Forging innovation: How Quad Industries and Carver Scientific are transforming extreme cold solutions
17 DEC 2024 | NEWS
Carver Scientific is focused on the development of innovative materials, processes, and technologies that bring transformative change to the way electricity is generated, managed, and stored. This includes developing equipment for military applications that will eventually use our energy products, such as a man-wearable heater specifically designed for Warfighters operating in extreme cold conditions. This heater must provide adequate warmth, operate with minimal power consumption, ensure safety for direct contact with the body, and be compatible with a range of military and civilian battery systems. A second product focus is battery warmers for phones and other end user devices used by Warfighters in these extreme conditions.
Ritchie Priddy, Director of Business Development at Carver Scientific, shares more about the cooperation with Quad Industries to co-develop this heater.
Why did you choose Quad Industries as your partner?
PTC heaters provide the best solution for most of our applications. We had worked with a US-based company, but they were not able to provide the R&D assistance we sought on a market that was just beginning to emerge. We needed to find the right PTC printer who had the expertise and R&D interest and was willing to work with a small start-up to develop and manufacture a military product. One of our partners suggested we contact Quad Industries.
What goals or objectives did you aim to achieve with this project?
With the adoption of the US and NATO Arctic strategies, we anticipated a growing focus on cold-weather combat and recognized an emerging market for innovative solutions. As development progressed, two primary needs became clear: 1) targeted, efficient man-wearable heaters for the Warfighters; and 2) ensuring that electronics and batteries remain functional in extreme cold. To address these, we not only developed the heater but also introduced a power module that dramatically enhances energy efficiency across a wide range of man-wearable and electronics products. Together, these innovations form a highly effective solution for cold-weather operations.
Due to the war in Ukraine and the rapidly emerging NATO and European requirements to develop and deploy solutions for maintaining the functionality of equipment like phones and radios in extreme conditions, opportunities to accelerate our market entry with proven technologies have occurred. We are witnessing a growing demand in Europe for lightweight, low-power garments and medical products designed for extreme cold weather. This shift allows us to refocus on addressing man-wearable needs effectively.
In cold-weather operations, reliable communication is critical and split-second decisions can mean the difference between life and death. When we were approached by a NATO special forces R&D group they explained the life-threatening challenge they faced: their phones and other electronics were freezing in extreme cold, rendering them unusable. As temperatures drop batteries rapidly degrade and that damage can be irreversible. With our controllers the heaters keep the internal battery components operating within the optimum temperature range. Third party tests show that this product can keep batteries operating down to below minus 40 degrees! To our knowledge no one else has been able to do this. The reviews we’ve received from Warfighters in the field have been very positive and our products are now being sold throughout NATO.
By combining Quad’s heaters with our advanced power modules, we successfully resolved this issue for a specific category of communication devices. Building on this success, we are now working to integrate these solutions across a wider range of military and law enforcement equipment, with plans to extend their application to various civilian products.
How did you connect with Quad?
A mutual partner played a key role in facilitating our partnership with Quad. After meeting the Quad team, we were confident they could not only meet our requirements but also keep us at the forefront of advancements in printed electronics. Their strong positioning, industry connections, and collaboration with firms pushing technological boundaries made them the ideal partner.
Together, we worked on designing several configurations and began purchasing multiple heaters, which were shipped to our Baton Rouge, LA (USA) facility for integration with our electronics. We’ve since delivered multiple rounds of man-wearable and electronics prototypes to military, police, and even civilian customers, each iteration showing improved capabilities.
Quad brought not only exceptional expertise but also innovative ideas we hadn’t considered, which proved invaluable. They continue to provide critical insights into industry developments, emerging technologies, and opportunities for collaboration, ensuring we remain ahead of the curve.
How has the partnership with Quad developed over time?
We’re very pleased with our collaboration. I’ve had the opportunity to visit their facility in Belgium twice, and through numerous product-market discussions, we’ve discovered their extensive expertise can directly enhance our product development across various markets.
Their insights into existing solutions have also been invaluable. For example, during a project with a cold-weather clothing manufacturer, a non-Quad heater was accidentally left on under some fabrics over the weekend. The heater melted but did not ignite. Quad helped us investigate the issue, testing the melted heater and identifying the cause. Importantly, we’ve never had an incident with any Quad-manufactured heaters.
We feel confident that we could bring in the Quad-team in our discussions with our end-users without concern. That too, is very important to us.
Additionally, working with a European partner has distinct advantages. While U.S. procurement of cold-weather gear has been slow, our presence in NATO markets has grown significantly, and sales of our electronics and battery warmers have surged. Our European distributor and their clients appreciate that a European firm like Quad is instrumental in our product development.
What is the result of your co-development so far?
The products we have integrated with Quad heaters have successfully passed Extreme Cold Weather testing by NATO SOF and are undergoing further testing during cold-weather field exercises in the U.S., Canada, and NATO territories. We’ll return to Norway in January to conduct additional real-world experiments.
We have demonstrated that our solutions can keep batteries operating and charging even in ambient temperatures as low as minus 40 degrees. To our knowledge, no other company has achieved this capability below zero Fahrenheit (-17.8°C).
How do end-users react to the technology?
End-users are consistently impressed by the performance of the heaters. When we turn them on during demonstrations, they’re amazed at how quickly the heaters activate and cool down when turned off. One of the most impactful demonstrations is handing them a heater riddled with bullet holes that still functions—it’s incredible to see their reaction, especially since these are individuals who are rarely impressed. These demonstrations have opened many minds and doors for us.
The man-wearable heaters have received similarly positive feedback, particularly during field exercises. Users have tested them in extreme scenarios—inside boots during airplane jumps in Alaska or embedded in clothing for patrol missions or sniper stakeouts lasting hours in the cold.
Are there areas that need improvement?
While the man-wearable heaters have been well-received in various settings, including field demonstrations, individual tests, and actual police operations, they require further development in specific areas like water resistance. In fact, we’ve had a lot of interest in using these heaters in diving operations.
What has been the most significant outcome so far?
The biggest achievement has been ensuring communication devices remain operational at temperatures well below zero. Since passing NATO extreme cold testing, we’ve been approached by numerous companies. At the Association of U.S. Army show—an event with over 35,000 attendees and 700 booths—several companies actively sought us out to discuss integrating our solutions into their products, including drones, medical equipment, and clothing. This level of interest is unprecedented for us, and we expect significant sales to result from it.
Why is Quad Industries an ideal partner?
Collaborating with Quad gives us access to cutting-edge technology and the latest developments, keeping us at the forefront of creating life-critical products. Quad Industries has demonstrated unique capabilities in the military market and proven to be one of the most innovative technology partners we’ve encountered. We feel we’ve only scratched the surface of their potential and continue to discover new opportunities to integrate their heaters and controllers into diverse applications.
