The aim of the project is to validate the use and benefits of silicon carbide (SIC) powder produced by laser driven-chemical vapor deposition (LCVD) for the high-power microelectronics field, which is…

The Department of Energy Office of Energy Efficiency and Renewable Energy awarded a $1,007,860 Cooperative Agreement to Free Form Fibers LLC on August 1, 2026, under the Conservation Research and Development program (CFDA 81.086) to validate silicon carbide powder produced by laser-driven chemical vapor deposition for high-power microelectronics applications.

The project aims to establish a domestic supply capability for high-purity SIC powder and develop a sustainable manufacturing process that can replace silicon-based wafers with silicon carbide substrates in the microelectronics field. Successful completion will validate a new production method and demonstrate domestic manufacturing viability for this critical material.

Free Form Fibers LLC, a small business based in Saratoga Springs, New York, will perform the work at its New York facility through January 31, 2028. The company specializes in advanced high-performance materials for aerospace, defense, semiconductor, and energy applications and has prior experience conducting Department of Energy research and development on silicon carbide composite structures and related joining techniques.

The aim of the project is to validate the use and benefits of silicon carbide (SIC) powder produced by laser driven-chemical vapor deposition (LCVD) for the high-power microelectronics field, which is replacing silicon-based wafers with substrates made from silicon carbide. The impact of successful completion of this project will validate a new process to fulfill domestic supply needs of a high purity SIC powder, and establish a modern process to manufacture the SIC in a sustainable fashion.