Our work / Grapheno-1
Direct-to-Phase II SBIR awarded
Arresting Fatigue Cracks at the Source
SBIR-Driven Development of a Field-Deployable Electrochemical Repair System
- SBIR concept development
- Mechanical & electrical engineering
- Prototyping
- System design
- Prototype fabrication
Written by Ralph Hill, Mechanical & electrical systems, 3D manufacturing
Prototyping Engineer
Updated August 31, 2026
Project at a glance
- Client
- Grapheno — SBIR-funded materials company
- Category
- Industrial repair equipment / R&D hardware
- Starting point
- Lab-proven electrochemical crack-repair chemistry, no deployable device
- What we delivered
- System and hardware design, field-deployable prototype development, engineering documentation for SBIR reporting
- Key constraints
- Reliable operation outside the lab, portability for field crews, repeatable electrochemical process control
- Outcome
- A field-deployable repair system targeting fatigue cracking, the cause of roughly 90% of metallic structural failures
Fatigue-related failures account for nearly 90% of metallic structural failures and cost the U.S. economy an estimated 4% of GDP annually. Grapheno-1 was developed to confront this challenge directly.
The client
Grapheno engaged LA New Product Development Team at the pre-award SBIR stage, during the formulation of a proposal focused on electrochemical fatigue crack treatment.
At that point, Grapheno had a strong scientific foundation and laboratory-validated electrochemical methods, but needed a technically feasible, system-level product concept that SBIR reviewers could evaluate as executable.
The challenge
Fatigue cracking is one of the most persistent and dangerous failure mechanisms in metallic structures, particularly in aerospace, defense, transportation, and critical infrastructure. Even small cracks can propagate under cyclic loading, leading to catastrophic failures, grounded assets, and unplanned downtime.
Traditional mitigation methods often rely on crack removal, drilling, shot peening, or full component replacement. These approaches are invasive, costly, and frequently require taking assets out of service. What has long been missing is a portable, field-deployable solution capable of reliably arresting crack growth in place, extending service life without removing material or replacing parts.
LA NPDT played a central role in shaping the Grapheno-1 concept by:
- Translating electrochemical research into a field-deployable system architecture
- Defining realistic use cases, operator workflows, and maintenance scenarios
- Establishing a credible development, prototyping, and validation plan
- Aligning system design decisions with SBIR evaluation criteria and transition expectations
This work directly supported the proposal narrative and helped demonstrate that the technology could move beyond the lab and into real operational environments.
Our solution
Following the SBIR award, LA NPDT became the primary design, engineering, and prototyping partner for Grapheno-1. Our responsibility was to execute the concept defined during the proposal phase and transform it into a working system capable of supporting testing, demonstration, and program milestones.
Grapheno-1 was engineered as a self-contained electrochemical treatment platform, with design priorities that included:
- Portability for field and depot environments
- Repeatable, controlled treatment conditions
- Robustness under real maintenance constraints
- Clear operator interaction and process consistency
- Reliability over long-term deployment
This phase moved the program from conceptual feasibility to physical implementation.
Mechanical, Electrical, and System-Level Design Execution
Grapheno-1 required tight integration across mechanical, electrical, and system-level engineering disciplines. LA NPDT led the design and integration of:
- Structural housings and internal mounting frameworks
- Interfaces for electrolyte delivery and applicator integration
- Power architecture, battery integration, and electrical distribution
- Physical controls and user-interface components
Design decisions emphasized repeatability, reliability, and future scalability. The system was engineered not just to demonstrate feasibility, but to serve as a foundation for follow-on SBIR phases and eventual commercialization.
Prototype Fabrication and System Integration
LA NPDT fabricated the Grapheno-1 prototype, producing custom mechanical components, assembling electrical subsystems, and integrating everything into a fully functional unit. This phase included:
- CNC-machined and fabricated custom components
- Prototype housings and internal assemblies
- Electrical wiring, system bring-up, and integration
- Fit checks and functional verification
The completed prototype provided a tangible demonstration that the SBIR concept could be built, operated, and evaluated as a real system.
Bridging SBIR Research and Real-World Deployment
Grapheno-1 represents a critical bridge between laboratory research and operational maintenance technology. By combining Grapheno’s electrochemical treatment expertise with LA NPDT’s product development and engineering capabilities, the project advanced from research into a deployable, testable system.
The prototype enabled:
- Demonstration of treatment repeatability
- Evaluation of technician workflows and usability
- A clear foundation for Phase II development and scaling
This approach aligns directly with the core intent of SBIR programs, reducing technical risk while accelerating transition toward real-world application.
Services provided for Grapheno-1
- 01
SBIR Concept Development & System Architecture
Supported pre-award SBIR concept formulation by defining a realistic, field-deployable system architecture. - 02
Mechanical Design & Engineering
Designed enclosures, structures, and layouts suitable for portable field operation. - 03
Electrical Design & Integration
Developed power architecture and electrical systems required for controlled electrochemical treatment. - 04
Prototype Fabrication & Assembly
Fabricated custom components and assembled a fully functional SBIR prototype. - 05
System Integration & Validation Support
Integrated subsystems and supported early testing and demonstration activities. - 06
Ongoing SBIR Technical Collaboration
Provided continued engineering support as the system evolved through program milestones.
The result
Grapheno-1 introduces a new approach to fatigue crack management by focusing on arresting crack growth rather than removing material or replacing components.
This approach has the potential to significantly reduce maintenance costs, extend asset life, and improve safety across aerospace, defense, transportation, and industrial infrastructure.
Equally important, this project demonstrates how an SBIR-focused partnership can move advanced science toward deployable capability. For companies pursuing SBIR funding, Grapheno-1 illustrates how LA NPDT helps bridge the gap between proposal-stage concepts and working prototypes.
A Trusted SBIR Design and Prototyping Partner
Grapheno-1 exemplifies LA New Product Development Team’s role as a strategic SBIR partner, supporting companies from early concept formulation through engineering execution and prototyping.
If you are preparing an SBIR proposal or need a technically credible partner to develop and prototype your concept, we’re ready to help. See what that looks like before the deadline on our SBIR Phase I concept design and prototyping page.
Related reading: what a Direct to Phase II prototype has to prove.
Capabilities used on this project
Rapid prototyping services
3D printing, CNC machining, urethane casting and functional prototype builds with published materials, tolerances and lead times.
Concept design
Sketch exploration, form studies and CAD concepts that turn an idea into a buildable direction.
Industries this project belongs to
See how we approach development in each of these categories, and the other products we have taken from sketch to production there.
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