Nanofibers for The AI Thermal Bottleneck

Microchips are getting hotter and hotter

Advanced chip packages now exceed 600 W/cm2 local power density, roughly 5,000 times the heat flux of sunlight hitting Earth's surface. At that density, the thermal interface material (TIM) becomes the limiting factor, not the chip itself.

Existing thermal interface Materials (TIMs) aren’t holding up

Too bulky
Not optimized for heat dissipation
Prone to drying
Prone to delamination

Zephyr is the fabrication layer

3-5x

less solvent required than incumbent methods

50%

filler loading, enabling enhanced composite materials

200x

cheaper than electrospinning at scale

Works with any thermoplastic, processed at ambient conditions
Production scales linearly by adding modular units (no throughput ceiling)
Controlled fiber alignment enables directional heat transfer, critical for AI chip cooling
Bath-based spinning with parallel needle arrays, no syringe pumps, no clogs

Our architecture enables

better thermal materials

Produce random or highly aligned mats with precise directional control. Aligned nanofibers steer heat where it needs to go, rather than relying on randomly mixed particles

Fiber Alignment

Deposit fibers conformally on any substrate, metals, polymers, ceramics, and other materials, eliminating the interface discontinuities that cause delamination under compressive cycling.

Substrate coating

Nanofibers with embedded conductive particles at up to 6x higher filler loading than conventional materials, with even distribution confirmed by EDX mapping

Filler Loading

Unlike liquid metal and copper nanostructure alternatives, Zephyr's nanofiber architecture conducts heat without conducting electricity. No secondary coating, no short-circuit risk, no redesign of the package to accommodate a conductive interface layer.

Electrically insulating

Greases and gels migrate under the compressive cycling of real operating conditions, thinning the bondline and degrading thermal performance over time. Zephyr's solid nanofiber mat holds its position and its thickness, maintaining consistent interface contact across the product lifetime.

stable Under pressure

World-class scientists with a proven track record

$11M+ capital raised

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8+ products commercialized

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5 patents issued/pending

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25+ publications

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$11M+ capital raised 〰️ 8+ products commercialized 〰️ 5 patents issued/pending 〰️ 25+ publications 〰️

Nick Martin

Co-Founder & CEO

Jo Norris

Co-Founder & CTO

Daseul Jang, Ph.D.

Head of R&D

Rakesh Ravi

Technical Advisor

Neil Washburn, PH.D.

Former President, Inolex (personal care green chemistry)
20+ years at DuPont, Senior Tech and Global Manager
Ph.D. Analytical Chemistry, UW-Madison

Advisor

Josh Paulson, CFA

Founder, Miriel AI; early team at RStudio
Former President and GM, REX Home Loans
Startup investor and advisor across AI, proptech, and climatetech

Advisor

Understanding the AI Hardware Stack

Market Opportunities outside of TIMs

FILTRATION

Biomedicine

ELECTRONICS

TEXTILES

services

We help develop new fiber-based materials using our mechanical nanofiber process. Our team evaluates polymer compatibility, refines formulations, and produces early prototypes ranging from aligned fibers to uniform mats and complex geometries.
We offer detailed analysis of fiber and material performance using our facility’s advanced instrumentation suite. Our testing covers morphology, surface behavior, thermal and chemical properties, and mechanical performance, giving your R&D team clear, decision-ready data.
We apply controlled nanofiber coatings directly onto films, textiles, membranes, and composite surfaces. The process supports aligned or random deposition, cross-link–ready surfaces, and tailored performance properties. If your surface needs new functionality, we can put it there.

tell us what you’re building

Our team will review your goals and outline how we can support your material development, testing, or coating work.

zephyr materials

Location

1201 Technology Drive, Aberdeen MD 21001