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Custom Polymer Film Development

Peak Nano’s Films as a Service (FaaS)

Custom film development in months, not years — with no new polymer chemistry required.

Explore the Technology

Peak Nano’s Custom Polymer Films Development Films as a Service (FaaS)

For decades, advancing film performance meant waiting for polymer manufacturers to invent the next resin, a process that can take a decade and considerable expense. Peak Nano's Films as a Service (FaaS) platform removes that bottleneck. Instead of waiting on new polymer chemistry, our proprietary nanolayering technology arranges commercially available polymers into precision nanolayer architectures, from dozens to thousands of ultra-thin, precisely controlled layers, to unlock performance no single resin or simple blend can achieve. The performance comes from architecture rather than chemistry, which is why a program runs in months instead of years and at a fraction of the cost of new resin development.

Why Peak Nano Is Your Solution for Custom Nanolayer Polymer Films

Peak Nano's FaaS platform delivers unmatched speed, precision, and commercial flexibility by bridging the gap between raw materials and scalable production without the traditional risks of polymer synthesis.

Faster Film Development & Commercialization

We work with companies to build a research plan tailored to your industry's goals and needs.

  • Weeks, not years: Rapid prototyping and testing cycles that shrink innovation timelines.
  • Faster path from concept to production: Move from initial requirements to qualified candidates without as many regulatory delays.
  • Expertise: Our nanolayering experts combine deep materials science with your industry know-how to get to the best solution, faster.

Lower Cost

Achieve more performance with less material through efficient system-level design.

  • Less material: High-performance downgauging options.
  • Lower-cost materials: Replace expensive specialty resins with optimized commercial polymers.
  • Efficient multilayer architectures: Maximize functional output per micron of thickness.

Improved Performance

Engineer films for demanding performance requirements.

  • Higher barrier: Superior protection against moisture, gases, and chemicals.
  • Higher temperature resistance: Thermal stability for extreme industrial and aerospace environments.
  • Higher dielectric performance: Advanced energy storage and breakdown strength.
  • Higher toughness: Enhanced mechanical resilience and puncture resistance.
  • Longer lifespan: Minimized degradation under aggressive operational stress.

Lower Risk

Build With Proven Materials & Infrastructure

  • Existing polymers: Eliminate the uncertainty of unproven resin chemistries.
  • Existing suppliers: Maintain continuity with trusted material vendors.
  • Existing equipment: Design architectures compatible with current processing lines.
  • Scalable manufacturing processes: Built from the ground up for repeatable extrusion.

Competitive Edge & Scalability

Design films for the demands of tomorrow.

  • Evolving regulations: Proactive compliance through safe, standard material choices.
  • Sustainability goals: Support for recycle-ready structures, mono-material recycling, and waste reduction.
  • Domestic supply-chain resilience: U.S.-based development and manufacturing oversight.

Flexible Commercialization

  • Peak manufactures: Let Peak Nano produce your specialized film runs.
  • Customer manufactures: Transfer architectures directly to your internal facilities.
  • Contract manufacturer produces at scale: Seamless handoff to qualified third-party partners.

Why Peak Nano Is Your Solution for Custom Nanolayer Polymer Films

Peak Nano's FaaS platform delivers unmatched speed, precision, and commercial flexibility by bridging the gap between raw materials and scalable production without the traditional risks of polymer synthesis.

Faster Film Development & Commercialization

We work with companies to build a research plan tailored to your industry's goals and needs.

  • Weeks, not years: Rapid prototyping and testing cycles that shrink innovation timelines.
  • Faster path from concept to production: Move from initial requirements to qualified candidates without as many regulatory delays.
  • Expertise: Our nanolayering experts combine deep materials science with your industry know-how to get to the best solution, faster.

Lower Cost

Achieve more performance with less material through efficient system-level design.

  • Less material: High-performance downgauging options.
  • Lower-cost materials: Replace expensive specialty resins with optimized commercial polymers.
  • Efficient multilayer architectures: Maximize functional output per micron of thickness.

Improved Performance

Engineer films for demanding performance requirements.

  • Higher barrier: Superior protection against moisture, gases, and chemicals.
  • Higher temperature resistance: Thermal stability for extreme industrial and aerospace environments.
  • Higher dielectric performance: Advanced energy storage and breakdown strength.
  • Higher toughness: Enhanced mechanical resilience and puncture resistance.
  • Longer lifespan: Minimized degradation under aggressive operational stress.

