Moulding of High Performance Composites Materials

From Innovation, Science and Economic Development Canada

The aim of the challenge is to develop a technology for moulding Ultra-high molecular weight polyethylene (UHMWPE) composite materials into complex geometry parts featuring double curvatures.

Sponsoring Department: National Research Council (NRC)

Funding Mechanism: Contract

Opening date: November 23, 2018
Closing date: January 14, 2019, 14:00 Eastern Standard Time

Please refer to the tender notice for this challenge on Buy and Sell

Phase 1 award recipients

Challenge

Problem Statement

The NRC provides R&D services to the Canadian defense industry; it is conducting studies that will provide data to manufacture personal protection equipment (PPE), but is lacking tools that can apply uniform pressure on complex geometry parts featuring near-vertical walls, and for testing different material solutions. The newest generations of lightweight, high performance composites materials, developed for ballistic protection applications are made from UHMWPE. These materials are very difficult to mould, especially into small objects involving complex geometries featuring double curvatures (ex. a hemisphere). These materials also require extremely high moulding pressures, and a very tight and accurate temperature control.

This challenge seeks a modular tool for moulding small parts made with UHMWPE-based composite materials, such as a helmet shell for a soldier (which is almost spherical), allowing for a precise control of the manufacturing process over a wide spectrum of pressures and temperatures, which can be reconfigured at minimum cost to support the industry in the development of specific applications. The generic tool sought in this challenge used in conjunction with NRC's high tonnage press, would allow NRC to study UHMWPE molding conditions, including pressure and temperature.

Desired outcomes and Considerations

The desired outcome is the development of a generic tool/tooling platform capable of moulding, using the newest generation of ballistic protection UHMWPE-based composites, personal protection equipment about the size of, and similar in shape to a military helmet (e.g. ACH Gen 2), under various controlled conditions of pressure and temperature.

Essential Outcomes

Proposed solutions must:

Allow moulding at different pressure and temperature conditions.
1. Temperature range: 25 Degrees Celcius to 150 degrees Celsius
2. Pressure range: 0 to 12 000 psi (pound-per-square-inch)/0 to 83 MPa (Megapascal)
Allow accurate temperature control over the entire surface of the tool (±2°C). Temperature must remain constant and uniform over the entire mould surface and during the entire moulding cycle.
Allow to apply uniform pressure on the material up to 12 000 psi. Pressure must be uniform over the entire surface, with a maximum deviation of 10%, even on near-vertical walls.
Be usable with a standard vertical compression moulding press.
Allow moulding family of parts of different thicknesses (i.e. same geometry, but thickness varies). Thickness to vary between 5 and 15 mm.
Withstand 500 moulding cycles before routine maintenance and overhaul is required.
Be certified according to all relevant Canadian safety standards, such as CSA if any electrical system is included.

Additional Outcomes

Ideally, the pressure buildup should result mostly from closing a matched-die tool (i.e. die forced into a cavity), but the assistance of other pressurization means would be acceptable.

Background and Context

The NRC, through its Security Materials Technologies (SMT) program, has the mandate to support the Canadian Defense Industry and foster innovation.

Personal protection equipment (PPE) such as helmets or ballistic inserts used by the military or police corps represents major market opportunities for the Canadian defence industry. Since 2000, NRC has developed significant expertise in the fabrication of aramid-based composite helmets. In recent years though, high-end personal protection equipment is being made from the newest high performance UHMWPE-based composites. These new materials offer unmatched ballistic protection at extremely low weight but they are cardboard-like and difficult to work with. They also require extremely high moulding pressures, and a very tight and accurate temperature control. Manufacturing PPE components using these UHMWPE-based materials requires large tonnage presses and expensive metallic tools. The large initial capital investment needed for industry to adopt these new materials has been a major barrier.

NRC has conducted some studies with UHMWPE-based materials; however the high moulding pressure and accurate temperature control required by these new materials currently preclude NRC from working at the component or system level, i.e. what is most relevant for industry. A generic, modular tool, would thus allow NRC to conduct studies to develop new PPE solutions, offer industry a full development platform to test different concepts, optimize designs and fabricate prototypes.

The generic, modular tool, developed during the challenge will allow the applicant to gain highly sought-after expertise in designing tools for moulding the latest generation of UHMWPE-based composites into complex geometries. This will allow the applicant (and Canada) to become a worldwide leader in the moulding UHMWPE-based composites for personal protective equipment, but also in other areas such as vehicle armour and spacecraft protection.

