IGF::OT::IGF HRL LABORATORIES, LLC, PROPOSES A 12 MONTH EFFORT TO DEVELOP AN ULTRA-LIGHTWEIGHT CORE MATERIAL THAT HAS HALF OR LESS THE DENSITY OF STATE-OF-THE-ART HONEYCOMB CORES, WHILE EXCEEDING THEIR MECHANICAL PROPERTIES. BY COMBINING OUR TEAM'S UNIQUE CAPABILITY TO MANUFACTURE ULTRALIGHT MICRO-TRUSS MATERIALS WITH OUR ABILITY TO DESIGN AND OPTIMIZE CELLULAR ARCHITECTURES, WE WILL ACHIEVE GROUNDBREAKING 40% MASS REDUCTION FOR SANDWICH STRUCTURES FOR FUTURE AEROSPACE VEHICLES. OUR APPROACH COMBINES MECHANICALLY EFFICIENT, ARCHITECTED MICRO-TRUSS TEMPLATES WITH HIGH-STRENGTH, NANOCRYSTALLINE METAL COATINGS. BOTH MANUFACTURING STEPS INVOLVED, HRL'S POLYMER MICRO-TRUSS FABRICATION AND ELECTROPLATING OF NANOCRYSTALLINE COATINGS, ARE INHERENTLY SCALABLE AND COST-EFFECTIVE, ENSURING THAT SCALE-UP TO LARGE STRUCTURES CAN BE ACHIEVED, WHILE MEETING NASA'S CHALLENGING COST TARGET. WE HAVE ALREADY FABRICATED 12X12X0.5 ULTRALIGHT MICRO-TRUSS CORES WITH A DENSITY OF 2 LB/FT3 AND SUPERIOR PROPERTIES TO SOA HONEYCOMB AS WELL AS CURVED MICRO-TRUSS SANDWICH PANELS FOR ONGOING DEVELOPMENT EFFORTS. UNDER THE PROPOSED EFFORT, WE WILL MATURE AND SCALE-UP NANOCRYSTALLINE METALLIC MICRO-TRUSS CORES FOR THE NEXT-GENERATION OF NASA'S ULTRA-LIGHTWEIGHT SANDWICH PANELS.