1. Highlighting Clean Energy Innovations in Upstate New York
Pure Quantum
American Fuel Cell
Conamix
EcoCeramic Envelopes
Micatu
Scalable Nanomaterials:
Membrane Electrode Assemblies:
Direct Growth Nanowires:
Energy Efficient Building Façade:
Rugged, High Precision Sensors:
MOVING TECHNOLOGY FROM THE LAB TO THE MARKETPLACE
3. 3
NEXUS-NY is a program created and managed by High Tech Rochester (HTR), a venture development
organization based in Rochester, NY. HTR’s programs and services span early stage tech commercialization,
incubation of high-tech startups, and growth consulting services for small to mid-sized manufacturing firms.
For more information on HTR and its impact on the Upstate NY region, visit:
www.htr.org
Pure Quantum Dr.Stanley Whittingham
NYSERDA EcoCeramic Envelopes
American Fuel Cell Eastman Business Park
Cornell University Micatu
Conamix About the Authors
Reimagining how We Light our World
with Quantum Dots
An Interview with an Energy Pioneer
How NYSERDA is Moving Energy Technology
Out of the Lab and Into the Marketplace
Building a Better Building,
From The Outside-In
Enabling Next Generation
Clean Mobility Solutions
Building an End-to-End Ecosystem
for Energy & Materials Innovation
An Innovation Hub in
Energy Materials
Developing Photonic Motion and Vibration
Sensors for Wind Turbine Condition Monitoring
Transitioning Breakthrough Nanowire
Technology Out of the Laboratory
and Onto the Road
Brief Profiles on the Authors
High Tech Rochester
150 Lucius Gordon Dr.
West Henrietta, NY 14586
585-214-2400
NEXUS-NY
info@nexus-ny.org
@NEXUSNY
Managing Editor
Bob Loeb
bob.loeb@htr.org
Design
bzdesign, inc.
bz@bzdesign.co
www.bzdesign.co
4. 4
Pure Quantum is at the forefront of this movement.
A clean-tech startup from Cornell University comprising
professors, PhD candidates and master’s students,
Pure Quantum believes solid state lighting (SSL) to be
the future’s best bet for efficient, sustainable lighting.
Its expertise in the creation and functionality of
quantum dots—customizable and versatile
nanoparticle semiconductors—has afforded the
startup a unique opportunity with which to succeed
in this expanding and evolving market.
“The [SSL] industry is very vast, with many players and
moving parts,” explains Pure Quantum’s Joseph Caron.
“The challenge was never ‘could we sell our technology,’
but rather in identifying which appropriate industry
segments and opportunities to pursue.”
Enticed by the incentives of the U.S. Department
of Energy (DOE) as well as the swelling demand for
innovative and cheaper SSL sources, Pure Quantum,
via its quantum dot technology, has focused its efforts
exclusively toward improving the manufacture of
the material used in light emitting diode (LED) bulbs:
producing quantum dots in very large quantities
with uniform quality and properties.
SOLID STATE LIGHTING
While LED popularity increases every year, the public’s
overall awareness remains dim; incandescent bulbs
and compact florescent lamps (CFL) persist as clear
consumer favorites. CFL bulbs are a trusted, energy-
efficient choice with an attractive price point; however,
their price is not reflective of their disposal cost and
environmental damage. Nor does their retail price
reflect the opportunity cost of avoiding LED bulbs.
When compared to CFLs, home LED bulbs are 30%
more energy efficient with an average life span of
50,000 hours (CFL bulbs last around 10,000 hours).
Additionally, LED bulbs eschew the dangerous, rare
Like a race to claim a promised land, the U.S. Department of Energy’s
initiative to adopt solid state lighting has sparked a frenetic interest
from scientists, engineers and entrepreneurs from almost every
sector of industry. It is an all-encompassing call to arms:
Let’s reimagine how we light our world.
CONNECTING THE DOTS
by Kevin Carr
5. 5
earth elements and toxicity so pervasive in CFL and
incandescent bulbs, an attractive incentive for today’s
more environmentally conscious population.
Researchers in the last thirty years have unleashed
the exciting potential of LEDs as alternative lighting
sources. In supporting a somewhat nascent technology,
government subsidies have been used to lower prices.
Currently, LED bulbs can be found for sale below $10,
a magnitude of order lower than their $100
introductory price.
But this subsidized price is still not low enough to
enable the mass paradigm shift the DOE has hoped
for. As Caron explains, “Consumers are looking for low
prices now. A one dollar incandescent bulb is a very
attractive option when placed next to a ten dollar LED
alternative. Awareness is secondary to price.”
The DOE has spent millions on SSL-specific research
since 2003. In 2014 alone, the DOE dedicated $10.5
million. The goal, of course, is to reestablish the market
dominance: a wide adoption of LEDs as primary lighting
sources for residential, commercial and industrial
consumers, both public and private, a turning away
from fluorescents and incandescents.
The DOE estimates that switching to LED lighting over
the next two decades could save the country $250
billion in energy costs over that period, reducing the
electricity consumption for lighting by nearly one half,
and avoiding 1,800 million metric tons of carbon emission.
With $250 billion in
the balance, it is easy
to comprehend the
DOE’s investment.
But to accomplish this feat, LED bulbs must continue
to improve in many areas: reliability, color, intensity
and cost. Becoming ubiquitous, then, means that
the SSL industry must continue to make strides
in research and product development. For Pure
Quantum, it is a challenge worthy of its reward:
a big dream beginning on the smallest of scales.
CONNECTING THE DOTS
Quantum dots are surprisingly captivating nanoparticles.
Manufactured in the laboratory, these materials offer
the promise of customization. In their bulk state (many
hundreds or more molecules grouped together),
semiconductor materials exhibit specific and well know
properties. When these same materials are made to be
physically small, their properties can be designed/tuned
for specific use. In the case of SSL, the physical property
that is most interesting is fluorescence (the absorption
of one wavelength and the emission of another).
Joe Caron monitoring lab tests.
6. 6
Scientists can engineer quantum dots to emit specific
colors when excited. In this way a blue diode can be
made to emit white light.
“Quantum dots have been researched intensely for the
past thirty years,” explains Caron. “But only in the last
few years have [dots] been commercialized and used
in products. There has been an absolute explosion of
possibilities, a grab bag.”
Caron’s sentiment is on point: Quantum dots are
currently used in many industries and for many
objectives, such as lighting, biomedical, solar power
and security. Lately, this technology has proven
especially useful for entertainment electronics.
In 2013, Sony launched a line of TVs using quantum
dots; Amazon used similar technology in the Kindle
Fire HDX 7 and HDX 8.9. Apple’s iPhone 6 is rumored
to be using quantum dot technology for its screens.
inexpensive, highly scalable phosphor material for SSL
manufacturers, helping to lower LED bulb price points
to a more attractive and sustainable level.
The Pure Quantum team – business lead Joseph
Caron, 23; co-technical lead Curtis Williamson, 24;
co-technical lead; Douglas Nevers, 27; advisor Richard
Robinson; and advisor Tobias Hanrath - is achieving
a lower LED price point in the research lab—a charge
first inspired through the research of Robinson,
a Cornell University professor.
QUANTUM BEGINNINGS
Richard Robinson’s work in nanoparticle synthesis,
nanomaterials, and structures of materials culminated
in The Robinson Group, a Cornell-based lab that
focuses primarily on “nanoscale energy research.”
A melting pot of experience and new ideas, his lab
pairs undergraduates and graduate students with
professors in a skillful and cutting edge manner.
Joseph Caron, Curtis Williamson and Douglas Nevers
first worked together in this setting.
Williamson and Nevers are chemical engineering PhD
candidates at Cornell who currently share the role of
lead researchers at Pure Quantum. Williamson is a
former employee of Evident Technology, a competing
quantum dot manufacturer; as a Pure Quantum
team member, he merges academic and industrial
experience. Nevers brings to the team more than
four years of chemical engineering experience
with a specific focus on energy systems. Both were
enthralled with the idea of expanding their work
onto a larger scale.
Caron is a first year master’s student in materials
science and engineering. He became specifically
interested in transitioning the discoveries and
inventions that emerged from Robinson’s lab into
commercial products: “I wanted to make sure what
I was doing had real world implications.”
This trio worked together in an unofficial capacity
until NEXUS-NY offered them an opportunity to
collaborate on the commercialization of their
technology. “NEXUS-NY was the catalyst,” explains
Caron. “We saw it as a great opportunity to take
what we were doing to the next level.”
Concerning lighting, quantum dots offer a solution to
the LED’s biggest dilemma: the absence of a natural
white light. The previous and still-ubiquitous solution
blends blue, red, and green LEDs together in a unique
way that emits a whitish color. This practice meets most
consumers’ needs; however, Pure Quantum is betting
on a better, more efficient way. By employing quantum
dots to act as phosphors (i.e., light converters), a blue
LED light is filtered, or absorbed, and quantum dots
convert this energy into a warm, white light.
Currently, the phosphors in phosphor-converted LED
bulbs make up ten percent of its cost. By creating
sustainable kilogram quantities of quantum dots,
Pure Quantum’s research has the potential to generate
Doug Nevers and Joe Caron
7. 7
MOVING FORWARD
Pure Quantum formally joined NEXUS- NY in January
of 2014 and has since thrived as a member of the
inaugural cohort of the clean energy accelerator.
In addition to the goals and fruits of their innovative
quantum dot batches, the team now considers the
health of the overall business. Says Nevers, “It is a
crash course on the scientific method of business.
Specifically, I am learning how to test and validate
business propositions or hypotheses, and understand
how my research efforts best fit within the larger
economic market.”
Pure Quantum has already made progress on
multiple fronts. They’ve defined target markets,
have focused on funding, and have improved their
capability to develop and test its product. “NEXUS
has been an eye-opening experience,” explains Caron.
“Despite initial hurdles, all of us have found that we
very much enjoy the challenge of creating a business.”
Their work in the lab has progressed quickly.
