This innovation forms a sprayable polymer film using powdered precursor materials and an in-process heating method. This device directly applies a powdered polymer onto a substrate to form an adherent, mechanically-sound, and thickness-regulated film. The process can be used to lay down both fully dense and porous, e.g., foam, coatings. This system is field-deployable and includes power distribution, heater controls, polymer constituent material bins, flow controls, material transportation functions, and a thermal spray apparatus.

The only thing required for operation in the field is a power source. Because this method does not require solvents, it does not release the toxic, volatile organic compounds of previous methods. Also, the sprayed polymer material is not degraded because this method does not use hot combustion gas or hot plasma gas. This keeps the polymer from becoming rough, porous, or poorly bonded.

This work was done by Scott Coguill, Stephen L. Galbraith, Darren L. Tuss, Milan Ivosevic, and Lawrence Farrar of Resodyn Corporation for Glenn Research Center.

Inquiries concerning rights for the commercial use of this invention should be addressed to

NASA Glenn Research Center
Innovative Partnerships Office
Attn: Steve Fedor
Mail Stop 4–8
21000 Brookpark Road
Cleveland
Ohio 44135.

Refer to LEW-18246-1.


NASA Tech Briefs Magazine

This article first appeared in the September, 2008 issue of NASA Tech Briefs Magazine.

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