolyte and cathode powders to form bi- and tri-layer structures, separating anodes and electrolytes while encouraging efficient ionic movement and long cell lifecycles. Tests found that battery cells incorporating this dry-processed interlayer achieved ultrahigh current density and low overpotential, indicating that the interlayer prevents rough patches, resists dendrite formation, and supports efficient charge and discharge over time. The interlayer has demonstrated a high lithium-ion flux (i.e., a high critical current density of ~25 mA/cm²) and has shown that full battery cells incorporating the protective layer can be successfully cycled (with an areal capacity of 7 mAh/cm²). This innovation contributes to both the SABERS (LEW-TOPS-167) and SABERS 2.0 (LEW-TOPS-188) portfolios, improving the state of the art for solid state batteries. The anode interlayer is currently at a TRL 4 and is available to license independently or as part of the larger SABERS solid-state battery suite.

Storage and transfer of fluid commodities such as oxygen, hydrogen, natural gas, nitrogen, argon, etc. is an absolute necessity in virtually every industry on Earth. These fluids are typically contained in one of two ways; as low pressure, cryogenic liquids, or as a high pressure gases. Energy storage is not useful unless the energy can be practically obtained ("un-stored") as needed. Here the goal is to store as many fluid molecules as possible in the smallest, lightest weight volume possible; and to supply ("un-store") those molecules on demand as needed in the end-use application. The CFC concept addresses this dual storage/usage problem with an elegant charging/discharging design approach. The CFC's packaging is ingeniously designed, tightly packing aerogel composite materials within a container allows for a greater amount of storage media to be packed densely and strategically. An integrated conductive membrane also acts as a highly effective heat exchanger that easily distributes heat through the entire container to discharge the CFC quickly, it can also be interfaced to a cooling source for convenient system charging; this feature also allows the fluid to easily saturate the container for fast charging. Additionally, the unit can be charged either with cryogenic liquid or from an ambient temperature gas supply, depending on the desired manner of refrigeration. Finally, the heater integration system offers two promising methods, both of which have been fabricated and tested, to evenly distribute heat throughout the entire core, both axially and radially. NASA engineers also applied the CFC to a Cryogenic Oxygen Storage Module to store oxygen in solid-state form and deliver it as a gas to an end-use environmental control and/or life support system. The Module can scrub out nuisance or containment gases such as carbon dioxide and/or water vapor in conjunction with supplying oxygen, forming a synergistic system when used in a closed-loop application. The combination of these capabilities to work simultaneously may allow for reduced system volume, mass, complexity, and cost of a breathing device.

The technology is an all-printed Physically Unclonable Function (PUF) electronic device based on a nanomaterial (such as single-walled carbon nanotube) network. The network may be a mixture of semiconducting and metallic nanotubes randomly tangled with each other through the printing process. The all-printed PUF electronic device comprises a nanomaterial ink that is inkjet deposited, dried, and randomly tangled on a substrate, creating a network. A plurality of electrode pairs is attached to the substrate around the substrate perimeter. Each nanotube in the network can be a conduction path between electrode pairs, with the resistance values varying among individual pairs and between networks due to inherent inter-device and intra-device variability. The unique resistance distribution pattern for each network may be visualized using a contour map based on the electrode information, providing a PUF key that is a 2D pattern of analog values. The PUF security keys remain stable and maintain robustness against security attacks. Although local resistance change may occur inside the network (e.g., due to environmental impact), such change has little effect on the overall pattern. In addition, when a network-wide resistance change occurs, all resistances are affected together, so that the unique pattern is maintained.