Maximum value and travel

Maximum contract value:

Multiple contracts could result from this Challenge.

The maximum funding available for any Phase 1 Contract resulting from this Challenge is $150,000.00 CAD (plus tax) including shipping, travel and living expenses, as applicable, for up to 6 months.

The maximum funding available for any Phase 2 Contract resulting from this Challenge is $500,000.00 CAD (plus tax) including shipping, travel and living expenses, as applicable, for up to 2 years. Only eligible businesses that have completed Phase 1 could be considered for Phase 2.

This disclosure is made in good faith and does not commit Canada to contract for the total approximate funding.

Travel:

For Phase 1 it is anticipated that two meetings will require the successful bidder(s) to travel to the location identified below:

Kick-off meeting: Montreal, Quebec

Final Review Meeting: Montreal, Quebec

All other communications should take place by telephone or videoconference.

Eligibility

Solution proposals can only be submitted by a small business that meets all of the following criteria:

for profit
incorporated in Canada (federally or provincially)
499 or fewer full-time equivalent (FTE) employees^{Footnote *}
research and development activities that take place in Canada
50% or more of its annual wages, salaries and fees are currently paid to employees and contractors who spend the majority of their time working in Canada^{Footnote *}
50% or more of its FTE employees have Canada as their ordinary place of work^{Footnote *}
50% or more of its senior executives (Vice President and above) have Canada as their principal residence^{Footnote *}

Application guide

Evaluation Criteria

Part 1: Mandatory and Minimum Pass Mark Criteria

Proposals must meet all mandatory criteria (Questions 1a and 2) and achieve the minimum pass mark for Question 3 in order to be deemed responsive and proceed to Part 2.

Mandatory and Minimum Pass Mark Criteria (Applicant/Bidder's proposal must address)
Question	Evaluation Schema
1 a. Scope Describe your proposed solution and how it responds to the challenge. Include in your description the scientific and technological basis upon which your solution is proposed and clearly identify how your solution meets all of the EssentialOutcomes (if identified) in the Desired Outcomes and Considerations section in the Challenge Notice.	Mandatory - Pass/Fail Pass The Applicant/Bidder's proposed solution is clearly articulated, within the scope for the challenge and addresses all Essential Outcomes (if identified) in the Challenge Notice. Fail There is little or no evidence that the proposed solution is likely to meet the challenge. OR The proposed solution is articulated as out of scope for the challenge. OR The proposed solution does not address all Essential Outcomes listed in the challenge. OR The proposed solution is poorly described and does not permit concrete analysis.
2. Current Technology Readiness Level (TRL) Indicate the current TRL of your proposed solution. (Drop Down Menu of the Application/Bid Submission Form) Describe the research and development activities that have taken place to bring the proposed solution to the stated TRL.	Mandatory - Pass/Fail Pass: The Applicant/Bidder has demonstrated that the proposed solution is currently between TRLs 1 and 4 (inclusive), and provided justification by explaining the research and development (R&D) that has taken place to bring the solution to the stated TRL. Fail: The Applicant/Bidder has not provided sufficient evidence to demonstrate that the current TRL is between 1 to 4 (inclusive) including: There is insufficient/no evidence provided for TRL judgment. The solution involves the development of basic or fundamental research. The solution is at TRL 5 or higher. Insufficient/unclear/no justification explaining the R&D that took place to bring the solution to the stated TRL. The explanation simply paraphrases the description of a given TRL level.
3. Innovation Describe the novelty of your solution and how it advances the state-of-the-art over existing technologies, including competing solutions.	Point Rated with Minimum Pass Mark The minimum pass mark for this criteria is 4 points. 0 points/Fail: The Applicant/Bidder has not demonstrated that the proposed solution advances the state-of-the-art over existing technologies, including available competing solutions; OR The stated advancements are described in general terms but are not substantiated with specific, measurable evidence. 4 points: The Applicant/Bidder has demonstrated that the proposed solution offers one or two minor improvements to existing technologies, including available competing solutions, that have potential to create competitive advantages in existing market niches. 6 points: The Applicant/Bidder has demonstrated that the proposed solution offers three or more minor improvements to existing technologies, including available competing solutions, that together are likely to create competitive advantages in existing market niches; OR The Applicant/Bidder has demonstrated that the proposed solution offers one significant improvement to existing technologies that is likely to create competitive advantages in existing market niches 8 points: The Applicant/Bidder has demonstrated that the proposed solution offers two or more significant improvements to existing technologies, including available competing solutions that are likely to create competitive advantages in existing market niches and could define new market spaces; OR The Applicant/Bidder has demonstrated that the proposed solution can be considered a new benchmark of state of the art that is clearly ahead of competitors and that is likely to define new market spaces

