LIGHTER. STRONGER. FASTER

We’re Printing The Future of SuperAlloys

Thaero™ is a US owned and operated high deposition rate hybrid manufacturer of aerospace grade metal-matrix nanocomposites. Our goal is to strengthen our Nation’s defense industrial base by commercializing frontier advanced materials in partnership with US universities, National Laboratories, US Government agencies and leading US equipment manufacturers.

We leverage the latest in scalable supersonic cold spray and solid-state metal 3D

printing technologies creating novel, high-temperature nanomaterial-infused alloys for

mission-critical components essential to maintaining the competitive edge in the US

defense, space and nuclear industries.

Using AI to Discover New Materials

Our proprietary AI driven nanomaterials informatics software accelerates materials discovery through molecular dynamics simulations and machine-learning guided high throughput experimentation while leading us to rapidly prototype novel metal-matrix nanocomposites using our in-house advanced hybrid manufacturing techniques.

BNNT-ALLOYS

Our IP portfolio includes 8 exclusively licensed patents (granted and pending) from FIU covering the production of BNNT-Alloys and metal matrix nanocomposites using hybrid friction stir AM, cold spray AM, WAAM/DED, ultrasonic casting, and thermal spray.

Metal Matrix Nanocomposite Applications

Thaero's applications include lightweight structural alloys, lightweight terrestrial vehicles, hypersonic vehicles, Lunar and Martian landers, lightweight ballistic materials, high temperature alloy structures, high thermal conduction aviation structures and radiation hardened alloys.

In a paper published in the Journal of Materials Research in 2022, a joint NASA-FIU

study concluded that "adding BNNTs to the Ti alloy matrix greatly enhanced the

wear resistance, yield strength, and radiation shielding performance.”

Why Solid State 3D Printing?

A groundbreaking advancement in additive manufacturing, solid state 3D printing builds near net shapes at an astonishing speed, up to 1,000 times faster than conventional beam based metal 3D printing. Solid state 3D printing also possesses the remarkable ability to embed hardened sensors and electronics, combine dissimilar materials (ceramics, nanoparticles, alloys, fibers), and repair damaged structural components while creating novel superalloy structures. Operating in an open atmosphere without the need for a vacuum, solid state 3D printing offers exceptional scalability, unrestricted by conventional chamber size limitations. This innovation revolutionizes hybrid additive manufacturing, which is essential for the strengthening of our Nation's defense industrial base.

Why
BNNT-Alloys?

Boron Nitride Nanotubes (BNNTs), the world's lightest and strongest material, were first synthesized at UC Berkeley in 1995. When infused into lightweight alloys, BNNTs generate a novel multifunctional supermetal matrix nanocomposite. This unique nanocomposite boasts exceptional properties, such as neutron absorption, a significant increase in mechanical strength, improved ductility, enhanced wear resistance, high thermal conductivity, and electrically insulative properties while maintaining thermal stability above 850 degrees C in air.