80% Faster To Market - How A Global Aerospace Leader Solved PFAS Elimination in 4 Months

The Challenge

A leading global aerospace manufacturer ranked among the top five faced $450 million in revenue risk due to 85% of their PFAS-based sealant formulations becoming obsolete by 2026. Despite substantial internal investments, they struggled to achieve the breakthrough needed to meet their targets.

Critical Requirements

• Service temperature exceeding 300°C with over 10,000 thermal cycles
• Tensile strength greater than 12 MPa at elevated temperatures
• Resistance to fuel and hydraulic fluids
• Complete regulatory compliance documentation

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Traditional Approach

Traditional Approach Typically Requires 18-24 Months:

• Manual review of thousands of patents and research papers
• Trial-and-error formulation with minimal computational support
• Sequential experimental cycles with weeks between each iteration
• Data stored in isolated spreadsheets, hindering pattern recognition across experiments
• Expert reliance on simulations, accessible to only 10-15% of the team

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The Results with N-ERGY AI

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The N-ERGY Solution: Platform-as-a-Service Delivery in 3-4 Months

Month 1: Integration & Foundation

What N-ERGY Did:

• Integrated customer's existing simulation data and experimental records into unified platform architecture
• LLM Co-Pilot automatically curated 5,000+ sealant records from patents and regulatory databases
• Established performance targets through natural language interface

Month 2-3: AI-Driven Discovery Loop

Intelligent Screening

• AI models used customer's DFT simulations to screen millions of ingredient combinations
• Narrowed from millions → 30 viable candidates with >80% confidence

Automated Experimentation

• Robotic synthesis and characterization in N-ERGY's lab
• Real-time analytics triggered adaptive experiments
• Closed-loop: Each experiment automatically refined computational models

Autonomous Optimization

• AI continuously predicted thermal and mechanical properties
• Non-obvious discovery: Platform identified novel polymer combinations the customer hadn't considered

Month 4: Breakthrough Delivered

Customer Specifications Met

• PFAS-free formulation meeting all specifications - ready for qualification testing

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Why N-ERGY's Integrated Platform Made the Difference

Traditional approaches keep simulation, experimentation, and data analysis in separate silos with manual handoffs taking weeks.

N-ERGY's platform integrated:

• The customer's existing computational models and simulation data as training inputs
• AI screening of millions of combinations using simulations as surrogates (not replacing physics, but amplifying it)
• Robotic experiments in N-ERGY's lab feeding real-time data back into models
• Autonomous optimization discovering non-obvious material combinations at scale
• Enterprise-ready data architecture enabling rapid replication across their portfolio

The result: breakthrough innovation in months, not years - delivered as a service