Part 2: Point-Rated Criteria

Proposals that do not achieve the overall minimum score of at least 55 points out of a possible 110 points (50%) will be declared non-responsive and given no further consideration.

The overall minimum score is determined by adding the Applicant/Bidder's scores from the following questions together (1b, 3, 4-13).

Point-Rated Criteria (Applicant/Bidder's proposal to address)
Question	Evaluation Schema
1b. Scope Describe how your proposed solution addresses the Additional Outcomes (if identified) in the Desired Outcomes and Considerations section in the Challenge Notice. If no Additional Outcomes are identified in the Challenge Notice, Bidders/Applicants will receive 10 points	Insufficient or no information provided to demonstrate that the solution will address any of the Additional Outcomes. 0 points Information provided clearly demonstrates that the solution will address some (<50%) of the Additional Outcomes. 5 points Information provided clearly demonstrates that the solution will address most (50% or more) of the Additional Outcomes. 8 points Information provided clearly demonstrates that the solution will address all (100%) of the Additional Outcomes. 10 points
4. Phase 1 Science and Technology Risks Identify potential scientific and/or technological risks to the successful development of the proof of concept and how they will be mitigated in Phase 1?	Insufficient or no information provided to demonstrate that the Applicant/Bidder has considered potential risks and mitigation strategies and/or information provided contains significant gaps. 0 points Information provided demonstrates that the Applicant/Bidder has considered some potential risks and associated mitigation strategies but there are minor gaps in risks and/or associated mitigation strategies. 5 points Information provided clearly demonstrates that the Applicant/Bidder has sufficiently considered the risks and defined associated mitigation strategies. 10 points
5. Benefits to Canada Describe the benefits that could result from the successful development of your solution. Applicants/Bidders should consider the potential benefits using the following three categories: Innovation Benefits: Expected contribution towards the enhancement or development of new industrial or technological innovations. Assessment factors could include: potential spillover benefits, creation of intellectual property, impact on productivity of the new technology, etc. Economic Benefits: Forecasted impact on the growth of Canadian firms, clusters and supply chains, as well as its expected benefits for Canada's workforce. Assessment factors could include: number of jobs created, number of high-paying jobs, project-related revenue growth, etc. Public Benefits: Expected contribution to the broader public, including inclusive business and hiring practices (e.g., gender balance), investment in skills and training and environmental best practices. Assessment would consider the degree to which the Applicant/Bidder demonstrates that the solution is expected to generate social, environmental, health, security or other benefits to Canada. Assessment factors could include: solution-related environmental benefits, investment in local communities and solution-related impact on Indigenous communities.	Innovation Benefits Benefit not identified or insufficient claim of benefit. 0 points Benefit has marginal increment or limited justification. 1.5 points Benefit is significant and well justified. 3 points Economic Benefits Benefit not identified or insufficient claim of benefit. 0 points Benefit has marginal increment or limited justification. 1.5 points Benefit is significant and well justified. 3 points Public Benefits. Benefit not identified or insufficient claim of benefit. 0 points Benefit has marginal increment or limited justification. 1.5 points Benefit is significant and well justified. 3 points
6. Phase 1 Project Plan Demonstrate a feasible Phase 1 project plan by completing the table. Include: Project milestones; project activities under each milestone; time required to complete each milestone (e.g., days, weeks and/or months); (Indicate if any milestones and activities will be completed concurrently) total time required to complete the project; and key success criteria. Note: Phase 1 cannot exceed 6 months and TRL 4.	Insufficient or no information provided to demonstrate a feasible project plan for Phase 1 and/or the project plan exceeds the maximum duration indicated in the Challenge Notice. 0 points Project plan for Phase 1 is conceivably feasible but not clearly demonstrated and/or includes gaps. 5 points Information provided clearly demonstrates a feasible project plan for Phase 1. 10 points
7. Phase 1 Project Risks Identify potential project risks (eg. Human resources, financial, project management, etc) to the successful development of the proof of concept and how they will be mitigated?	Insufficient or no information provided to demonstrate that the Applicant/Bidder has considered potential risks and mitigation strategies and/or information provided contains significant gaps. 0 points Information provided demonstrates that the Applicant/Bidder has considered some potential risks and associated mitigation strategies but there are minor gaps in risks and/or associated mitigation strategies. 5 points Information provided clearly demonstrates that the Applicant/Bidder has sufficiently considered the risks and defined associated mitigation strategies. 10 points