Impressively, Williamson and Nevers’ output per
“The ability to finely
control material at the
nanoscale level enables
mesmerizing applications.
The vision to mass-produce
[quantum dots] intrigues
me, given the seeming
paradox of nanometer
precision at large
production scales.”
-Douglas Nevers
quantum dot batch (in kilogram quantities) is
already comparable to the world’s leading manufac-
turers. Though still very much in research and
development, the team is confident in their vision.
But engineering challenges remain. Keeping the
dots uniform while in big batch production is not
as simple as “multiplying small recipes by ten.” The
larger the batch, the more complicated the dispersity
(i.e., matching of sizes). Nevers explains, “Designing a
robust process to produce quantum dot phosphors
at a large scale is the biggest challenge we are
currently facing. Since we are relatively new to SSL,
we are actively adapting our quantum dot expertise
to meet the growing needs of the market.”
Caron is also busy. As business lead, he is researching
potential long-term relationships and partnerships
to fuel and fund Pure Quantum for years to come.
He presents with confidence and expertise as he
aptly describes the markets, the competition, and
the important need for specified focus in a vast
LED industry. Caron’s fervor for clean technology is
matched only by his passion for business leadership,
and his abilities have guided him into the most
outspoken role in the group, one that is beginning to
look and sound increasingly familiar as a start-up CEO.
“Joe is doing very well in our program,” explains
NEXUS-NY executive director Doug Buerkle. “Joe has
fully embraced the entrepreneurial process. He has
actively and effectively engaged numerous customers
and successfully led a pivot towards SSL after first
exploring battery applications for his team’s quantum
dot technology. The team as a whole has met many
of the early challenges of a start-up business with
great focus.”
The potential of solid state lighting has never looked
brighter. The path towards complete adoption,
however, remains clouded. Pure Quantum aptly
represents SSL’s greatest paradox: reliance upon
disciplined science and willingness for intrepid
adventure. If and when Pure Quantum succeeds,
the Department of Energy may have them to thank
for discovering new land. In the least, Pure Quantum
will have played an active role in achieving $250 billion
dollars in national energy savings.
8. 8
From Concept to Prototype
to Viable Products
Researchers and inventors across the New York State
are innovating at a breakneck pace, especially in the
energy technology sector. Capturing and commer-
cializing this flood of innovation is the challenge that
NYSERDA is addressing with its unique Proof of Concept
Center (POCC) program. This program is designed to
enable early market testing of product concepts,
testing that helps inventors build viable business
models around their inventions.
The POCC model takes the classic ‘software startup
accelerator’ model found in tech startups across
the globe and applies many similar processes to the
complex world of energy-related technology innovation.
The goal is to rapidly move conceptual designs into
practical use in the marketplace. To learn more about
the basics of the POCC program, New Energy spoke
with Jeff Peterson of the New York State Energy
Research and Development Authority (NYSERDA).
About Jeff Peterson
Jeff Peterson manages the Innovation and Business
Development Program at the New York State Energy
Research and Development Authority. Activities
within the group focus on catalyzing and building a
long-lasting ecosystem in New York to accelerate
the start-up and growth of early-stage clean energy
technology businesses. Examples of active programs
include six clean energy incubators, three proof-of-
concept centers, and test centers for solar electric
systems and small wind blades.
Peterson participates in activities involving the
promotion of renewable energy. He serves on the
GAMECHANGER:
How NYSERDA Is Moving Energy Tech
Out Of The Lab & Into The Marketplace
by Martin Edic
9. 9
board of directors for the American Solar Energy
Society and provides peer reviews of manuscripts
submitted to Energy Policy – International Journal of
the Political, Economic, Planning, Environmental and
Social Aspects of Energy.
In the past he was a member of the National
Academy of Engineering Committee on U.S. - Chinese
Cooperation on Electricity from Renewable Resources
and the National Research Council Panel on Electricity
from Renewables, in both cases serving as the lead
for the chapter on the deployment challenges to
deliver technologies to the market.
He received a bachelor’s/master’s degree in Wood
Science from the University of Massachusetts and
a master’s degree in Industrial Administration from
Union College.
What was the idea behind developing the
Proof of Concept Centers and how did it evolve?
The Proof of Concept Centers (POCC) program was
launched by Governor Andrew M. Cuomo to help
inventors and scientists across New York State turn
high-tech, clean-energy ideas into entrepreneurial
successes. They enable universities, scientists, and
research organizations to partner with business
experts and early-stage investors in order to move
technical innovations beyond the lab and into the
market. This encourages the growth of clean energy
in New York State. The POCC’s are part of a broad
set of strategies to establish an active ecosystem that
fosters entrepreneurship and innovation in clean
energy technologies.
What are the principal goals for the program?
The goal of the program is to increase the likelihood
that clean-energy technology inventions will evolve
into successful business enterprises. The centers are
accelerating the creation of new startup companies
and commercialization of innovative technologies by
connecting the developers of promising new technol-
ogies with business mentors and potential investors.
Where are the POCC programs located?
There are three POCC programs across New York State:
• Columbia University in New York City, partnering
with SUNY Stony Brook, Brookhaven National
Laboratory, and Cornell NYC Tech
• High Tech Rochester Inc.
• New York University Polytechnic School of Engineering,
partnering with the City University of New York
How did NYSERDA select the organizations to
run the POCCs?
The three POCC programs were selected from a pool
of proposals submitted in response to a NYSERDA
competitive solicitation. Based on a review and
technical evaluation by NYSERDA and outside experts,
it was determined that these organizations offered the
best and most creative approaches to the program.
HighTech Rochester’s NEXUS-NY (New Energy
Xcelerator in UpState New York) program utilizes
the Lean Startup methodology designed by Steve
Blank at Stanford. Are other programs using this
process? If so, how has it impacted the success of
the programs?
The Columbia University and New York University
programs, while independent, have established
a combined brand called PowerBridge NY. They
cooperate in running the program and offer combined
training sessions. PowerBridge NY is also following the
Lean Startup methodology. The first class of teams is
still hard at work in the POCC programs. It is too early,
therefore, to discuss success of the program.
Based on input from the NEXUS-NY teams in particular,
the Lean Startup approach to customer discovery is
stimulating a lot of creativity and is helping the teams
direct their attention to strong market opportunities.
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10. 10
Are there plans for physical locations for
this and future classes of startups, i.e. labs,
accelerators, etc?
The POCC program is part of a broad strategy
to support clean energy technology startups in
New York State. In addition, there are six clean
energy technology incubators in New York and an
Entrepreneurs-in-Residence program (operated by
HTR) that provide mentoring/coaching to early stage
companies.
What kind of early feedback are you getting
on this year’s programs? Are there things you’d
do differently?
NYSERDA contracted with the New York Academy of
Sciences (NYAS) to assist in the establishment of an
advisory board for the program. The advisory board
includes private, public and academic representa-
tives from across the country with deep expertise in
technology and innovation-based economic devel-
opment. The first meeting of the advisory board was
in June. Each POCC outlined its respective activities.
Feedback from the board has been incorporated into
the next round of requests for applications.
Do you see this expanding?
These are five-year programs. At the end of the
second year, each POCC will provide NYSERDA
with a plan to make the program sustainable, to be
able to operate without NYSERDA funding support.
Modification or expansion of the program will be
considered at that time.
What kind of impact do you envision this
having on both local economies and the
general climate for energy startups in NY?
The primary goal of the program is to translate
clean energy technology research and invention
into successful business enterprises. To the extent
that this is successful, we expect there to be a local
economic impact as the businesses grow and add
jobs. From a broader perspective, we expect the
programs to have influence across the research
community to build an entrepreneurial perspective
and drive towards new business ventures.
What program auspices does the POCC fall under?
The program is within the NYSERDA Research and
Development program and is a component of the
Innovation and Business Development group.
We also spoke to Doug Buerkle, who directs the
High Tech Rochester NEXUS-NY POCC program.
The program expects to graduate eight teams in
the coming weeks. Many of these teams have
already formed companies that will go on to
receive seed funding and continuing support
from both HTR and NYSERDA.
Doug, what was the overall takeaway from
your work with the first POCC NEXUS-NY
‘class’ experience?
There are several things that stand out. I was initially
pleasantly surprised by the high quantity of high-quality
applications we received from scientists who wanted to
join the program. We believed we had a strong value
proposition but, as with any startup, you never really
know until you launch. Part of this has to do with two
other takeaways: the quality of research taking place
in Western New York coupled with the entrepreneurial
passion, especially amongst some of the younger
scientists in our area.
Western NY is not universally identified as a hotspot for
energy innovation, but I’d put our research institutions
up against any in the country. Our research happens to
take place in a decentralized fashion, but the combined
capabilities of our universities are astounding. Lastly,
I wasn’t sure how strongly our commercialization
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11. 11
objective would resonate. I believe many observers
would agree that universities have largely struggled to
commercialize their innovations. I have been extremely
impressed with the seriousness and passion exhibited
by participants of the first NEXUS-NY cohort.
When you explain the program to area business
people, what is your concise description and how
does it resonate within the business community?
We generally say that NEXUS-NY helps accelerate the
commercialization of energy innovations emanating
from New York’s research institutions. At the highest
level we want our teams to accomplish three things
through the course of our program. First, we want
them to fully understand the customer’s problem
as it relates to their proposed technical solution.
This is where the customer discovery process comes
in. Second, we want them to de-risk their technology
by building early prototypes. Finally, we want them
to generate third party validation of their technology,
ideally by engaging early potential customers in
sample evaluation and/or demonstration projects.
What are the continuing plans for the NEXUS-NY
program?
Thankfully NYSERDA has funded NEXUS-NY for five years.
As a startup ourselves, we’ve learned a lot during our
first cohort. We’ll take what we’ve learned, make some
adjustments and start our second cohort in January
of 2015. By the end of 2015, we will have developed a
sustainability plan that proposes how we can continue
to operate after the initial five-year period.
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“The PRIMARY GOAL
of the program is to
translate CLEAN ENERGY
TECHNOLOGY research
and INVENTION
into successful
BUSINESS ENTERPRISES.”
