OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Space Technology; Renewable Energy Generation and Storage; Advanced Materials OBJECTIVE: Develop innovative non-thermal plasma catalysis techniques and/or models to generate functional energy materials (liquid fuels, battery materials, fuel cell catalysts, etc.) not achievable through conventional methods. DESCRIPTION: New manufacturing methods for advanced energy materials are essential to ensure resilient supply chains, create contested logistics advantages, and provide assured energy for defense platforms including batteries, fuel cells, generators, and other mission-critical systems. Non-thermal plasmas have emerged as a unique synthetic tool due to their relatively low energy cost and amenability to thermally sensitive materials compared to thermal plasmas.[1] Non-thermal plasma catalysis presents a unique opportunity to manipulate chemical reactions in ways that are unattainable under standard conditions, resulting in many reported academic schemes for manufacturing of novel battery materials[2], liquid fuels[3], and nano-catalysts[4]. Recent Department of Defense investments through the Office of Basic Research Multidisciplinary University Research Initiative (MURI) have also produced insights into non-thermal plasma/liquid catalysis which may open the aperture to additional manufacturing opportunities.[5] Since these technologies have remained concentrated in university laboratories, academic/commercial partnerships represent a key technology accelerator to bring plasma-based energy materials to market. In non-thermal plasma-enhanced catalysis, the interaction between plasma and catalyst leads to synergistic effects that enhance reaction rates, selectivity, and material properties. The plasma can alter the physicochemical properties of the catalyst, such as increasing surface area through nanoparticle formation or changing oxidation states to improve catalytic activity. Conversely, the catalyst can influence the plasma by enhancing local electric fields and altering discharge characteristics, which can lead to the formation of new reactive species. This topic seeks to understand and harness these interactions to develop scalable manufacturing processes for functional energy materials including battery materials, liquid fuels, and nano-catalysts. Of special interest are non-thermal plasma/liquid interface manufacturing schemes, which can offer greater control over reaction environments and enable the production of materials with unique structures and functionalities. Potential dual-use applications include advanced coatings for aerospace components and semiconductor processing methods that can enhance domestic manufacturing supply chain resilience for DoD and Civilian materials alike. Medical and biological applications of non-thermal plasma are not of interest. PHASE I: Demonstrate the feasibility of innovative non-thermal plasma catalysis methods to synthesize functional energy materials with enhanced properties. Conduct laboratory experiments and/or computational modeling to validate plasma-catalyst interactions by measuring and/or modeling improvements in reaction rates, selectivity, stability, and material properties (e.g., particle size distribution, surface chemistry, product purity) verses conventional methods in a laboratory environment. Map initial parameter controls (e.g., reactor geometry, plasma discharge power, catalyst loading) to gauge scalability and identify design parameters in preliminary engineering flow block diagrams considering mass and heat balance. Of additional interest is the utilization of empirical or synthetic datasets to develop predictive models or AI/ML algorithms capable of relating plasma operating conditions to resulting material characteristics. The desired Phase I outcome is a laboratory-scale proof-of-concept demonstration showing reliable plasma-mediated synthesis routes (TRL 4), providing a technical foundation for integrated reactor development in Phase II. PHASE II: Develop and refine a minimally viable integrated manufacturing platform that incorporates non-thermal plasma catalysis, process controls, and post-analysis based on Phase I results. To accelerate the scaling of plasma-based manufacturing strategies, the integrated prototype system should: Operate with an output >10 g/hr for solid material and >100 mL/hr for liquid fuels while retaining material quality and consistency previously demonstrated at the laboratory scale. Demonstrate stable plasma operation for >72 hours cumulative or continuous run time with <10% loss material throughput, material morphology/chemical quality, energy consumption, or general performance. Achieve precise control over plasma parameters and catalyst configuration to ensure reproducible material properties (particle size, purity, etc.) across multiple production runs with a coefficient of variation (CV) <10% for key metrics. Reduce energy consumption per unit mass of product by >15% verses conventional methods as determined by Phase I benchmarks, validated via full mass and heat balance calculations with the parameterized system. Thoroughly test the system under simulated operational conditions. Collaboration with DoD research centers or industry partners is encouraged to provide feedback on performance, usability, and cost considerations. The outcome is a minimally viable integrated platform (TRL 5) with directives for full prototype and pilot-scale assembly and extensive field testing in Phase III. PHASE III DUAL USE APPLICATIONS: Develop pilot-scale manufacturing capability by incorporating Phase II testing results, improving reactor design, throughput, and material handling systems. By the end of Phase III, the technology should be TRL 7 and progressing toward at-scale integration for plasma-based manufacturing of advanced energy materials, supporting both defense objectives and broader commercial markets. This technology could make impacts beyond military applications, for example, in advanced coatings for aerospace, semiconductor processing, and environmental remediation, amoung others. REFERENCES: 1. Chokradjaroen, X. Wang, J. Niu, T. Fan, N. Saito, Fundamentals of solution plasma for advanced materials synthesis, Materials Today Advances, 14, 100244, 2022. 2. Do an, ., Gas-Phase Plasma Synthesis of Free-Standing Silicon Nanoparticles for Future Energy Applications. Plasma Process. Polym., 13: 19-53, 2016. 3. Liu, W., Xia, M., Zhao, C. et al. Efficient ammonia synthesis from the air using tandem non-thermal plasma and electrocatalysis at ambient conditions. Nat Commun 15, 3524, 2024. 4. Uwe R. Kortshagen, et al. Nonthermal Plasma Synthesis of Nanocrystals: Fundamental Principles, Materials, and Applications, Chemical Reviews 116 (18), 11061-11127, 2016. 5. Peter J. Bruggeman, et al. Plasma-driven solution electrolysis. J. Appl. Phys. 28 May 2021; 129 (20): 200902. KEYWORDS: Non-Thermal, Plasma, Energy, Manufacturing, Nanomaterials, Fuel, Catalyst, Battery Non-Thermal, Plasma, Energy, Manufacturing, Nanomaterials, Fuel, Catalyst, Battery
