Warsaw University of Technology graduates invent technologies that enhance the sintering process

Originally Published in June 2017

GeniCore produces devices to make composite materials. The company’s sintering technology produces a range of materials that can be used to manufacture metal and composite machinery, surgical equipment, as well as construction and stone drilling among other things. Its devices have already been used in Japan, and multiple projects are pending in Europe and Asia.

With a doctorate in materials science and engineering, president and CEO Marcin Rosiński came up with the concept for GeniCore as a student at the Warsaw University of Technology. He founded the company in 2012 with his college friend Damian Mątewski, after working in the fields of sintering techniques and technology development, as well as conducting academic research.

Mątewski was inspired by the engineering company his father worked for, so he finished his graduate studies at Warsaw University of Technology and attended the Warsaw School of Economics. With experience in business and management, he partnered with Rosiński to establish the company.

GeniCore developed a sintering machine, which holds 12 international patents. The machines are tailor-made for each customer’s needs. They work with applications for manufacturing materials for various industries, including automotive, construction, road maintenance and metals. GeniCore offers two devices: Pulse Plasma Compaction (PPC), and Upgraded Field Assisted Sintering Technology (U-FAST).

The technologies compact powders of pure metals, metal alloys, as well as ceramic and metal composites. During the sintering process, the powder is heated by short, electrical pulses. The company says its devices are more energy efficient than its competitors’.

“We want to give our customers more possibilities to use better materials,” said Mątewski. The company’s devices control the heat and pressure needed to sinter the materials. The process begins by pouring powder into a graphite mold. The chamber is closed and the heat source—a pulsing electric current—is turned on. Once enough energy and heat is applied, the powder is compressed and becomes solid.

“DEC is a very innovative material that isn’t available on the commercial market.”

To ensure the technology will work for the client’s application, GeniCore offers a feasibility study. Additionally, clients receive a trial batch to test the materials that will be used for the application.

The company is also working on developing the composite diamond enhanced cemented carbide (DEC) which is impact-resistant and is extremely hard. “DEC is a very innovative material that isn’t available on the commercial market,” said Mątewski. He said the firm’s goal is to produce this material in factories in Poland.

The potential for sales of this product are huge – up to 2 billion euros, according to the company. However, the R&D and scaling require continuous capital investment. Thanks to European Union funding, the company has managed to make progress in the technology’s development – but capital outlays are still needed.

GeniCore is working with the Polish Space Agency to find ways to increase its chances of participating in European Space Agency initiatives. The PSA provides assistance in preparing applications for ESA projects. The program targets enterprises that have created innovations for the space industry, developing new products and materials to enter the space market.