-Jeff Peterson
12. 12
AMERICAN FUEL CELL
by Jay Pfluke
From our houses to our hospitals, to our factories
and our 21st century communications capabilities,
to the motorized vehicles we depend on, there is a
new energy source, a non-polluting, renewable, and
inexpensive source that can supply us with both the
stationary and mobile power required for these and
numerous other applications.
Fuel cell technology is emerging as a viable, elegant,
innovative, and clean alternative to our nation’s
dependence on crude oil. Fuel cell technology has
many advantages over other forms of energy gener-
ation and storage, though perhaps the key advantage
is that its fuel source is hydrogen, a truly clean and
abundant resource.
Based on its innovative approach to the development
and production of the key element of a fuel cell, the
membrane electrode assembly (MEA), American
Fuel Cell (AFC) expects to be at the forefront of
the adoption of fuel cell technology as the next
game-changing energy alternative.
RIT scientists observe MEA under test
at the Golisano Institute for Sustainability
13. 13
In fact, according to Daniel O’Connell, the co-founder
and CEO of AFC, fuel cells are the answer to America’s
dependency on oil. O’Connell, along with co-founder
and COO Dave Wetter, and senior industry expert
Edward Himes, make up the core team of American
Fuel Cell.
The three have worked together on alternative energy
solutions for more than 25 years. They began AFC
after leaving their previous
employer, General Motors,
where they worked exten-
sively on advanced tech-
nology and electric vehicle
programs. Combined, the
three principals have more
than 90 years of automo-
tive experience, with 40
of those years devoted to
fuel cell and electric vehicle
technology.
All three have been working
as consultants in the energy
industry, which gives AFC
a distinct and disciplined
edge in the development
of fuel cells: a particular
focus on the design, manu-
facture, and implementa-
tion of fuel cell modules, “a
process that can change the
energy industry as we know
it today,” says O’Connell. To
put the advent of AFC into
perspective, there is a need
for startups in this field, according to Navigant Research:
At the end of 2013, 20 companies accounted for more
than 95% of total revenue for the stationary fuel cell
sector. The downside of this concentration is an innova-
tion pipeline that may not be sufficiently robust to drive
the technological advances that this emerging sector will
require over the next five to ten years.
When compared to other teams in the NEXUS-NY
program, AFC is somewhat unique: It doesn’t have an
academic affiliation – the principals come from industry.
Also, AFC didn’t invent the fuel cell. Rather, its unique
value or niche is in the team members’ understanding of
how to optimize the system’s interactions and their vision
of lowering the cost of manufacturing by 20% or more.
While it focuses on one individual component, the MEA,
AFC has a broad understanding of the overall fuel cell
system, including the stack of cells, which fits into a power
module that, when supplied with hydrogen, creates the
electrical power that drives
a vehicle or device. In the
cost breakdown of a fuel
cell, 22% of the cost is in the
MEA, the most expensive
component of all.
As it designs and develops
its proprietary MEA, AFC’s
focus is on reducing the
platinum used as the
catalyst within the MEA
and on improving the
manufacturing process
to align with the fuel cells’
ultimate application. Now
in the prototype phase,
small-scale models of AFC’s
MEA are being produced
in a laboratory and are
currently in testing phase;
the scale-up to volume
production will begin in
late 2014.
Beginning with the MEA
for fuel cells, AFC also has
its sights set on the production of unitized electrode
assemblies, fuel cells stacks and modules. But for now,
the name of their game is membrane electrode assembly.
Many startups refer to their unique and possibly
patented technologies as their secret sauce, a recipe
of ingredients that coalesce into their unique technology.
As in the case of many successful startups, some of the
ingredients are tangible, some are in a process, and
some are the intangible qualities of their leaders; AFC
expects to generate advantages in all three areas.
The current technology
– OIL –
WILL NOT SUSTAINAmerica’s fuel consumption,
FUEL CELLTECHNOLOGY WILL.
-Dave Wetter
14. 14
According to AFC, one of the premier locations to
produce a Membrane Electronic Assembly is in
Rochester, NY. One of the components of a MEA
is the membrane itself - a thin film, which is what
Rochester, and more specifically, Eastman Kodak,
is known for. With Kodak’s coating equipment in
close proximity to AFC’s lab, the company is primed
to “enhance the Kodak equipment to produce a
cost-effective, high-volume, high-quality MEA,”
says Wetter.
Mixing in the capabilities of several other local
companies and prominent universities, it is clear
that Rochester has the proficiencies and the
qualified people to help AFC thrive. Despite the
downsizing of many industrial giants, “the people
with the technical savvy and passion for a cleaner
environment have remained in the Rochester area”
according to O’Connell. These are the people and
this is the area AFC is planning to leverage.
What really separates and distinguishes American
Fuel Cell is its passion: for clean energy technology,
for creating jobs in upstate New York, and for
creating a cleaner environment. AFC is not only
aiming to become a company that will optimize
MEA technology, but one that creates jobs. They will
reach out to people who have been displaced and
get them back to work doing what they love. Wetter
and O’Connell believe local suppliers will also play
a large part in creating jobs. For example, there
are manufacturing plants in New York that produce
enough hydrogen (as a byproduct) to fuel the at
least 1,000,000 Fuel Cell Electric Vehicles (FCEZV).
Harvesting and transporting that fuel source would
employ many. AFC’s focus will be to create a
synergistic community. For AFC, it is not just about
creating jobs, it is also about becoming an advocate
for the community.
Anatomy of a Membrane Electrode Assembly (MEA)
15. 15
A key tenet of the NEXUS-NY program is “customer
discovery,” a scientific process for validating product/
market fit. For AFC, the market, and interest in its value
proposition, was confirmed: fuel cell manufacturers
and users want MEAs that are lower in cost, that can
be manufactured in large volumes, and that can be
adapted and modified depending on the end application.
Also, it doesn’t hurt that AFC’s MEAs are American-made.
Among the applications for AFC MEAs and other
components are backup power (such as for cell phone
towers, hospitals, military and other mission-critical
applications), mobility (such as for fork lifts and other
off-road industrial vehicles) and automotive (with the
need for a source of clean power, fast refill, and longer
distances driving).
Surveillance drones, temporary lighting, and
communications equipment - currently all powered
by fuel cell technology - are being used in war zones
and disaster areas throughout the world. There will
always be a need for these applications; therefore,
there will always be a need to make a more efficient
and affordable fuel cell stack.
The integration of electronic vehicles is within AFC’s
scope as well. “We would like to be a supplier to the
automotive industry at some point,” said O’Connell.
In the fuel cell industry there is a lot of talk, especially
from combustion engine purists, about horsepower
and performance. Let’s not forget that O’Connell,
Wetter, and Himes are “car guys” at heart with
decades of experience with GM.
“Fuel Cell powered vehicles are all about torque,
instant torque,” stated O’Connell. He refers to an
electric drill to describe the amount of torque MEA’s
provide. “When you hit the trigger on an electric drill,
there is instant power that can really twist your wrist
if you’re not ready for it.”
That same torque is present in Electric Vehicles.
O’Connell mentions that drivers of EVs begin to
appreciate the power available as soon as they test
drive one. He recalls the surprise and “EV smiles”
he has seen on first-time test drivers
Dan O’Connell outside the Fuel Cell Testbed
at RIT’s Golisano Institute for Sustainability
16. 16
Productivity is essential in a world of logistics. Forklifts
and pallet trucks do a tremendous amount of the
loading and unloading within the logistical chain.
Currently, there are an estimated 6,575 fuel cell
forklifts throughout the United States and Canada,
and that number is sure to increase as companies are
finding these vehicles are living up to their promise.
“Fuel Cells are not just about torque,” Wetter added.
“As long as there is fuel, the power remains constant.”
In turn, productivity remains at peak levels.
There are not too many startups that can boast about
longevity and numerous successes. A major point
of differentiation that separates AFC from other
clean-energy start-ups is trust. O’Connell, Wetter, and
Himes have known and worked together for more
than two decades. Wetter and O’Connell promote a
culture of faith. Passion, knowledge, and experience
are common characteristics, but their resolve and
ability to execute will define their company.
Both Wetter and O’Connell cite trust amongst their
team for allowing them to “deliver and do what
we said we would do.” What they have done and
continue to do is fuel each other’s desire to create
jobs in Rochester and help contribute to a cleaner
environment: “It really comes down to providing a
technology that will make our world a better place,”
they say. “We have seen first-hand what small teams
can do, from start to finish, produce technology that
supplies clean energy.” Creating the right team has
been fairly easy with such a wealth of local talent.
Starting a new fuel cell component manufacturing
company is not without its trials. Despite coming
from a corporate world, AFC’s abundance of
experience has not necessarily prepared the
principals to run a small company.
As a startup company, AFC now has to approach
developing and optimizing the company holistically.
Decisions on parts, labor, office space, and marketing
are team-based. “There’s no more picking up the
phone and getting someone else to order parts,” says
Wetter. This is where NEXUS-NY has helped AFC grow,
providing strategic elements to help manifest the
company’s vision.
NEXUS-NY provides partial funding to accelerate the
growth of AFC’s technology. However, optimization of
an MEA requires additional funding. AFC is projecting
it will take significant investment over the next two
years to produce its ideal MEA. In progressing this
far, however, O’Connell and Wetter both agree that
NEXUS-NY‘s help has helped them move forward
with their goal of forming a successful and profitable
manufacturing company.
American Fuel Cell MEA prototype
17. 17
The t-shirts and bumper stickers in the tourist shops around
Cornell University read Ithaca is Gorges. In time, they may be
selling trinkets that say Cornell is Energy Innovation. Tucked
away amongst the bucolic waterfalls and ravines of central
New York are Cornell scientists working in state-of-the-art
research facilities second to none in the United States.
