The Department of the Air Force (DAF) is seeking innovative manufacturing technologies and solutions through its Direct-to-Phase-II Small Business Innovation Research (SBIR) program, specifically targeting dual-purpose applications that meet clear stakeholder needs from the Air Force and Space Force. Applicants must demonstrate their proposed solutions align with one or more of the focus areas, including advanced manufacturing for engine production, advanced composite structures, semiconductor innovations, radiation-hardened electronics, system integration, and affordable energetics. This initiative aims to explore and transition advanced manufacturing capabilities into defense applications while fostering growth in the industrial base. Interested parties must submit their applications by July 9, 2025, and include a Government Engagement Memorandum to validate support from a DAF customer organization. For more details, visit the solicitation link at https://www.sbir.gov/topics/12188.

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Trusted AI and Autonomy;  Directed Energy (DE); Hypersonics; Microelectronics; Integrated Network Systems-of-Systems; Quantum Science; Space Technology;  Advanced Materials; Human-Machine Interfaces; Advanced Infrastructure & Advanced Manufacturing 

 

OBJECTIVE: This focused open topic is specific to manufacturing. Applications must reasonably demonstrate the proposed solution falls within at least one or more of the following focus areas: engine production with advanced manufacturing, advanced composite structures, semiconductor production innovations, radiation-tolerant/hardened electronics, system integration and interoperability, and affordable energetics. 
 
This Department of the Air Force (DAF) focused open topic seeks Manufacturing Technologies for transition into the United States Air Force (USAF) and United States Space Force (USSF). This topic is offered in partnership with AFWERX/SpaceWERX. 

 

Primary objectives of this focused open topic include exploring innovative manufacturing solutions applicable to both defense and non-defense markets, scaling capability, and growing the industrial base for defense. This topic seeks companies with the capability to prototype validated concepts under an accelerated Phase II schedule. This topic is aimed at applied research and development efforts rather than "front-end" or basic research (R)/Research & Development (R&D). 

 

Topic Unique Government Engagement Memorandum (GEM) Requirements 

 

Your application must include a Government Engagement Memorandum (Attachment 1) that  

proves you have support from a valid DAF customer within one of the following organizations: PEO Weapons/Stand-in Strike Division, PEO Fighters and Advanced Aircraft/Advanced Aircraft Division, AFRL/RX, or AFRL/RG Prime.  

 

*A valid signature from one of the listed Customer organizations must be present on the Government Engagement Memorandum for your application to be considered. Applications lacking a completed Government Engagement Memorandum will be disqualified. The Government Engagement Memorandum is the only document accepted to verify DAF customer support. 

 

Applicants ARE NOT required to obtain TPOC and End-User signatures. TPOCs and End-Users  

will be identified by the customer if the proposal is selected for award.  

 

To aid applicants' connection with potential DAF customers an optional process is being offered  

to facilitate communication. This process allows small businesses to share information about their technologies, allowing government partners to determine if they have an interest in providing a Government Engagement Memorandum of support via completion of an online webform. 

 

Webform Process 

 

Applicants choosing to engage in this optional process will complete a web form  

following this link https://forms.gle/A1zinCu6Q9xqs1ji7. Applicants engaging in this process shall submit the completed web form not later than 12:00 PM ET on 18 June 2025. After this time the webform will close to new submissions to allow potential Government customers a reasonable time to review applicant submissions. 

 

Upon submission of the requested information via the webform, Government customers will review it to determine their interest in the technology. 

 

If any Government customer(s) have an interest in providing a Customer Engagement Memorandum to the applicant, the Government customer(s) will communicate their intent to sign the Government Engagement Memorandum. Further, the Government customer, by signature and completion of the Government Engagement Memorandum, commits that the Government signatory will identify by name a valid TPOC and End-User not later than September 15th, 2025 or at another time as agreed in writing by an AFWERX Contracting Officer.  

 

Up to 20 applicants can receive a signed Government Engagement Memo from each of the four specified Government customer organizations.  

The webform will request the following information from applicants: 

Name of company 

Company POC name/contact information 

Alternate POC name/contact information 

Technical abstract (no more than 500 words) 

Anticipated benefits of the research or development toward the six identified Manufacturing focus areas(no more than 300 words) 

Identification of one or more of the identified customer organizations the company believes may be interested in their proposed solution 

The DAF prefers applicants use the webform to streamline the process. However, applicants, at  

their sole discretion, may choose to source their Government Engagement Memorandum signatures directly with the four identified Government customer organizations.  

