How the technology works
From engineered particles to infrastructure performance
Aesyon's platform is a materials capability: a controlled way of engineering copper so it can be formulated into products that perform in demanding electrical and thermal environments.
Process flow
Four stages, one platform
01
Raw copper input
The platform starts from abundant, broadly available copper feedstock rather than scarce precious metals.
02
Particle engineering
Copper is engineered at the particle level — controlling structure and surface behavior to address oxidation and stability limits.
03
Material formulation
Engineered particles are formulated into processable inks, pastes and compounds tuned to each application's process window.
04
Application performance
The resulting materials are designed to deliver reliable conductive performance in real production hardware.
Why Aesyon copper is different
Copper Is the Material. Chemistry Is the Enabler.
Copper offers compelling electrical, thermal, economic, and supply-chain characteristics, but oxidation and processing limitations have historically restricted its use in certain high-performance applications.
Aesyon combines engineered copper particles with proprietary antioxidant chemistry designed to limit oxidation, enable lower-temperature processing, and improve compatibility with industrial manufacturing.
Platform progression
- Particle Engineering→
- Functional Chemistry→
- Formulation→
- Manufacturing Process→
- Component→
- Energy Infrastructure
Designing materials with predictable functionality
Engineering Copper for Predictable Functionality
Designing material behavior around the requirements of the application.
Aesyon's platform is designed to do more than substitute copper for higher-cost materials.
By combining particle engineering, functional chemistry, formulation, and process control, Aesyon is developing copper-based materials whose electrical, thermal, processing, and mechanical characteristics can be tailored around specific application requirements.
Electrical Performance
Develop formulations around the conductivity required by the application.
Processing Behavior
Control oxidation and curing behavior to support lower-temperature, commercially relevant manufacturing processes.
Mechanical & Material Properties
Use chemistry and formulation as pathways to tune material characteristics for application-specific requirements.
Manufacturing Compatibility
Design material functionality alongside the process in which it will ultimately be manufactured.
Copper is the material. Engineering its behavior is the platform.
Material characteristics described here are design objectives and development pathways; performance in any specific application is under evaluation and subject to application-specific qualification testing.
Preliminary / lab-scale data
Measured performance
Low-temperature processing
Demonstrated below 140°C.
Rapid processing
Demonstrated in less than two minutes under reported laboratory conditions.
Electrical conductivity
Laboratory results on the order of 8 × 10⁶ S/m under reported test conditions.
Approximately 14% of bulk copper conductivity under the cited laboratory conditions.
Substrate compatibility
Processing conditions compatible with low-cost PET substrates.
Process advantage
Designed to reduce reliance on high-temperature processing and reducing atmospheres.
Solderability
Promising solderability demonstrated in development testing.
Performance varies by formulation, substrate, manufacturing process, and application. Application-specific validation is required. Results reported here are laboratory-scale and are not commercial qualification.
Predictable functionality
Engineered for predictable functionality
Aesyon's antioxidant chemistry provides a pathway to tailor processing behavior and material functionality for different application requirements.
Processing temperature
Formulations can be developed for different manufacturing temperature ranges.
Mechanical properties
The platform provides a pathway to tune material characteristics for application-specific requirements.
Electrical performance
Particle chemistry and formulation can be optimized around required conductive performance.
Application flexibility
The same underlying materials platform can support multiple application-specific formulations.
These characteristics describe development pathways enabled by the platform. Not every characteristic has been commercially demonstrated.
Manufacturing compatibility
Designed for existing manufacturing
A lower-cost material creates limited value if adoption requires customers to rebuild their manufacturing process.
Aesyon's copper formulations are being developed to minimize process-flow changes from established conductive-material manufacturing methods.
Common printing methods
Designed for compatibility with established industrial printing processes.
Lower processing temperatures
Designed to broaden compatibility with commercially relevant substrates.
Reduced process complexity
Aesyon's chemistry is intended to reduce dependence on specialized reducing atmospheres and high-temperature processing.
Solderability
Designed to support integration with established electronics assembly processes.
Material substitution must work technically, economically, and operationally.
Application validation
Prove performance and economics one application at a time.
Aesyon's commercialization strategy is based on validating specific formulations in commercially relevant applications before broader market expansion.
- Lab Validation→
- Customer Evaluation→
- Application Demonstration→
- Small-Batch Production→
- Toll Manufacturing→
- Commercial Production
Application
Printed conductive traces
- Incumbent material
- Silver conductive paste / ink
- Required performance
- Conductive traces printable with established industrial printing processes
- Aesyon formulation
- Engineered copper particles with antioxidant chemistry, low-temperature cure
- Test status
- Laboratory demonstration
- Economic opportunity
- Material-cost reduction from copper feedstock substitution
- Qualification status
- Qualification planned
Application
RFID antennas
- Incumbent material
- Silver conductive ink / Etched Copper
- Required performance
- High-volume roll-to-roll printing on low-cost substrates
- Aesyon formulation
- Screen-printable copper formulation for PET substrates
- Test status
- Application development
- Economic opportunity
- Conductive material cost is a significant share of tag cost
- Qualification status
- Qualification planned
Application
EMI / EMF shielding
- Incumbent material
- Silver-loaded and metal-filled coatings
- Required performance
- Continuous conductive coverage with process compatibility
- Aesyon formulation
- Copper-based conductive coating formulation
- Test status
- Customer evaluation
- Economic opportunity
- Cost reduction in shielding material content
- Qualification status
- Qualification planned
Status labels describe internal development stage only. No customer results, endorsements or completed qualifications are implied.
Technology foundation
3 Foundational Patents
Proprietary antioxidant chemistry and metal-compounding technology form the intellectual-property foundation of the Aesyon Energy Materials Platform.
- Antioxidant chemistry
- Copper and metal compounding
- Particle and formulation know-how
- Manufacturing process development
Why we win
Performance is necessary. Integration is what makes it adoptable.
Materials only scale when they fit the manufacturing reality of the customer. Aesyon designs for that constraint from the beginning.
Manufacturing compatibility
Formulated to work with established deposition and printing processes, so customers are not required to rebuild production lines.
IP protection
The platform is built on proprietary particle engineering and formulation know-how developed in-house.
Supportive economics
Where substitution is technically viable, copper's input cost creates structural room to improve application economics alongside performance and supply benefits.
Platform business model
One core materials capability supports multiple product families across adjacent markets, rather than a single-product roadmap.
Validation
Development guided by technical and federal review
Aesyon's technology development has been supported by competitive federal research funding, including a $3M National Science Foundation award, alongside ongoing application-specific testing.
Federal research support
$3M NSF award supporting continued platform development.
Application testing
Performance and reliability evaluation conducted per target application.
Partner qualification
Customer-led qualification programs define production readiness in each market.
Technologies described here are under active development. Testing results referenced are preliminary and application-specific; qualification timelines vary by market and customer process requirements.