AN EMERGING INNOVATION HUB
IN ENERGY MATERIALS
by Andrew Harrison
Hector Abruna, Director – Energy Materials Center
at Cornell (EMC2)
Paul Mutolo, Director of External Partnerships
– Energy Materials Center at Cornell (EMC2)
Michele van de Walle, Industrial Outreach Director
– Cornell Center for Materials Research (CCMR)
Lyndon Archer, Co-director – KAUST Center for
Energy and Sustainability
Emmanuel Giannelis, Co-director – KAUST Center
for Energy and Sustainability
NEW ENERGY RECENTLY
SPOKE WITH FIVE CORNELL
INNOVATION LEADERS:
WHY IS THE WORK AT
CORNELL IMPORTANT?
Emmanuel Giannelis explained where the collective
drive comes from. “As a society, the energy question is
one of the two biggest questions we need to address
in the next several years, and pretty quickly (the other
being health). If we are able to solve the energy question,
we can also address the water and environmental
impacts. Energy needs are predicted to double by 2050
and we don’t have a good way to say that we are going
to be able to meet that demand.”
The work of these leaders ranges in focus, but not in
magnitude. They are trying to solve problems that will
fundamentally change how energy is created, stored
and transmitted. Theirs and others’ innovations at
Cornell will affect the cars we drive, the computers
we use, and the cell phones we carry.
18. 18
The Cornell Center for Materials Research (CCMR) has
been part of many high impact projects. Funded since
the 1960s by the National Science Foundation (NSF),
CCMR distributes grants to Cornell faculty members as
well as to industry participants within New York State
and beyond who would like to work with faculty or
use the school’s facilities and tools. CCMR accepts
grant applications regardless of an affiliation with
the university.
At CCMR, Michele van de Walle explains her role:
“My mission is to connect industry scientists and
Cornell faculty members to develop partnerships
and help New York State small businesses in all
areas related to materials.
“We do that by assisting in quite a few areas such
as developing prototypes, exploring new markets,
solving technical roadblocks, conducting QA/QC,
and developing new materials,” she adds. “In addition
we are helping by developing innovative products,
improving manufacturing processes, characterizing
image materials, validating technologies and developing
sustainable materials. We also work on technology
transfer and economic development.”
Cornell has tools, instruments and facilities that most
companies either can’t afford or don’t buy because they
don’t need them all of the time. “In addition, we have
world class experts in their respective fields and we
can find the right experts for businesses and provide
a flexible and cost-effective way to get help,” she adds.
In terms of industry, the work at CCMR has also helped
bring businesses to Ithaca in order to be closer to
the Cornell talent and facilities. Numerous successful
start-ups have sprouted in the central New York region
based on work funded by CCMR.
One of the groups on campus that CCMR helps fund and
also taps as experts is the Energy Materials Center at
Dr. Richard Robinson with Joe Caron and Doug Nevers
CCMR HAS ACTIVE
PROJECTS IN THE
FOLLOWING AREAS:
• Atomic Membranes
• Controlling Complex Electronic Materials
• Mechanisms, Materials, and Devices for Spin
Manipulation
• Seed Projects - Exploratory Research
o Nanometer-scale patterning from templates
of covalent organic frameworks
o Diamond MEMS for quantum control and
sensing
o Characterization of Ligand Passivation
Strategies for Semiconductor Nanocrystal
Solids
19. 19
Cornell (EMC2). At EMC2, they talk about the research
they are doing in trying to develop better performing
materials in fuel cells and batteries. “Fuel cells are the
most efficient means we know of for converting
a chemical fuel into electricity,” Paul Mutolo said.
“In a heat engine, like the engine in your car, the
maximum theoretical efficiency is about 50%,” Hector
Abruna adds. “The actual efficiency of your car is
about 25%. Cars have been around for a long time so
they are highly optimized. A fuel cell, which is relatively
new and un-optimized, is already at 50% to 60% in
the lab. And it could go up to 90% efficiency.”
Their work also focuses on what is next, with long term
goals for developing revolutionary innovations. “We are
looking for science-based solutions to problems that
are in a five to ten-year time frame, not next month.
These are complex problems that require multiple
inputs,” Abruna said.
In recent years, industrial participants have proven to
be very good at incremental innovation, optimizing the
performance of what already exists. But, disruptive
technologies usually come from basic research.
“Industry looks to groups like us for the future,” Abruna
explains. “I’m paraphrasing, but no amount of optimi-
zation will take you from a candle to a light bulb - it
requires a very different knowledge base to get from
one to the other.”
Making a shift like that - candle to light bulb - is not so
simple. “The innovation ecosystem starts in the lab.
You need materials to make big drops in cost, big
improvements in durability and big jumps in perfor-
mance. Those materials require deep knowledge of
atomic level processes that govern how a battery
works and how a fuel cell converts a fuel into electricity.
Knowing what the roadblocks are to current material
sets gives us ideas on how to overcome those
obstacles and get to a new material that will overcome
those problems,” Mutolo says.
In many academic settings, research has a very hard
time transitioning from the lab to the commercial
space, no matter how good the technology. “There
must be a link between the basic research we perform
and the end application within industry,” says Abruna.
“Paul (Mutolo) shepherds the discoveries here into the
application space, trying to get around the valley of
death that can happen in academia.”
“We are not working tucked away in a research lab
hoping a groundbreaking technology will then find a
home. We try to have industry conversations early,
understand their needs, and solve important problems.
That is market pull. It’s not just cute science followed
by technology push,” Mutolo says. “It’s addressing real
needs and providing scientifically sound solutions to
their problems.”
At the KAUST Center for Energy and Sustainability,
they are working on their own solutions to complex
problems. Giannelis has a broad portfolio of work in
A FEW SELECT
INNOVATIONS FROM
EMC2:
• High performing oxygen reduction catalysts,
one of the stumbling blocks in fuel cells.
• Development of alkaline membranes that
allow researchers to work in base rather than
acid. These membranes enable lower cost
materials and higher efficiencies.
• Development of a polymer system for
batteries that allows the use of metal anode
electrodes, such as metallic lithium. This
innovation helps reduce dendrite formation,
one of the primary failure mechanisms in
lithium-ion batteries.
• Theories to understand reactions at
electrified interfaces. “We have Thomas Ariis
here and he is a genius,” says Abruna.
• Development of experimental tools to inves-
tigate fuel cell technology under operating
conditions. “This is very hard because these
are very reactive interfaces and to observe
them at the atomic and nano scale while they
are operating as designed is complicated,”
Mutolo observes.
20. 20
three main areas: carbon capture and conversion, water
(developing better membranes for water purification),
and energy conversion and storage.
“On the capture side, we are developing absorbents.
These are porous materials that act as sponges to
absorb/capture CO2. If you put them at the exhaust of
a power plant, and as you burn coal or natural gas, you
need to grab that CO2. You fill the sponge with CO2.
And you need to release it. You can’t take the sponge
to landfill. It’s not economically feasible,” he explains.
“As you reuse the sponges, they may start with 10%
CO2, but after capture, you have 100% CO2, which
you can use for various applications including getting
more oil out of an oil well or to make fuels and organic
compounds,” adds Giannelis. “We have a grant from
New York State to take that to the next level and
commercialize that technology. The conversion part
is still exploring different options.”
And the options in the conversion process could lead
to great things. Lyndon Archer explained a potential
application: “If you look at internal combustion, you
can define a hybrid vehicle in a different way by using
a battery that captures CO2 from the exhaust of your
engine and coverts it into electricity. Initially it sounded
like science fiction. But a year ago we showed it could be
done. “What this means is you’d have a car burning fossil
fuels, but instead of CO2 being put into the air, the CO2
gets captured and converted into electricity. You’d have
a little cylinder in your car that would accumulate the
CO2 as it’s released from the battery. Then like an
oil change, you’d flip that cylinder out and off you go,”
he adds. “A zero emission vehicle using the hybrid
power system would allow us to do carbon capture
in an automotive format. We are hot on that trail.”
Regarding water filtration, the KAUST Center is working
with a collaborator from Yale on membranes that don’t
foul. Typically, when a filter is exposed to water, it picks
up microorganisms that make the membrane inefficient.
The more microorganisms it picks up, the more they foul
the filter, which in turn requires more energy to get the
water clean.
“We have developed technology that makes membranes
that don’t foul as easy and that can also be cleaned.
We can make these membranes easily and in a scalable
process. We’ve demonstrated this, we’ve measured the
properties and we have applied for a patent and are
looking for partners in the water industry,” Giannelis said.
On the energy conversion and storage side, they are
working on renewables. “For solar and wind, you have
to convert energy, store it and then deliver it as needed.
Sometimes it’s sunny, sometimes it’s not. Sometimes it is
windy, sometimes it’s not. Batteries and super-capacitors
are required to store that energy and use it as needed.
Like a memory device, it’s about storage capacity. How
much can you store per volume? The more efficient the
battery, the more you can store per volume,” described
Giannelis.
This also relates to the auto industry. In an electric car,
a drawback is how much space you need for batteries
in order to operate the car. If you had very efficient
batteries, you could store a lot of energy into a tiny
space in terms of weight and volume.
Part of Archer’s work has been focused on boosting
batteries that use metals as their anodes, such as lithium,
aluminum and sodium. “The common problem from all
three, over multiple discharge cycles of the battery, is that
the metal forms complicated electrodeposits (dendrites).
The dendrites, over many cycles of charge and discharge,
will pierce the separator in the battery and short circuit
the cell, which can cause the battery to catch fire. This is
a problem relevant for the safety of batteries but also in
the quest to get high energy out of batteries. In a lithium
ion battery, if you remove the carbon, the capacity for
storage goes up by a factor of three, and some argue a
factor of ten.”
This gives current battery technology a jolt. But the grand
challenge is how do you stop these metals from forming
dendrites, which ultimately cause the battery to fail?
Archer and his group think they have a potential solution.
“There is a fundamental stabilizing mechanism where the
membrane is able to prevent the dendrites from growing.
21. 21
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This method allows you to cycle lithium metal-based
batteries for hundreds of cycles and thousands of
hours with no evidence of these dendrites being formed.
We showed this in a paper last year,” Archer said.
