The Department of Defense, specifically the Navy, is seeking innovative solutions through the SBIR program for the development of green chemistry applications aimed at scalable production of carbon-based advanced textiles for hypersonic flight vehicles. The primary objective is to create a sustainable processing method that reduces chemical waste and enhances the production of advanced organic textiles used in carbon fiber, which is critical for the thermal protection systems of hypersonic applications. This initiative addresses the urgent need for environmentally friendly production methods in a market projected to grow significantly, while also mitigating supply chain vulnerabilities associated with current carbon fiber sourcing. Interested parties should note that the solicitation is set to open on April 23, 2025, with a closing date of May 21, 2025, and further details can be found at the provided source link.

## Description

The advent for advancements in Hypersonics has been upon us for the last two decades. Matching the performance metric of continually going faster with each new design iteration, the Thermal Protection System (TPS) plays a major role in a hypersonic flight vehicle&rsquo;s (HFV) performance at high MACH numbers. The TPS operates to protect the substructure of the HFV from high temperature aerodynamic heating. The majority of the TPS structure is composed of carbon fiber, derived from textiles such as polyacrylonitrile (PAN) or rayon [Refs 1,2]. In the production of these textiles, a great deal of chemical waste is produced, creating a large footprint that is a detriment to the environment. This often limits locations for carbon fiber production and U.S.-based access, and drives costs due to increased demand. The supplier base is relatively small and consists of fewer than five companies, which [Ref 2] has led to an overburdened supply chain [Ref 3]. Additionally, the advanced organic textile used in producing carbon fiber is sourced from overseas, where a sudden loss of supply would significantly disrupt DoD and other defense-related programs [Ref 3]. Despite the fragility of the supply chain, the carbon fiber market is estimated to be USD $6.5B in 2022 and $21.7B in 2032, where over 40% of the industrial value is tied to the aerospace or defense market [Ref 2]. There is a potential gap of over 55,000 metric tons by 2026 where it would take several years to add additional capacity [Ref 2]. Sustainable alternative methods to producing these base level textiles would expand market level availability and drive cost margins for the Hypersonics and carbon fiber industry. This SBIR topic looks for novel approaches that address scalability using the principles of green or sustainable chemistry to reduce waste products and ensure EPA compliance in the production of advanced organic textiles for carbon fiber production. Green chemistry is a field devoted to sustainability and forms a framework of twelve principles: prevent waste, atom economy, less hazardous synthesis, design benign chemicals, benign solvents and auxiliaries, design for energy efficiency, use of renewable feedstocks, reduce derivative, catalysis, design for degradation, real-time analysis for pollution prevention, and inherently benign chemistry for accident prevention [Ref 4]. Some of the toxic and hazardous waste products produced from current processes include, but are not limited to, HCN, NH3, CO2, CS2, and H2S [Ref 5]. Work produced in Phase II may become classified. Note: The prospective contractor(s) must be U.S. owned and operated with no foreign influence as defined by 32 U.S.C. &sect; 2004.20 et seq., National Industrial Security Program Executive Agent and Operating Manual, unless acceptable mitigating procedures can and have been implemented and approved by the Defense Counterintelligence and Security Agency (DCSA) formerly Defense Security Service (DSS). The selected contractor must be able to acquire and maintain a secret level facility and Personnel Security Clearances. This will allow contractor personnel to perform on advanced phases of this project as set forth by DCSA and SSP in order to gain access to classified information pertaining to the national defense of the United States and its allies; this will be an inherent requirement. The selected company will be required to safeguard classified material during the advanced phases of this contract IAW the National Industrial Security Program Operating Manual (NISPOM), which can be found at Title 32, Part 2004.20 of the Code of Federal Regulations.

## Objective

Develop a processing method using green chemistry to produce carbon fiber from advanced organic textiles for hypersonic applications. Provide sustainable alternatives to commonly used chemicals or processes by reducing solvent byproducts, hazardous chemical use, and increasing yield that address long-term affordability.

## Phase I

Develop a proof of concept for a sustainable, repeatable chemical process that yields advanced organic textile fibers for the production of carbon fiber with comparable thermomechanical properties to existing textiles for TPS applications in hypersonic environments. Provide materials thermomechanical characterization analysis, including, but not limited to, density, moisture content, and break strength of the advanced organic textile. Demonstrate that this process could result in a reduction of toxic and hazardous waste and volatile compounds. Provide a detailed plan for full scale production of the advanced organic textile. The Phase I Option, if exercised, will include the initial design specification and capabilities to build a prototype solution in Phase II.

## Phase II

Mature the process by testing the appreciability of the conversion of advanced organic textiles to carbon fiber. Provide materials thermomechanical characterization analysis, including, but not limited to, char yield, density, moisture content, and break strength after carbonization. Demonstrate the feasibility of production through processing the advanced organic textiles through a carbon fiber conversion process, either traditional or novel. It is probable that the work under this effort will be classified under Phase II (see Description section for details).

## Phase III: Dual Use Applications

If the demonstration in Phase II is deemed to be of high interest to the Government, support the Government in transitioning the technology for Government use. Ensure that the transitioned product is able to support current and future weapon and space systems, as well as a wide range of other air-, land-, and sea-based systems. Continue to scale the green/sustainable chemistry process to enable the continuous production of advanced organic textiles for carbon fiber production based on the prototypes developed in Phase II. Integrate the converted carbon fiber into a woven part to be &ldquo;thermomechanically&rdquo; characterized. Integrate the technology into a flight experiment to validate the efficacy of the produced carbon-based TPS part. Carbon fiber is used in commercial space applications as well as many Navy/DoD components, such as Navy Strategic Systems Programs (SSP), Navy Conventional Prompt Strike (CPS), and Primes developing TPS. Sustainable, green chemistry-developed advanced organic textiles would be of interest to the aforementioned programs. This project should transition to defense contractors for high-speed weapons and space systems.

Green Chemistry Application for Scalable Production of Carbon-Based Advanced Textiles Supporting Hypersonics

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