Spraying Systems Co to Highlight Innovations in Battery Composite Manufacturing at TechConnect

Wheaton, IL – Spraying Systems Co. announces its participation in the upcoming TechConnect World Innovation Conference and Expo, an event focused on applied research and early-stage innovations. Booth 507 will feature representatives from Spray Analysis and Research Services, a division of Spraying Systems Co., where attendees can learn more about the company’s latest technologies and research initiatives. Dr. Amir Asadi, Associate Professor at Texas A&M University and a co-founder of Advanced Micro Sprays (AMS) — a spin-off of Spraying Systems focused on fabrication of meta surfaces and multifunctional coating using advanced spraying solutions — will be representing Spraying Systems Co.’s Spray Analysis and Research Services division, presenting significant advancements in the manufacturing of structural battery composites using their newly developed SFA (supercritical fluid atomization) system. Dr. Asadi is scheduled to speak on June 11 at 9:00 AM as part of the conference program.

The presentation, titled "Supercritical CO2 Spray for Scalable-Green Manufacturing of Structural Battery Composites: Towards Battery-Powered Transport" will take place during the conference, scheduled from June 9-11, 2025, in Austin, Texas. This research, co-authored by experts from Texas A&M University and Spraying Systems Co., including Paul W. Vesely, Justin Burger, and Rudolf Schick, addresses critical challenges in the pursuit of advanced energy storage solutions for e-mobility.

Enhanced Battery Technology

The growing demand for e-mobility, particularly in urban, air and space mobility, underscores the need for enhanced battery technology. Current battery technology, especially for demanding applications like electric aviation, faces hurdles in achieving the necessary energy density and structural integration. Carbon fiber reinforced polymer battery composites (CFRP-SBCs) offer a promising synergy between structural integrity and energy storage. However, for CFRP-SBCs, a primary challenge has been to overcome their typically lower energy density and to develop manufacturing processes that are not only effective but also scalable for industrial adoption. The investigation into supercritical CO2 spray technology, as will be presented, was driven by the need for a more facile and efficient manufacturing route for these promising multifunctional materials.

Dr. Asadi’s presentation will focus on an innovative approach utilizing supercritical CO2 spray technology, termed 'Scalable-Green Manufacturing' in the research. This method is engineered for the scalable and environmentally conscious production of these advanced composites. The 'Scalable' aspect indicates that the process is designed with industrial throughput in mind, moving beyond laboratory-scale production to methods suitable for larger volume manufacturing. The 'Green' aspect relates to potential environmental benefits; supercritical CO2 is often regarded as a more environmentally benign processing fluid compared to some traditional organic solvents, potentially reducing the environmental footprint. Additionally, the precision control inherent in engineered spray systems aims to optimize material usage and reduce waste. The research investigates how this precision spray technology can be instrumental in addressing the intricate manufacturing requirements of CFRP-SBCs, aiming to improve performance and facilitate their broader application in battery-powered transport, including electric flights and electric vertical take-off and landing (e-VTOL) aircraft.

For over 25 years, the TechConnect World Innovation Conference and Expo has served as a vital platform connecting innovations from universities, laboratories, and startups with industry leaders and investors. The event is recognized for fostering collaborations that drive technological advancements across various sectors.

About Spray Analysis and Research Services

Spraying Systems Co.’s Spray Analysis and Research Services division is dedicated to solving complex industrial challenges through the expert application of spray technology. This research, a deeply collaborative effort, saw the division bring invaluable expertise to the project. Their profound understanding of spray physics, encompassing areas like fluid dynamics, atomization processes, and droplet characterization, was crucial. The utilization of supercritical CO2 as a medium in spray processes represents a sophisticated application of spray science in advanced materials manufacturing. Developing such a novel application for composite manufacturing requires precise control over numerous spray parameters. The ability to model spray behavior, potentially using Computational Fluid Dynamics (CFD), and to engineer custom spray solutions for unique operating conditions and materials system—a core strength of Spraying Systems Co.—significantly aided in refining this advanced manufacturing technique. The research presented by Dr. Asadi aligns with the division's mission, showcasing how engineered spray solutions can lead to process optimization and the development of high-performance materials.

Attendees of the TechConnect World Innovation Conference are encouraged to attend this insightful presentation to learn more about this development in manufacturing technology for structural battery composites. This work highlights a pathway toward more efficient and sustainable energy storage solutions, crucial for the future of electric mobility.