“Very recently we discovered that if the surface coating
is enriched in lithium fluoride or in general, lithium
halides, the batteries can be stabilized, even in a liquid
electrolyte. In other words, by adding a little bit of a
special salt in a special electrolyte, you can now suddenly
solve this really massive problem of dendritic growth in
lithium. This work was just highlighted in Nature Materials.
“Both of these enable very high capacity anodes in
batteries. Batteries can have much longer lifetimes.
Cars, on a single charge, can travel distances that
are comparable to gasoline-fueled engines. The goal
is longevity and reducing cost. This can also be applied
to robotics, where there is a big need for long-lasting
batteries.”
In looking at all the different work taking place at
Cornell, it is apparent that technological advances in
materials are not a wish, they are a must. But that is
easier said than done. The groups’ innovation efforts
and collaboration with industry can be applied in many
ways. The end result may help shift the scale in energy
materials science in the same magnitude as the shift
was from the candle to the light bulb.
22. 22
Journey to Commercialization:
There were no TV cameras or representatives from
the Guinness Book of World Records present, but
in February of 2013 in Ithaca, NY, a world record
was broken. Perhaps not the kind of record that
inspires the popular media or comedy monologues
on late-night TV, but a record that could someday
affect how the world travels.
In a lab at Cornell University, Dr. Tobias
Hanrath, associate professor of chemical
engineering and one of his graduate
students, Ben Richards, set the record
for producing the largest quantity of
silicon nanowires: 3 grams, an accom-
plishment that could revolutionize the
field of clean energy, and in particular,
the manufacture of batteries for
electric vehicles.
The duo has created and patented a
technology for manufacturing high
performance, functionalized silicon.
Moreover, their process enables a
scalable approach whereby nanowires
are grown directly on a flexible current
collector and without costly CVD
(Chemical Vapor Deposition) equipment.
Silicon has established itself as the material of choice
in solar cells and is positioned to do the same for
next generation, high capacity Lithium-ion batteries.
The prospect of creating much higher capacity
batteries based on silicon anodes has inspired
intense world-wide research activities. While there
have been tremendous advances in fabricating
lab-scale electrodes and understanding their
performance, there is growing recognition that this
progress is insufficient; significant
barriers concerning scalable and cost-effective
manufacturing have yet to be resolved.
by Andrew Harrison
Transitioning Breakthrough
Nanowire Technology
Out of the Laboratory
and Onto the Road
Car companies, environmentalists, academics
and politicians would love to be able to help solve
the electric car battery/clean energy/oil dilemma.
Higher capacity and/or lighter weight batteries
could revolutionize the transportation industry.
Enter the work of Hanrath and Richards.
“A single electric vehicle would require
on the order of 10kg of nanostructured
silicon for the high-capacity battery.
Conventional thin film technologies
are unable to meet that demand.
That’s where our process comes in.”
-Tobias Hanrath
23. 23
Much of the previous work done in the field was based
on technology typically used in computer microchip
manufacturing – an approach in which thin films of
material are deposited onto a current collector in
complex and costly ways. The approach used by
Hanrath and Richards grows silicon directly onto
copper in a solid state reaction, allowing production
to scale and the tuning of nanowire features to be
more precise.
Hanrath and his colleagues have been working on
silicon nanowires for a while, but recent breakthroughs
in their application in batteries have underscored
the need for a
high-throughput
process. “To success-
fully transition [the
technology] we need
to be able to fabricate
these materials at the
level of hundreds of
kilograms” says Hanrath.
“Moreover, one would
like to directly grow
the materials where
we need them (i.e. on
the electrode) to avoid
additional processing
steps. We recognized
that our process stands
out as a very attractive
solution to address this
scalability challenge.”
Fabricating 10,000
grams (10 kilograms) of
silicon nanowires is a daunting engineering challenge,
but Hanrath and Richards believe they’ve taken an
important first step in their lab. Hanrath believes the
challenge is similar to the development of polymers
and plastics 50 years ago. “Transforming polymers
from a bench-scale scientific discovery to a multi-billion
dollar industry involved several interesting chemical
engineering challenges,” Hanrath noted. “We’re excited
about the prospect of applying similar concepts
to develop methods for the scalable production
of high-quality nanowire electrodes to enable the
deployment and commercialization of emerging
energy technologies,” he adds.
The potential is exciting, too, resulting in batteries
that can hold a charge three times that of present
day conventional batteries, resulting in three times
the driving range between charges. Alternatively,
batteries can be three times lighter in weight with
the same range.
Hanrath explained, “It’s relatively easy for us to scale
this up; we’ve demonstrated we can do this. We can
take it from three grams to three kilograms. It’s a
matter of using it in a bigger reactor and addressing
the processing technologies to structure the silicon
on a larger scale.”
The team’s business mentor, Charles Hamilton, explains:
“Functionalized silicon for battery anodes has been very
exciting to a lot of people for a number of years, but it
hasn’t lived up to its potential because of the inability
to scale the manufacturing. The missing link is the ability
to scale in a different way. “
“People have been trying to use the methods of microchip
manufacturing, which are great if you’re going to make a
high value microchip, but that is not scalable if you need
to make 10kg of battery material at a cost effective price.”
“The solid state growth of these functionalized materials
shows great potential in regards to scalability,” Hamilton
Charles Hamilton, Dr. Tobias Hanrath, and Ben Richards
24. 24
adds. “The methods Tobias and Ben have discovered
allow us to tune the manufacturing so we can adjust
the characteristics of that material. Sometimes
you’re going to want to have a certain density or
certain form factor to get the results you want given
a specific application.”
“The method they have discovered allows us to
manufacture functionalized silicon at scale and do
it in a precisely tunable way. Those are the two key
advantages we saw that made us say ‘OK this makes
sense as a start-up company’.”
In January 2014, the team turned its idea into
a start-up company called Conamix.
I’m here as a coach to help them transition that into the
commercial world,” Hamilton described.
The transition is not a small one. Hamilton continued,
“If we are making things at the three gram scale but we
need to make them at the kilogram scale, there is a lot of
road between here and there. My role as a mentor in the
program is to help identify what those barriers are and
help make a path forward together in trying to overcome
those barriers.”
“I work on the business risks, such as interacting with
patents, investors and commercial partners and
they help determine the key technical risks.”
The NEXUS program
is assisting the team in
figuring out how to move a
technology that they think
is ready for the market
from the lab bench to the
commercial space.
“It’s one thing to write an
academic paper about the
potential of a material or
technology,” says Hanrath.
“It’s another thing to talk to
people in the commercial
space and test hypotheses
and see if the opportunity is
really there. Ben is getting
his PhD experience with the work we are doing, but how
do you transition that knowledge to the commercial
space? It’s been an interesting learning experience
for both of us.”
Passing the Stink Test
Phase one of the NEXUS-NY program consisted of a
lot of customer discovery, early prototyping and some
preliminary testing: Does this technology that you
thought was commercially viable in the lab translate
into a real life scenario?
Or as Hanrath explained in his blunt but intellectual style,
“Does it pass the stink test?”
Partnering with NEXUS-NY
To take their innovation to the next level, the duo
applied to be part of the NEXUS-NY program.
Out of 56 applicants, the group was one of 12
selected to participate and receive assistance,
including funding to develop initial prototypes.
Conamix used the NEXUS-NY funds to build and
test early coin cell batteries and to build a crude
roll-to-roll reactor.
NEXUS paired them with Hamilton, whose entre-
preneurial background in startups and clean energy
was an ideal match. “I was looking to partner with
great innovators. I’m kind of like the ambassador of
the commercial side. These guys are about technical
innovation and discovering new materials.
“We were intrigued because NEXUS-NY was
focused on how to commercialize research and how
to transition from the lab to the commercial side.
Beyond the scientific challenges tackled in our lab,
we wanted to learn how we could commercialize
this. We saw the NEXUS-NY program as really
interesting opportunity to explore this.”
-Tobias Hanrath.
25. 25
The NEXUS-NY advisors say you’ll find out your
answers to the stink test really quick when you call
potential customers and other players in the field. “In
our case, the initial idea and what we were aiming for
pretty much held up,” Richards says.
They worked through the customer discovery with
Hamilton guiding them. He explained, “Phase one
and beyond is really about identifying the barriers
and the resources to get over them. I have experience
doing that and have been through it a few times,
scaling up new materials and figuring out how to find
resources to keep these things moving forward. From
grants, to outside investment, to partnerships with big
commercial companies, each one of those pieces is
a tool to help you overcome one of those hurdles.”
NEXUS has given the group some financial assistance
to work on bridging the barriers, in particular with
early prototyping and testing. This will help the team
build their business case to prospects and investors.
“When you talk to a potential customer, you find out
what you need to show them to convince them that
you have something real, tangible, and something
with a lot of potential,” says Hanrath. “We took that
feedback from phase one back to the lab and built a
prototype, so when we have a second conversation
with the customer, we’ll be able to show them, ‘We’ve
built a prototype- we’ve demonstrated that we can
actually do this,’” he adds.
Both Hanrath and Richards said the journey of
commercializing their work has been more compli-
cated than they pictured. “The barrier for transi-
tioning into the industry is steeper than I initially
thought,” says Hanrath. “I may have been naïve
because in an academic environment you generally
don’t have much exposure to that. “
Blending Two Worlds
There may be a lot of road to travel, but they are
charging forward. “NEXUS gives us a time-frame,
support and money. There is a gap between
commercializing technologies that are discovered in a
laboratory setting in academia, and trying to bridge it is
a large part of this. It’s really a blend of the two worlds.”
Their work is poised to be a game changer for car
batteries. Yet, in an emerging technology field, there
are a range of potential applications that their research
could also impact.
Their customer research has also shown some
compelling opportunities in thin film display or thin film
electronics. Interfacing nano-electronics with biological
systems as sensors for normal interfaces is another
potential arena for them.
“These are all interesting and opportunities we are
aware of and will look into, but you can’t start a
company and say we are going to try five different
things,” says Hanrath. “Then you run into no focus and
not much progress on any of the five things. We have
found that batteries stand out as the most clear and
present opportunity for us.”