 

Customer Organization Missions and Points of Contact 

 

PEO Weapons/Armament Directorate/Stand-in Strike Division (AFLCMC/EBI):  

Designs, develops, produces, fields, and sustains a family of air-to-ground and air-to-air munitions for both U.S. and allied nations to defeat a spectrum of enemy targets. AFRL.RG.PEOWeapons@us.af.mil 

 

PEO Fighters and Advanced Aircraft/Advanced Aircraft Division (AFLCMC/WAC):  

Responsible for ensuring the U.S. Air Force and its allies have the most effective fighter and advanced aircraft. The directorate manages everything from the initial development and production to the long-term maintenance and upgrades of aircraft like the A-10, F-15, F-16, and F-22, as well as special programs. Fighters and Advanced Aircraft (AFLCMC/WAC) is also spearheading the development of the future of air dominance with the Next Generation Air Dominance (NGAD) program. The PEO's focus is on constantly delivering cutting-edge capabilities through innovative strategies to stay ahead of potential threats. AFRL.RG.PEOFighters@us.af.mil 

 

AFRL's Materials and Manufacturing Directorate (AFRL/RX): Develops materials,  

processes, and advanced manufacturing technologies for aircraft, spacecraft, missiles, rockets, and ground-based systems and their structural, electronic and optical components. Air Force product centers, logistic centers, and operating commands rely on the directorate's expertise in materials, nondestructive inspection, systems support, and advanced manufacturing methods to solve system, expeditionary deployment, and operational challenges. AFRL.RG.Materials@us.af.mil 

 

AFWERX Prime (AFRL/RGP): Cultivates innovative technologies and empowers  

Airman and Guardian talent to mature groundbreaking capabilities for rapid operational impact. AFRL.RG.AFWERXPrime@us.af.mil 

 

Manufacturing Technology Focus Areas and Definitions 

 

Proposed solutions for this Manufacturing Technology focused open topic must fall within at least one of the following six (6) focus areas: 

 

Engine Production with Advanced Manufacturing: Innovations in manufacturing processes,  

materials, and automation to improve the performance, efficiency, cost basis, and reliability of engines for Air Force and Space Force applications. This includes, but is not limited to, additive manufacturing, digital twins, and advanced robotics for engine component production and assembly for aircraft, spacecraft, other flying systems, incremental sheet forming for engine structures (ducts, cases, etc.), oxide dispersion stabilized materials for hot engine components, environmental coatings opportunities, and other relevant technologies. 

 

Advanced Composite Structures: Development and application of novel materials, manufacturing techniques, and structural designs for high-performance composite materials for Air Force and Space Force applications. This includes, but is not limited to, automation of composite manufacturing, advanced fiber placement, and innovative joining methods for aerospace vehicles, space structures and related equipment, graphene-based materials, integrated isogrids to reduce part count, high pressure molding to reduce production cycle times, utilization of chopped fiber to create complex parts at high production rates, low cost Thermoset (TS) and Thermoplastic (TP), Thermoplastic Welding and weld inspections, automation solutions for final stage assembly, and other relevant technologies. 

 

Semiconductor Production Innovations: Advancements in semiconductor manufacturing processes, equipment, and materials to improve device performance, reduce costs, and increase production efficiency for Air Force and Space Force systems. This includes, but is not limited to, innovations in lithography, etching, deposition, and packaging technologies for radiation-hardened electronics, advanced sensors, communication systems, nano imprint lithography, wide-band gap semiconductors, lightweight semiconductors, 3D advance packaging (PCB board elimination), and other relevant technologies. 

 

Radiation-Tolerant/Hardened Electronics: Development of manufacturing techniques and materials for electronic components and systems that can withstand harsh radiation environments relevant to Air Force and Space Force missions. This is critical for applications in space-based systems, high-altitude platforms, hypersonics, and nuclear environments. 

 

System Integration and Interoperability: Innovations in processes and technologies to improve integration and interoperability of defense relevant manufacturing equipment and systems. This includes, but is not limited to, digital manufacturing, manufacturing data management and utilization, manufacturing system integration tools and advanced assembly techniques for vehicles, platforms, components of air and space systems, and other relevant technologies. 

 

Affordable Energetics: Development of cost-effective manufacturing methods for energetic materials and devices, including propellants, explosives, and pyrotechnics, and their containers or encasements for Air Force and Space Force applications. This includes, but is not limited to, innovations in synthesis, processing, and formulation of energetic materials for propulsion systems, and novel, low-cost materials and manufacturing techniques for energetics cases or containers, for missile systems, high-gurney self-sustaining energetics, and other relevant technologies. 

 

Applications for this Manufacturing Technologies focused open topic must clearly demonstrate that the proposed solution fits within one of the six (6) defined focus areas. Applications failing to reasonably validate their alignment within one or more of the focus areas will not be evaluated. 

 

DESCRIPTION: The DAF is a large and complex organization consisting of many functions, a vast majority of which have similar counterparts in the commercial sector. It is important that potential solutions have a high probability of keeping pace with technological change. Thus, solutions should be closely tied to commercial technologies and solutions supporting the proposed development. This topic is meant for non-defense commercial solutions to be adapted to meet DAF stakeholders' needs.  