8. Phase 1 Implementation Team Demonstrate how your project implementation team has the required management and technological skill sets and experience to deliver the project plan for Phase 1 by completing the table. A member of the implementation team can have more than one role. Include the labour rates and level of effort for each member. A day is defined as 7.5 hours of work, exclusive of meal breaks. The labour rates and level of effort will be reviewed as part of the evaluation for Question 10.	Insufficient or no information provided to demonstrate that the project team has the required management and technological skill sets and experience to deliver the Phase 1 project plan. 0 points Information is provided but there are minor gaps in required management and/or technological skill sets and/or experience to deliver the Phase 1 project plan. 5 points Information provided clearly demonstrates that the project team has the required management and technological skill sets and experience to deliver the Phase 1 project plan. 10 points
9. Inclusivity If your business were to receive funding from Innovative Solutions Canada, describe what actions (e.g., recruitment strategy, internships, co-op placements, etc.) might be taken in Phase 1 to support the participation of under-represented groups (e.g., women, youth, persons with disabilities, Indigenous people, visible minorities) in the research and development of the proposed solution.	No description and/or concrete examples of actions provided that would be taken to encourage greater participation of under-represented groups. 0 points A description and concrete examples of actions to encourage greater participation of under-represented groups provided. 3 points
10. Phase 1 Financial Proposal Demonstrate a realistic financial proposal for the Phase 1 project plan by completing the table.	Insufficient information provided and/or information provided significantly lack credibility. Does not demonstrate a realistic financial proposal for the Phase 1 project plan. 0 points Information is provided but some costs appear to be either over or under estimated for the Phase 1 project plan. 5 points Information provided contains credible elements to clearly demonstrate a realistic financial proposal for the Phase 1 project plan. 10 points
11. Phase 1 Financial Controls, Tracking and Oversight Describe the financial controls, tracking and oversight that will be used to manage the public funds throughout Phase 1.	Insufficient or no information provided to demonstrate the Applicant/Bidder's ability to manage public funds in Phase 1. 0 points Information provided is vague and/or contains gaps. The Applicant/Bidder has some controls, tracking and/or oversight in place to manage the public funds in Phase 1. 5 points Information provided clearly demonstrates that the Applicant/Bidder has strong financial controls, tracking and oversight to manage public funds in Phase 1. 10 points
12. Phase 2 Strategy Describe a realistic strategy for the prototype development if selected to participate in Phase 2. Responses should include: anticipated barriers key tasks estimated cost	Insufficient or no information provided to demonstrate that the Applicant/Bidder has contemplated a realistic strategy for the Phase 2 prototype development. 0 points Information provided demonstrates a conceivably realistic strategy for Phase 2 prototype development, however there are gaps and/or the strategy is vague. 5 points Information provided demonstrates that the Applicant/Bidder has a clear and realistic strategy. 10 points
13. Commercialization Approach Describe your overall commercialization approach for the proposed solution. Responses should include: Target markets (excluding Government of Canada) Non-ISC funding sources Transition to a commercially-ready product or service Any other indicators of commercial potential and commercial feasibility	Insufficient or no information provided to demonstrate that the proposed solution has commercial potential. 0 points Some information provided to demonstrate that the proposed solution has commercial potential, however there are gaps in the commercialization approach. 5 points A realistic commercialization approach is provided that demonstrates that the proposed solution has commercial potential. 10 points

Questions and answers

Please refer to the tender notice for this challenge on Buy and Sell.

All incoming questions regarding a specific challenge will be posted here with the corresponding response.

If you have a question about a challenge, please send it to ISED-ISDE@canada.ca.

You can also consult the Frequently asked questions about the Innovative Solutions Canada Program.

A glossary is also available.

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