The drive toward the 10kg of silicon in a car battery
continues. NEXUS brought the team of three together.
Then they formed a startup. And the future of Conamix
could bring new innovations, new jobs and new world
records to the state of New York.
Germanium Nanowire SEM
26. 26
Dr. Stanley Whittingham is a local living legend. His early research
in the 1970s led to breakthrough technology in lithium-ion
rechargeable batteries that has since enabled breakthroughs in
mobile computing, telecommunications and personal mobility.
He is the holder of 16 patents; an author of more than 200
research papers; a professor of chemistry and materials science
and the director of the Institute of Materials Science at SUNY
Binghamton; and the director of the Northeastern Center for
Chemical Energy Storage - Energy Frontier Research Center at
SUNY Stony Brook.
Admirably, Whittingham’s immense presence is also a humble one, and his reclusiveness might just make him
New York’s most interesting and unique hidden gem. New Energy asked Whittingham about his legacy, his future,
the state of energy storage, and why, after all these years, upstate New York remains his home.
You have conducted research all across the
country and throughout the world. With
Silicon Valley leading the world in technology
innovation, what is it about upstate New York
that has kept you here all these years?
Binghamton is a good place to do research; it is the
right size. It is not too big, and it is easy to collaborate.
I’ve been here since ’89.
I think to some extent New York State is friendly to
researchers. We have NYSERDA (New York State
Energy Research and Development Authority) to
help us. In the battery sector, we now have NY BEST
(New York Battery and Energy Storage Technology
Consortium). All these organizations in the back-
ground are willing to help develop projects and get
things commercialized.
Plus, we’re different. Silicon Valley doesn’t do all
that much clean energy. Their biggest advantage is
Sand Hill Road, where all the venture capitalists live.
Startups have greater difficulty getting started here,
but there is a growing number, specifically in batteries.
Energy Pioneer Profile:
DR. STANLEY WHITTINGHAM by Kevin Carr
Your research in the 1970s cleared a path for
much of the technology we use today. Do you
consider yourself the father of the rechargeable
lithium-ion battery?
In a sense, yes. We built the first ones, but [the
batteries] weren’t necessarily a commercial success.
Some folks have said it paved the way to come up
with viable materials, so that is special to hear.
Considering so, do you enjoy today’s technology?
Are you an iPhone or Macintosh person? Do you
drive an electric vehicle?
I’ve had a Mac since day one of the Apple business.
Today, I use a Mac Air computer, an iPhone and an
iPad, and they all automatically talk to each other.
It has also been interesting and very difficult to
explain to today’s students that these things
didn’t always exist.
I recently drove a Tesla car and enjoyed it.
Unfortunately, they’re not yet winter vehicles. I need
four-wheel drive to survive Binghamton’s snow.
Q
Q
Q
27. 27
Your commitments as a director and a professor
must keep you busy. Is there any time left in
the day to get your hands dirty in the lab?
Right now, yes, because we’re moving building
locations and I’m helping with that. We have a new
energy center, the Center of Excellence. It is a better
space, air conditioned.
But usually I’m more of a mentor these days.
I think the students would object if I went into the
lab. I would mess things up (laughs). Up to about
ten years ago, I would go in and fix the equipment,
but they do that all themselves now.
I do miss getting in there sometimes, but there
are just too many people and not enough time.
Now that you research exclusively within
academia, do you miss working in industry?
Sure, but both academia and industry have their
pros and cons. I worked in industry for 15 years.
It was a great place to be, early on. They really
wanted to make some breakthroughs, and if you
wanted something, you got it instantly. Research
[back then] could really move fast.
Today, you still get to do what you want in
academia but the process takes longer.
What are the greatest obstacles facing energy
storage? Are we closer to where we want to be?
Energy storage gets better every day. You go back
a few years, and you didn’t have your iPads and
iPhones; you had these big clunkers that had huge
batteries in them. But it is getting better all the time.
I don’t think there will be any huge breakthroughs,
what they call quantum leaps. Most likely, energy
storage will increase a few percent every year.
The biggest issue right now is dollars. And trying
to get the price down.
Are we on the cusp of an energy crisis?
No, not in the sense that we were in the ‘70s. There’s
energy out there if you are willing to pay for it. It is
not like the water crisis in California. New York is very
lucky when it comes to energy. We have hydropower
coming from Niagara; we have hydropower coming
in from Quebec.
Then why the rush to improve energy storage?
Why care?
Because without improved energy storage we are
not going to get the next generation of vehicles.
Switching to hybrid-busses, as New York City wants
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Artist Rendering: Smart Energy Research and Development Facility at SUNY Binghamton
28. 28
to do, requires better batteries. I expect in the next
five or six years all cars will be hybrid, what they call
stop-start. In almost every case now, when you rent
a car in London, the vehicles are already stop-start.
But we still need better batteries.
Additionally, if you’re going to have a grid system
powered by solar and wind, the energy comes when
Mother Nature decides and not necessarily when
we want it. A) you’ve got to store the power, but B)
you also have to smooth it out; solar and wind power
goes up and down from second to second; batteries
can be used to smooth the energy for a constant
output to the grid.
Considering all that you have accomplished,
explored, and discovered, what remaining
quandaries or unanswered questions are
you most excited about? What keeps you
up at night?
Big things will always move along but the little things
have a way of impeding, such as bureaucratic and
funding issues. Those keep me up at night. Thankfully,
we just received a big award from the Department of
Energy, which should keep us afloat for the next
four years.
Our focus remains on energy storage; we try to
understand how batteries work and how to make
them work better. Right now, we only get about 25%
out of our batteries. Ideally, we’d like to double that.
What we don’t do is keep our eye on where the
technology might be used or how it might be used.
[Industry] knows that better than we do. What we do
want to do is close the gap between what the practical
energy storage capabilities are versus what they ought
to be.
Which sectors of battery research are showing
the greatest potential and promise (both within
NY and elsewhere)? Also, are there any budding
young researchers whom we should be watching
out for?
Worldwide, the most active and promising research
area remains in lithium-ion, improving cathodes
(oxides and phosphates). The younger folks [who are]
getting going are Louis Piper and Guangwen Zhou,
both at Binghamton. At a more senior level, you
should keep an eye on Lyndon Archer at Cornell.
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Photos by Jonathan Cohen - Binghamton University
29. 29
BUILDING
A BETTER
BUILDING,
FROMTHE
OUTSIDE-INby Robert Barlow
Shay Harrison and Jason Vollen are technologists
who needed some luck to make a connection that
could significantly impact the building construction
industry. Harrison started a ceramic manufac-
turing business, Tegula Tile, in 2010 and was
searching for high-volume product opportunities.
Vollen, associate director of the Center for
Architecture, Science and Ecology (CASE) at
Rensselaer Polytechnic Institute (RPI), was
looking for a manufacturer willing to produce his
customized High-performance Masonry System
(HpMS) building tiles. They met through the Center
for Future Energy Systems (CFES) at RPI and soon
afterwards had their “aha moment.” It occurred
during a demonstration that Vollen and his grad
students had constructed involving a heat lamp
shining onto an HpMS facade tile assembly.
On the back side of the assembly, the collected energy
was sufficient enough to drive a piston in a mockup
engine. It was at this point that Harrison and Vollen
knew they had something special. They subsequently
began laying the ground work for the company they
co-founded, EcoCeramic Envelopes.
Harrison and Vollen believe building facades can
evolve into environmentally interactive components,
performing temperature regulation in a similar way
as does the human skin. Their early work demon-
strates bricks can become much more than simple
environmental barriers: they can regulate the flow
of energy in and out of a building.
In an era of heightened awareness about energy
consumption and conservation, HpMS can make a
significant impact on efficient use of energy in one of
the largest energy usage markets in the United States.
30. 30
According to the United States Department of Energy,
buildings account for 40 percent of energy consumption
in the U.S. and 48 percent of commercial energy is
used for heating and cooling. With traditional facades,
heat and energy may be generated on one side of the
building and lost through the opposite side. The HpMS
system intercepts, transforms, stores and redirects
energy flows throughout the entire building envelope.
The problem, according to Harrison, is that more than
half of all energy gains and losses occur through a
building’s exterior. “In conventional practice, building
envelopes are not-climate based and respond the same
despite significant differences in environment, location
and utility,” Harrison said. “The solution is to customize
a building’s exterior for those differences.”
This customization is what Harrison and Vollen
had in mind when they developed the HpMS as
an energy-managing building facade system that
integrates ceramic materials and advanced
digital design.
Unlike conventional building materials such as brick,
concrete or terracotta, HpMS components are made
of refined ceramic materials resulting in stronger and
more durable building blocks with improved insulating
properties. But that’s only half of the story.
By coupling advanced digital design, Harrison and
Vollen can tailor the HpMS-based façade to a specific
building’s exact site location. Not only are site measure-
ments taken of the positioning of the building and its
immediate surroundings but also the locale’s climate
patterns and historical weather data. These measure-
ments allow for the fine-tuning of the custom-designed
ceramic elements, which absorb or reflect the heat or
cold and which compose the building’s façade exterior.
Vollen began working on the HpMS concept and
computer design methodology when he was a
professor at the University of Arizona and continued
its development, with help from a couple of his graduate
students, during his tenure at RPI. Much of his technical
research focus is on the relationship between archi-
tecture designs and the surrounding environments.
The collaboration between these two entrepreneurs
came out of necessity. “Jason needed to find a manufac-
turer willing to work on producing HpMS shapes, which
are three-dimensional – not flat bricks – and therefore
require different processing approaches from
traditional facade brick manufacturing,” Harrison said.
“I was, and still am, really excited about the concept so
we began our collaboration in 2012.”
Among the design variables that can be implemented
in a custom HpMS system are the ceramic material,
tile color, texture, and angle of orientation. These
factors are selected in order to optimize thermal
exchange. The façade tile system will be installed
using industry-standard attachment methods and
will initially operate in a passive mode. Harrison and
Vollen are contemplating second-generation designs
that could integrate thermoelectric materials that
would generate electricity in order to supply the
building’s heating, cooling and electrical loads.