  

Proposed technical solutions should focus on the aforementioned 6 focus areas as well as the characteristics outlined in the Selection and Evaluation Criteria section of this solicitation.  

  

This is accomplished most effectively through a proposal with a mature non-defense technical solution and a clear understanding of its adaptation to meet a DAF customer's specific need, supported by documentation from a specific motivated, empowered DAF customer ready and willing to participate in the proposed prototype solution's trial.  

 

The AF SBIR Program follows the policies and practices of the Small Business Administration (SBA) 

SBIR/STTR Policy Directive (3 May 2023): 

https://www.sbir.gov/sites/default/files/SBA%20SBIR_STTR_POLICY_DIRECTIVE_May2023.pdf. 

 

PHASE I: This topic is intended for technology proven ready to move directly into Phase II. Therefore, Phase I awards will not be made for this topic. The applicant is required to provide detail and documentation in the D2P2 proposal which demonstrates accomplishment of a “Phase I-type” effort, including a feasibility study. This includes determining, insofar as possible, the scientific and technical merit and feasibility of ideas appearing to have commercial potential. It must have validated the product-mission fit between the proposed solution and a potential Air Force stakeholder. The applicant should have defined a clear, immediately actionable plan with the proposed solution and the DAF customer.  

  

The feasibility study should have: 

Clearly identified the potential stakeholders of the adapted solution for solving the Air Force need(s).  

Described the pathway to integrating with DAF operations, to include how the applicant plans to accomplish core technology development, navigate applicable regulatory processes, and integrate with other relevant systems and/or processes.  

Described if and how the solution can be used by other Department of Defense (DoD) or governmental customers. 

 

PHASE II: Proposals should include development, installation, integration, demonstration and/or test and evaluation of the proposed solution prototype system.  

  

These activities should focus specifically on: 

Evaluating the adapted solution against the proposed objectives and measurable key results.  

Describing in detail how the installed solution differs from the non-defense commercial offering to solve the Air Force need(s), as well as how it can be scaled for wide adoption, i.e., modified for scale.  

Identifying the proposed solution's clear transition path, taking into account input from affected stakeholders, including but not limited to, end users, engineering, sustainment, contracting, finance, legal, and cyber security.  

Specifying the solution's integration with other current and potential future solutions.  

Describing the solution's sustainability, i.e., supportability. Identifying other specific DoD or governmental customers for the solution. 

 

PHASE III DUAL-USE APPLICATIONS: Some solutions may go from Phase II to Phase III as soon as the product-market fit is verified. Potential Phase III awardees will transition to the adapted non-Defense commercial solution to provide expanded mission capability for a broad range of potential governmental and civilian users and alternate mission applications. 

 

NOTES: DAF may hold Ask Me Anything (AMA) webinars to answer applicant questions. For more information, applicants may visit https://afwerxchallenge.com/.  

 

AMAs and webinars will be held at the discretion of the DAF and are subject to change.  

 

Section seven (7) of the Small Business Innovation Research (SBIR) and Small Business Technology Transfer (STTR) Extension Act of 2022 requires the DoD to establish innovation open topic activities in order to: 

 

(A) Increase the transition of commercial technology to the DoD; 

(B) Expand the small business non-traditional industrial base; 

(C) Increase commercialization derived from investments of the DoD; and  

(D) Expand the ability for qualifying small business concerns to propose technology solutions to meet the needs of the DoD. 

 

Unlike conventional topics, which specify the desired technical objective and output, open topics can use generalized mission requirements or specific technology areas to adapt commercial products or solutions to close capability gaps, improve performance, or provide technological advancements in existing capabilities. 

 

REFERENCES: 

United States Department of Defense. (2023). National Defense Science & Technology Strategy 2023. 

United States Department of Defense. (2022). 2022 National Defense Strategy of the United States Summary. 

United States Space Force. (2024). Commander’s Strategic Guidance. 

National Science and Technology Council. (2018). Strategy For American Leadership In Advanced Manufacturing. 

United States Department of Defense. (2021). Department of Defense Additive Manufacturing Strategy   

Executive Order No. 13329 (2004). Encouraging Innovation in Manufacturing. 

 

KEY WORDS: Open; Other; Disruptive; Radical; Dual-Use; Commercial; Additive Manufacturing; Advanced Manufacturing; Smart Manufacturing; Industry 4.0; Digital Thread; Digital Twin; Advanced Materials; Robotics

Direct-to-Phase-II Call for Innovative Defense-Related Dual-Purpose Manufacturing Technologies/Solutions with a Clear Air Force and Space Force Stakeholder Need

Direct-to-Phase-II Call for Innovative Defense-Related Dual-Purpose Manufacturing Technologies/Solutions with a Clear Air Force and Space Force Stakeholder Need

SBIR Opportunity Analysis

SBIR Documents

Related SBIR/STTR Opportunities

Opportunity Snapshot

Key Dates