Custom polymer formulation development for tailored elastomers and coatings
Contract R&D service that designs and develops custom polymer formulations with tailored surface and mechanical properties. Underlying work includes coefficient-of-friction targets in the 0.4–0.6 range, high elongation, low modulus, and low extractables. Iterative development covers formulation selection, synthesis, vacuum stripping, and property measurement, with silicone and polyurethane chemistries as initial options. A previous similar polymer development project was successfully completed, supporting a TRL 4+ readiness estimate.
Overview
This is a custom polymer R&D and consulting service for organizations that need a polymer formulation engineered to specific mechanical, surface, and chemical-performance targets rather than relying on off-the-shelf materials. The approach is deterministic: molecular weight, reactive species, and monomer functionality are chosen to control bulk properties such as coefficient of friction, elongation, stiffness, and the amount of leachable compounds. This work is especially relevant for conformal coatings, electronic protection, specialty adhesives, sealants, and other flexible material applications that demand a carefully balanced combination of properties.
Technical specifications
The service starts by selecting candidate raw materials and chemistries based on the desired property profile. Silicone and polyurethane systems are expected to be the two initial chemical families considered.
Key development activities include:
- Designing polymer architecture via monomer molecular weight, weight of segments, and reactive functionality.
- Targeting a coefficient of friction in the 0.4–0.6 range through molecular-level structural selection.
- Controlling elongation and modulus by adjusting the molecular weight of raw materials.
- Vacuum-stripping methods to remove non-reactive species and reduce side reactions that create extractables.
- Iterative synthesis, prototype formulation, and property measurement.
- Developing custom test methods when standard ASTM tests do not exist for a required property.
- Identifying material candidates and determining whether raw-material pre-processing is needed during development.
A prior analogous project produced a polymer with several-hundred-percent elongation and rupture strength comparable to mild steel, demonstrating the feasibility of property tailor significant ranges.
Technology readiness level
This development is assigned a technology readiness level of TRL 4 or slightly above, based on the strong previous work done with similar elastomer chemistries. Actual readiness for commercial use still requires sourcing candidate raw materials, synthesizing trial formulations, and iterating against the target property set. If one chemistry proves incompatible with a required property, the development path continues with the remaining can economic chemistry. This is normal in polymer formulation work. The validated prior project also established the process of inventing new test methods when standard test methods are missing, which reduces one of the common risks in specialty material development.
About steve smith, consulting scientist
Steve Smith operates as a Consulting Scientist, providing expert research, development, and consultation in the physical sciences. With a background in physics and chemistry, he offers specialized expertise in solving complex technical problems that fall outside a client's core area of knowledge. His capabilities span diverse fields, including electronics, materials science, and chemical product development. He is also the President and Chief Scientist of Smith & Co., a manufacturing business he established in 1972. This company develops and produces its own specialty epoxies, polyurethanes, adhesives, and coatings used internationally in the marine, construction, and property restoration sectors. Smith's approach involves breaking down problems to uncover root causes and false data, drawing on his extensive experience in research, product design, and patent-holding innovation.
These services are critical for inventors, engineers, and businesses facing persistent technical failures or unique R&D challenges. Customers rely on his expertise for tasks ranging from enhancing system reliability and developing specialty materials to solving product failures in wood, paint, and chemical interfaces. His work is supported by decades of industrial experience, including contributions to aerospace electronics, radar transmitter design, and government-industry research initiatives like the CALCE Tin Whisker Group. By offering a confidential, project-based engagement model—often supported by formal non-disclosure agreements—he provides high-level scientific guidance and problem-solving capacity to clients requiring specialized, interdisciplinary knowledge.
delivered to your inbox.