“The occupants of an HpMS building won’t notice a
difference in interior climate when compared to a
‘normal’ facade brick system, unless they are the ones
paying the energy bills,” Harrison said. “Then they’ll
notice a lot!”
According to Vollen, HpMS offers enhanced thermal
performance and mechanical robustness combined
into an aesthetically unique and innovative exterior
wall that generates significant energy savings and
a fast return on investment.
In Harrison and Vollen’s vision, building envelopes will
have climate “intelligence” and their response will be
“WETOOK CUES FROM ANIMALS AND PLANTS
AND HOWTHEY MANAGETHEIR BODIES AND
SURFACE AREATO INTERACT WITHTHE
ENVIRONMENTTO KEEPTHEM COOL OR WARM,”
VOLLEN SAID.‘IT WAS NOT OUT OF OUR SCOPE
TOTHINKTHAT WE COULD COME UP WITH A
TECHNOLOGYTHAT COULD DOTHE SAME FOR
BUILDING MATERIALS.”
-JasonVollen
31. 31
completely customizable to the environment, creating
more insulation capacity for colder climates and
energy generation capability in hotter climates.
According to Harrison, the deployment of EcoCeramic
Envelopes follows a climate-based strategy, but also
allows for many different customizations.
“With these HpMS bricks, buildings can deploy more
windows and consume less energy heating and
cooling than with conventional façade materials,”
Harrison said.
Harrison and Vollen are utilizing the NEXUS-NY
program to create an initial prototype and a
demonstration wall that will serve as a data
collection test bed. The data gathered will be
compared to estimated HpMS energy savings
from computer modeling of the technology
and help refine the design methodology.
Harrison and Vollen initially estimate an energy
savings of between 10 and 20 per cent, though
this estimate has the potential to increase
substantially. The support they are receiving
from NEXUS-NY will enable them to continue their
laboratory studies and make a strong case for
further development.
“Without assistance from the NEXUS-NY program,
we would never have been able to move ahead
to the next stage in this project,” Vollen said.
To start, a full-size experimental chamber will be
built and several experiments will be performed
under different conditions with the objective of
stabilizing thermal fluctuations of the typical
building’s energy profile.
“There are still a lot of new things to learn about this
technology and being able to study actual effects of
something physical will only help the process move
forward,” Vollen said. “There are very few products out
there that can respond directly to climate, and HpMS
is one of them.”
Harrison believes HpMS will carve out a significant
niche in the building facade market, but that it will
not replace simple brick walls on every building.
“The entities and people who will be interested to
implement our facade system will have an affinity
for green technologies, are early adopters of new
technology, or want to offset significant expected
energy costs,” Harrison said. “They will be willing to
pay upfront and get a longer-term payback.”
Typical of the clients and client relationships they’ll
pursue are those with architectural and engineering
firms, construction firms and installers, and real
estate developers.
Harrison and Vollen already have a commitment from
the Schodack Central School District, near Albany, to
participate in a live, “real-world demonstration” next
summer on a school building.
They have applied for New York State Energy Research
and Development Authority funding to assist with
this project. Further, they’ll use the data from the
Schodack demonstration to create an estimate
for commercialization. It’s their hope the first fully
commercial project incorporating HpMS-designed tiles
into a building structure will begin sometime in 2016.
HpMS tile prototype
32. 32
EASTMAN
BUSINESS PARK
The Rochester, NY region holds a long history of
being a technological powerhouse that dates back
to the beginnings of the twentieth century. Business
leadership in film and photography, high-tech manufac-
turing, photonics and optics, and digital imaging carried
the Rochester economy well into that century; but,
like many aging models, growth slowed as technology
changed. Unlike the so-called ‘rustbelt’ cities, reliant
on commodity industries like coal and steel, Rochester
maintained its technology focus and is reemerging as a
burgeoning center of energy and materials innovation
led by a seemingly unlikely juggernaut built during its
heyday years, the massive industrial resource now
known as Eastman Business Park.
Eastman Business Park, known for years as Kodak Park,
is a huge complex (see sidebar on page 34 for some
amazing stats about the facilities) unique in the nation
for the infrastructure and specialized capabilities it
encompasses. These include on-site power and utility
resources, facilities dedicated to research, specialized
distillation and other chemical processing as well as
extensive film-to film coating (pictured above) and
test labs. Once it was thought that these facilities
were too specific to aging business models like analog
photography, but the emerging high-tech energy
storage and material science sectors are reviving the
usefulness of these resources. And that’s only the
beginning. Eastman Business Park is being actively
developed into an end-to-end resource for research,
product commercialization and manufacture of these
technically complex products.
Closing the Product
Development Lifecycle Loop
Developing energy storage products like batteries,
ultra-capacitors and fuel cells requires a complex
process of research and development, product design
and prototyping, and the testing of scalable manufac-
turing processes. Each step must be completed and
validated before these innovative technologies can
reach the market. Because of the unique history of
By Martin Edic
Building an End-to-End Ecosystem
for Energy & Materials Innovation
400mm wide coating/printing machine (Photo: Eastman Business Park)
33. 33
Eastman Business Park, all of these activities can be
supported within one ecosystem, giving companies
the ability to leverage costly infrastructure and
expertise all in one location.
Citing the example of a company developing
ultra-capacitors for energy storage, Michael
Alt, director of the Park, describes the challenge
Eastman Business Park is facing:
“If you look at the processes and facilities needs to
develop a capacitor like this, Ultracap, the company
developing the technology, ideally needed a
complete end-to-end solution. This included
access to:
• Sophisticated Metal Foil Coating Technology
• Metal Fabrication
• Test Beds for Accreditation
• Short Run Manufacturing
• Dry Rooms for Assembly
In our case, we offered all of the above, excepting
dry rooms. So, to capture this business and create
jobs here in Rochester, we’re investing in new
needed technology resources right on site at the
Park, next to our extensive existing facilities. As we
add these needed capabilities, we’re upgrading our
existing infrastructure to support current and future
technologies. We think it’s a great transition strategy
and we’re seeing a lot of interest from companies
across the globe.”
Alt went on to answer some follow-on questions
regarding the immediate future plans for the
Eastman Business Park (EBP).
Please describe the new facilities you have
planned or that are underway to complement
the extensive existing facilities at EBP.
There are many new and exciting EBP projects on
the planning horizon. However, most are still too
early-stage to discuss. One that we can talk about
publicly is a cornerstone of our burgeoning innovation
ecosystem at the Park, the Bioscience Manufacturing
Center at EBP. This will be a state-of-the-art 60,000
square foot fermentation center containing stainless
steel tanks ranging from 40K-250K liters. Operating
as a toll manufacturing facility for a variety of bio
companies, it will convert tons of sugars into a wide
range of renewable chemicals, products and fuels.
We anticipate the Center will create hundreds of
new advanced manufacturing jobs.
How are these facilities funded?
Like many of these types of projects, funding for
the Bioscience Manufacturing Center comes from
a multi-tiered capital stack, consisting of NY State
grants, private equity, loans and user fees.
What is the relationship between Kodak and
Eastman Business Park?
Eastman Business Park had been Eastman Kodak
Company’s primary film manufacturing hub for over
a century – and has developed into what is today one
of the largest, most diverse industrial and technology
parks in the United States. Kodak currently owns the
Park, but on March 25th, the company announced
that it would pursue the sale of EBP, stating that it
believed the uniquely well-equipped site can best
continue its transformation into a multi-use, multi-
tenant industrial facility under the ownership of a
firm focused on its redevelopment.
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Battery and Energy Storage Technology (BEST) Test and
Commercialization Center (Photo: Eastman Business Park)
34. 34
End-To-End Energy Storage
Eastman Business Park has targeted two markets
for its unique facilities and the expert scientists and
engineers working there: energy storage technology
and biomaterials innovation. Though both areas
have their unique requirements, there is a surprising
amount of crossover between the two technological
challenges as scientists and engineers explore how
the two fields can complement each other. The ability
to serve both fields is unique to the Park. The two
disciplines can share a unique menu of available
services and technology at EBP including:
• Chemistry and polymers development
capabilities to create new materials
• Thin film coating and handling capabilities for
the development, testing and manufacture of
next generation electrodes and membranes
• Knowledge, facilities and equipment to produce
materials in a low cost, roll-to-roll format
• Dry rooms and cell assembly equipment to
complete the manufacturing process
• Access to technologists with extensive,
hands-on knowledge of these processes
Eastman Business Park combines these capabilities
with a unique campus designed to support large
and small-scale high-technology manufacturing - an
overall facility with no comparable counterpart
worldwide. The goal is to create an end-to-end
destination for researchers and engineers seeking
rapid commercialization of their complex energy and
materials-related products.
With companies like Intrinsiq Materials, Nohms
Technologies, NatcoreTechnology and the New York
Battery and Energy Storage Technology Consortium
already working on-site, Eastman Business Park is on
track to make Rochester a global center for energy
storage commercialization.
For more information or to arrange a tour
visit www.eastmanbusinesspark.com
A Look At
EASTMAN BUSINESS PARK
By The Numbers
• 1200 acre campus
• 16 million square feet of manufacturing, lab,
warehouse and office space
• 18,000 square foot NY-BEST Center onsite for
energy storage testing and validation
• 88 reactors for specialty chemical applications,
from 100-1000 gallon capacity
• 5-50 FPM (foot per minute) range of coating
options onto substrates at thicknesses from
100nm to 500nm
• Strong connections with partner universities,
companies and public/private laboratories in the
energy storage sector
• 5-5000 FPM intermediate scale costing machine
on webs up to 17” wide and 5-500um think for
batteries, photovoltaics and more
• 200 acres of shovel-ready parcels for advanced
manufacturing of energy storage materials
• World class analytical labs onsite for creating
prototypes for new energy storage and delivery
systems
• 8-station inline high-volume coating machine
up to 1000 FPM at web widths up to 63” wide
35. 35
The average wind farm in the US has 134 wind
turbines, typically located on hillsides or offshore
where the steadiest winds blow. Each turbine is a
massive machine with many moving parts, most
located high above the base and subject to significant
physical forces. With parts rotating under heavy
loads, even slight problems can spiral out of control
quickly, requiring shutdowns and costly visits from
repair crews who must often deal with inhospitable
and remote environments.