Lower Risk

Build With Proven Materials & Infrastructure

  • Existing polymers: Eliminate the uncertainty of unproven resin chemistries.
  • Existing suppliers: Maintain continuity with trusted material vendors.
  • Existing equipment: Design architectures compatible with current processing lines.
  • Scalable manufacturing processes: Built from the ground up for repeatable extrusion.

Competitive Edge & Scalability

Design films for the demands of tomorrow.

  • Evolving regulations: Proactive compliance through safe, standard material choices.
  • Sustainability goals: Support for recycle-ready structures,  mono-material recycling, and waste reduction.
  • Domestic supply-chain resilience: U.S.-based development and manufacturing oversight.

Flexible Commercialization

  • Peak manufactures: Let Peak Nano produce your specialized film runs.
  • Customer manufactures: Transfer architectures directly to your internal facilities.
  • Contract manufacturer produces at scale: Seamless handoff to qualified third-party partners.

The Films as a Service (FaaS) Advantage: Contract Research to Production-Ready Scale

Films as a Service (FaaS) is Peak Nano's end-to-end contract research service for custom polymer films and nanolayer film architectures.

From initial project scoping and material selection through customer formulation, prototyping, performance testing, and manufacturing scale-up, Peak Nano provides a single development partner to help move your film from concept to a commercial-ready product.

  • Contract Research & Development: Project scoping, product development, custom polymer formulation, and prototyping tailored to your application and performance requirements. 
  • Testing & Validation: In-house testing and accredited third-party validation tailored to your application and performance targets. 
  • Manufacturing & Scale: Technical transfer documentation, process development, and manufacturing support to move your validated nanolayer film architectures from prototype to scalable production.

Custom Polymer Film Engineering from Concept to Commercialization

FaaS moves you through this process in structured, reviewable stages rather than a single fixed engagement.
 
Programs run in three phases with six checkpoints, quoted and scoped one phase at a time. You can enter at research, development, scale-up, or commercialization, and at each checkpoint you review the data against your own metrics and decide whether to continue, keeping the cost of finding out low. The project agreement defines intellectual property and commercialization rights before development starts.

Phase I: Proof of Concept (approximately 3 to 6 months)

  • Checkpoint 1, metrics and materials formulation: A focused review of your application, performance targets, operating conditions, and material constraints, converted into measurable success criteria.
  • Checkpoint 2, proof-of-concept coextrusion and testing: Our polymer scientists design candidate nanolayer architectures, screen polymer combinations and layer configurations, and extrude working samples on Peak-owned R&D lines. First coextruded samples arrive in weeks.
  • Checkpoint 3, review against metrics: Results are documented against your criteria, and the architecture is either refined or advanced.

Phase II: System Optimization (approximately 3 to 6 months)

  • Checkpoint 4, process optimization and scale-up: Layer count, thickness, symmetry, and composition are tuned, and processing conditions are proven from R&D onto pilot equipment. Testing combines in-house capability with accredited third-party labs, including application-specific accelerated aging where service life is the claim being supported.
  • Checkpoint 5, review against metrics: We do not advance to pilot production until the film performs against the targets set at intake.

Phase III: Pilot Production (approximately 3 months)

  • Checkpoint 6, prototype samples and pilot production: Prototype rolls and pilot quantities are produced on Peak-owned lines in Valley View, Ohio, for integration testing on your own converting and filling equipment.

First coextruded samples arrive in weeks. A validated, scalable structure takes months, not the years a new resin would require.

What You Go Home With

Three deliverables, independent of who ends up manufacturing the film.

1

A validated film architecture

Layer count, layer order, materials, and thickness are tested against the metrics you set at intake.

2

Scale-up Pathway

Processing conditions proven from R&D through pilot, documented in a Technical Transfer Package with specifications, SOPs, material sourcing guidance, and recommended manufacturing parameters.

3

Manufacturing Options

Peak Nano produces the film; you run it on your own lines, or a pre-qualified partner produces it at scale. The choice is made after the architecture is validated.

How Nanolayer Polymer Films Compare to Traditional Methods

Category Traditional Polymer Films Films Developed Through FaaS
Design Approach

Limited to resin supplier menu; blend or laminate

Engineer any property by design, layer by layer
Time to New Capability

2-10 years (new resin R&D + qualification)

Months (prototype from off-the-shelf polymers)
Material Cost

Often requires expensive specialty resins

Uses lower-cost, optimized, proven, and affordable commercial polymers
Customizability

Low to moderate

Significant flexibility and innovation (gradient index, tailored dielectric, selective barrier, etc.)
Sustainability

Constrained by resin chemistry

Downgauging, mono-material recyclability, and reduced waste
Intellectual Property

Commercial and supplier-owned specialty resins can limit what you own

Your custom film architecture and composition become part of your IP

Ready to Bring Your Custom Film to Life?

