Polymer Injection Molding for N-95 Respirator Masks

Background InformationMost personal protective equipment (PPE) in healthcare settings, such as N-95 masks, are designed to be disposable and single use. While this has advantages for sanitation purposes, the unprecedented high volume demand for these materials in COVID-19 treatment is anticipated to result in critical shortages. The development and rapid manufacture of reusable N-95 masks that may be sterilized between uses is needed to ensure the proper protection of healthcare workers and curb transmission of COVID-19. National Technology and Engineering Solutions of Sandia LLC (NTESS) has made an initial investment in the research and development of a new, reusable design and manufacturing approach for respirator masks made from injection molded polymer parts. NTESS is seeking potential respondents who are interested in investing in the further development of this technology to create a rapidly manufacturable product that could be deployed for the benefit of the U.S.

economy.Opportunity DescriptionNTESS is seeking a collaboration with an industry partner who has proven experience in the design, development, and manufacturing of polymer injection molded parts to demonstrate the design’s proof-of-concept. The objective of this collaboration would be the demonstration of a full scale prototype for proof of concept, with the possibility of taking the product to scale. Participants will work with NTESS on the continued development and testing of polymer injection molded parts and will provide a clear path to commercialization/deployment of the technology through refined product design, optimization for manufacturing, and Quality Assurance. Qualified participants will contribute resources, funds for respirator mask or healthcare personal protective equipment specialists (as needed), and in-kind support in the form of staff and facilities capable of polymer injection molding.What the Lab Brings to the CollaborationNTESS brings substantive experience in the design, testing and small-scale manufacturing of engineered solutions for high-consequence applications. Our expertise includes unique test facilities and labs, and a team of exceptional researchers from a range of disciplines including additive manufacturing and bioscience. Our program objectives are based on the know-how that we have developed through many years of research and development in these areas. We will reply primarily on our industry partner(s) for supply chain logistics, procurement of materials, and manufacturing.Information SoughtA detailed description of relevant background experience, expertise, and capabilities that could be brought into a collaborative partnership with NTESS is being sought. The following information is being requested (in addition, interested parties may provide additional relevant information as needed):Description of experience, expertise and capabilities in rapidly deploying technology for high-throughput, large volume solutions with rapid production turnaround.Description of the high-quality standard and information on quick turnaround (units over time).Description of other relevant experience, expertise, and capabilities.Description of past experience partnering with Research and Development organizations such as Federally Funded Research and Development Centers (FFRDC), Universities, National Laboratories, or Government Laboratories to develop and sell products successfully.Instructions to RespondentsInterested parties that meet the Mandatory Requirements provided below are invited to respond to this opportunity. Any information provided in response to this opportunity will not be returned. Any and all responses are voluntary, and NTESS will not pay for any information submitted in response to this opportunity. Only electronic submissions will be accepted.Responses should be emailed to mamonso@sandia.gov and should include the opportunity title and submitting organization's name in the subject line. Attachment size should not exceed 5MB and only the following document types will be accepted (.doc, .docx, .pdf). Responses should be submitted electronically no later than 5:00 p.m. MDT on 4/24/2020. Proposals submitted after this date might still be considered if current applicants don’t meet the requirements. Evaluation CriteriaNTESS will evaluate all responses and select prospective parties with which to engage in further discussions based on the following criteria, pursuant to NTESS's Technology Transfer mission: MandatoryMeet the DOE requirement of enhancement or accrual of economic and technological benefits to the U.S. domestic economy through the technology transfer.Required by DOE in the Technology Transfer Act of 1989.Provide experience, expertise, and capability in the rapid deployment of technologiesAbility to enter CRADA/SPP DesiredA local (New Mexico) or regional firm able to enter into a CRADA agreement with NTESS to develop specific manufacturing tools and techniques for polymer injection molding of respirator face masks.NTESS will consider teaming arrangements where two or more companies may form a team to satisfy the Desired Requirements.