Wind turbines are very sensitive to internal
mechanical wear or breakdowns, which can often
be detected prior to catastrophic failure by their
vibrational signature. If left undetected, costly repairs
and idle turbines ensue. One solution to this problem
is sensing equipment installed at critical points within
the turbine. When used in conjunction with advanced
algorithms, sensors can operate remotely and
continuously, and predict failure before it occurs.
Given these cost and downtime issues, predictive
condition monitoring of these complex turbines
becomes a mission-critical task. Unfortunately,
currently available sensor solutions involve very
high costs and do not significantly reduce the need
for onsite inspections and repairs. This is the problem
the team from Micatu, an upstate NY technology and
engineering company based near Corning, took on
as a test bed for its new series of remotely accessible
motion, temperature, and vibration photonic sensors
known as PHOCOM.
Micatu has selected the wind turbine market as a
demonstration and market entry point for its sensors
because the need is immediate, the solution is
applicable to multiple problems, and the PHOCOM
solution is very cost-effective relative to existing
sensor and monitoring solutions. The wind farm
market also supports Micatu’s core competency of
applying advanced engineering technology to address
environmental and energy-related issues.
by Martin Edic
Cutaway turbine drawing with PHOCOM sensor locations.
36. 36
Testing the Solution Through
the Nexus NY Customer
Discovery Process
Micatu was selected to participate in the 2013-2014
NEXUS-NY accelerator program for startups and
growth businesses developing energy-related
technologies in New York State. The program uses the
Lean methodology developed at Stanford University,
which guides businesses to commercialize technology
successfully by exposing it to the market prior to
an intensive development process. Customer input
is sought to validate the viability of the products
before extensive resources are applied to their
commercialization.
During its three-month customer discovery process,
Micatu tested its hypothesis that photonic sensors
could enable a breakthrough in monitoring the more
than 500,000 wind turbines currently in use. The
team interviewed more than 50 industry participants
including experts from both sensor businesses and
the wind energy industry. Those interviews validated
several premises and informed significant refine-
ments to their planned business model. The result
was a Condition Monitoring System (CMS) utilizing
their PHOCOM Monitoring System.
How It Works
PHOCOM combines an array of Point Optical
Detection Sensors (PODS) mounted at various sites
within the turbine. These sensors are passive, with
no moving parts and requiring limited power sources
within the turbine. They are connected to a central
processor unit that communicates sensor data up to
one kilometer away via a wireless or fiber network. The
passive nature of the sensors greatly reduces mainte-
nance and the wireless 24/7 monitoring reduces site
visits and helps repair crews identify issues before they
become serious problems, further cutting costs and
reducing downtime.
Reduced Install Costs and Increased
ROI For Operators
Existing sensor technologies involve complex and
costly equipment and installations. PHOCOM has a
cost structure that is less than half that of current
systems, thus enabling a quicker return-on-investment
(ROI). Micatu predicts a PHOCOM user will save $2.20
for every one dollar invested over a three-year window,
far above the current industry standards.
During the discovery process, the Micatu team
identified high interest not only among wind farm
operators and the alternative energy industry, but
also from large makers of existing sensor systems.
The team has several provisional patents and are
completing early stage development with the help
of funds from the NEXUS-NY Program.
Larger Market Opportunities
The wind turbine market is viewed as a market entry
and test bed for Micatu’s technologies. Further, Micatu
has identified other large market opportunities
including defense, aerospace and OEM plug-in markets.
While wind represents a $20 million/year market, these
larger sensor and monitoring markets create the
potential for an overall $30-50 million annual business.
Current Status
Micatu has invested more than $200,000 to date
and is seeking an additional $2.5 million to enter the
initial market. They are in discussions with multiple
companies in the sensor space, both large and small,
that have expressed a high interest in partnering
opportunities. These companies recognize the photonic
sensor as a potential game changer with many
potential applications beyond those mentioned here.
Rendering of PHOCOM Sensor
37. 37
Interview With Michael Jagielski of Micatu
First off, where did the name Micatu come from
and how do you pronounce it?
It is a combination of Michael and Atul, our founders
Mic---Atu. It’s branded to reflect precision in the
optics space. It is pronounced Mic – ahhh ---tu .
Talk a little about how the company started and
the kind of work you’ve been doing that led to
the development of PHOCOM.
The company was started back in 2011 as a research
and development company working in the Small
Business Innovation Research (SBIR) space. We have
extensive backgrounds in product development,
research and commercialization. We won a Phase 1
SBIR grant and successfully delivered a marketable
cancer research product
(www.micaarray.com) in
less than 10 months for
the National Institute of
Health (NIH). This resulted
in a nomination for a
Smithsonian Award and
a Federal Laboratory
Consortium Award based
on our “exceptional”
work within NIH. We
were recently awarded a
Phase 2 grant from NIH
for continued product
development and research
in the cancer “histology”
space.
PHOCOM was an accidental discovery in the lab one
day as we were trying to solve a different problem.
Dr. Pradhan was in the lab and noticed vibration
occurring from an optics bench that should have
been isolated from all vibration. Upon further
investigation, it was determined that we were
picking up minute vibrations from across the
technology campus from other tenants. As a result,
this measurement of minute vibrations was being
optically detected and the photonic sensor was born.
What led you to identifying the problems that
your sensors are designed to detect? Were you
previously working in the wind power industry?
Our founders are optics and electrical engineering
experts. We made an accidental discovery whose
commercial potential needed to be evaluated in a
more formal setting. That is how we got into the
NEXUS-NY program. Wind turbines represent an
energy play that has a very low barrier to entry.
Only 10% of the current installed base utilizes
sensors, thus the market is grossly underserved.
Talk about how the photonics sensor
system works.
PHOCOM replaces an age-old piezoelectric sensor
technology, which has been around for more than
150 years, with a photonic technology that has many
benefits associated with photonic technologies.
These include electronics
separated from the
actual sensor, EMF
protection, very long
cabling range, greater
sensitivity, and resistance
to harsh environments.
The optical sensor picks
up minute vibrations
and converts these to
electrical signals for
measurement.
A practical application
would be for use in
measuring vibration in a
large industrial machine
(electrical generator, fan
motor, wind turbine, gas turbine) and establishing
a fingerprint baseline where any deviation from the
baseline would indicate wear characteristics. These
can be monitored over time for standard deviations
from the norm and modeling can be used to predict
maintenance requirements in real time as opposed to
OEM recommendations. Companies can tailor their
maintenance routines and operational environments
to optimize longevity and increase output efficiency
while reducing costs for unscheduled downtime. This
is commonly referred to as “condition monitoring”.
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Pat Govang with Micatu CEO Michael Oshetski
38. 38
Does it require power supplies within the
turbine? If so, how do you power the sensor?
Power supplies can be from the turbine or from a
remote source as the electronics can be centralized
at a remote location if necessary. The power
requirements are very low.
How does the system send the data to the
remote monitoring computer operator?
Wi-Fi? Cellular, etc.?
You can set it up like that if you like or you can run a
fiber drop and connect it that way. There are many
different ways to accomplish this.
Have you developed software to handle the data
distribution and remote monitoring aspects of
the product?
We will be partnering with software vendors on the
back end for the analytics. Right now, there are no
standards in the industry for condition monitoring.
Siemens and Mitsubishi are trying to develop their
own and are spending large sums of money to build
more robust standards for condition monitoring.
What is the current state of technology develop-
ment? Is there an operating prototype, market-
able product, early adopter/beta customer, etc.?
We are in the phase of developing an operational
prototype in late Q4 2014. We are in contact with
several OEMs and wind farm operators for beta
development and testing platforms as well as
in contact with the National Renewable Energy
Laboratory for testing in its wind turbine simulation
environment. We expect to be ready for “go to
market” product launch in 18 to 24 months.
What are next steps for this product?
Prototype development and refinement and
beta-level testing agreements with several
wind farm operators and/or OEMs.
How did the NEXUS-NY program affect your
product startup process?
It was invaluable to our development of a structured
way of going out into the marketplace and speaking
with potential customers and competitors as well as
industry experts. We have a great deal of commer-
cialization expertise in-house but NEXUS-NY offered
a great benchmark to sanity-check our processes
and to validate our commercialization assumptions.
Their Phase 1 program is an outstanding platform
for any small business wanting to really explore the
market opportunity first, rather than the science.
They really did an outstanding job! Micatu has
internalized the NEXUS-NY methodology with our
own and it is in use every day for any new product
development opportunity we pursue.
What are your future plans? For example, what
would another use-case for the technology
look like?
There are hundreds if not thousands of possible
market applications anywhere you need to precisely
measure motion or displacement or vibration. Again,
anywhere you have an industrial electronic sensor
that measures motion or displacement or vibration,
you have the ability to replace that technology with
an optical technology at a much lower cost with
higher reliability and sensitivity.
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About the Authors
Robert Barlow is a freelance journalist who has reported
on anything and everything from murder trials and local
politics to film festivals and concerts for more than
five years.
Kevin Carr is a freelance writer, copy editor, and playwright.
He blogs at TheNumberKevin.com and studies entrepre-
neurship and creative writing at the University of Rochester.
Jay Pfluke is a freelance writer and creative minimalist.
Martin Edic is a business writer and B-B marketing
consultant in the Rochester, NY area. He is the author
of eight books on business and design.
Andrew Harrison is the Innovation Ambassador at Idea
Connection Systems/HumanGrid, the author of Love Your
84,000 Hours at Work: Stories on the Road from People with
Purpose and Passion and the writer of The Invisible Element:
A Practical Guide for the Human Dynamics of Innovation.