Discover how Peak Nano’s Films as a Service (FaaS) platform accelerates the development of custom nanolayer polymer films—from application requirements and nanolayer architecture design through prototyping, performance testing, validation, and manufacturing scale-up. 

Book a Discovery Call

Frequently Asked Questions (FAQs)

Working film prototypes are typically delivered within six to 10 weeks of design approval. A complete FaaS engagement — moving from initial technical requirements and nanolayer architecture design through testing, validation, and a production-ready structure — is measured in months, not years. FaaS accelerates development cycles by re-architecting commercially available polymers already used in your industry, rather than waiting years to synthesize and qualify brand-new polymer chemistry.

Nanolayer architectures reduce film and system-level costs through direct material efficiency and resin substitution:
  • Downgauging: Precision layer control reduces total material thickness while retaining or enhancing physical properties.
  • Resin Optimization: Expensive specialty barrier resins can be deployed in lower volumes or replaced with lower-cost commercial polymers without losing performance.
  • System Economics: Peak Nano evaluates cost holistically, factoring in material use, manufacturing throughput, end-product reliability, and warranty considerations.

Peak Nano tunes film properties through nanoscale structural architecture rather than shifting polymer chemistry. By combining dozens to thousands of precision-controlled layers, the platform leverages interfacial effects and layer confinement to achieve properties impossible with a single resin or conventional blend:

  • Barrier Enhancement: Exponentially higher oxygen and moisture barrier performance per unit of resin.
  • Mechanical Resilience: Greater puncture resistance and toughness at thinner profiles.
  • Additive Performance: Eliminates traditional trade-offs (e.g., barrier vs. flexibility), allowing films to express multiple optimized characteristics simultaneously.

Yes. FaaS-developed films are purposefully engineered for compatibility with existing manufacturing infrastructure. Peak Nano evaluates processing conditions early in the engagement, tuning critical parameters such as melt behavior, sealing windows, metallization compatibility, and lamination adhesion. This architecture-first approach eliminates the need to qualify entirely new resin suppliers or retrofit foundational manufacturing equipment.

Peak Nano builds compliance and sustainability into the development process from day one:

  • Regulatory Compliance: Using commercial polymers already used in approved applications simplifies FDA food-contact evaluations and safety reviews. Peak supplies comprehensive technical documentation as part of the Technical Transfer Package.
  • Sustainability & DfR: Nanolayer architectures drive material reduction and facilitate the creation of mono-material, recycle-ready structures.
  • Domestic Supply Chain: All R&D, pilot runs, and manufacturing take place in the United States (Valley View, Ohio), ensuring a secure, reliable domestic supply chain.

Customers retain flexible commercialization options tailored to their business model:

  1. Peak Manufacturing: Peak Nano produces the validated film at our U.S. facility.
  2. In-House Transfer: Peak transfers the precise architecture, processing guidelines, and scaling data for production on the customer’s own lines.
  3. Contract Manufacturing: Production is supported through pre-qualified manufacturing partners. Every path includes a complete Technical Transfer Package and ongoing engineering support.

Long-term durability is verified through rigorous, application-specific accelerated aging tests. Depending on the end-use sector, testing evaluates thermal aging, humidity exposure, electrical stress, mechanical fatigue, and cyclic loading. Performance-retention and lifespan metrics are fully documented during the FaaS validation phase prior to production scaling.

Potential failure mechanisms — such as layer delamination, mechanical micro-cracking, or oxidative degradation — are systematically evaluated and engineered out during FaaS testing. Nanolayer architecture provides granular design control, allowing engineers to adjust individual layer thickness, symmetry, and material pairing to alleviate stress concentrations and maximize structural reliability.

Intellectual property and commercialization rights are defined clearly within the initial project agreement. Customers receive the necessary architecture documentation, processing guidelines, and licensing or ownership rights for their specific applications, ensuring complete freedom to operate prior to production scale-up.

FaaS gives R&D and packaging engineers a direct path from concept to a production-ready film architecture without the multi-year delays of polymer R&D. By combining rapid 6–10 week prototyping, quantified performance iteration, strict manufacturing compatibility, and clear scale-up pathways, FaaS acts as a high-speed extension of your internal engineering team.

Request a Discovery Call

Discuss your application, performance requirements, prototype goals, and path to manufacturing with the Peak Nano team.