Additive Manufacturing & Repair of 7075 Aluminum for Weapon Systems
ID: AF241-0008Type: BOTH
Overview

Topic

Additive Manufacturing & Repair of 7075 Aluminum for Weapon Systems

Agency

Department of DefenseN/A

Program

Type: SBIRPhase: BOTHYear: 2024

Topic Link

https://www.sbir.gov/node/2479849

Additional Information

https://www.defensesbirsttr.mil/SBIR-STTR/Opportunities/
Timeline
    Description

    The Department of Defense (DOD) is seeking proposals for the topic of "Additive Manufacturing & Repair of 7075 Aluminum for Weapon Systems" in their SBIR 24.1 BAA solicitation. The objective of this research is to develop and demonstrate structural repair of 7075 aluminum parts using additive manufacturing (AM) processes. The goal is to provide recommendations on materials and processes for achieving structural repairs and to provide test results for the tensile strength of repaired test coupons.

    High strength aluminum, specifically AL 7075 T6, is widely used in aircraft and air warfighting components. However, some parts with a life-limiting wear condition are expensive to manufacture new but could be repaired and put back into service. The Air Force currently spends $2 million per year on manufacturing new rail bodies to replace ones that could be repaired. This technology could also be used to support aircraft sustainment, potentially saving hundreds of millions of dollars.

    The research will be conducted in three phases. Phase I involves developing a high strength alloy aluminum that can be used in additive manufacturing and repair. Phase II focuses on the development of a repair process and testing of repairs using the high strength alloy aluminum, aiming to achieve at least 70% of the original 7075 tensile strength. Phase III dual-use applications involve the implementation of repair capabilities for 7075 aluminum, which could be utilized by every military branch and aircraft manufacturer.

    The research topic is relevant to the field of additive manufacturing, repair, and aluminum materials. The project duration and funding specifics are not provided in the document. For more information and to submit proposals, interested parties can visit the DOD SBIR 24.1 BAA topic link: link.

    Files
    No associated files provided.
    Similar Opportunities
    DOD SBIR 24.4 Annual - Advanced Enabling High-Speed Technologies
    Active
    Department of Defense
    The Department of Defense (DOD) is seeking proposals for the topic of "Advanced Enabling High-Speed Technologies" in their SBIR 24.4 Annual solicitation. The Defense Advanced Research Projects Agency (DARPA) is specifically interested in technologies related to additive manufacturing techniques, materials, propulsion combined cycles, and hot structures. They are also looking for advancements in the understanding and characterization of novel fluid dynamics that enhance propulsion performance. The objective is to achieve coherence between a cooperating set of commodity devices, resulting in increased thrust to weight, fuel efficiencies, and propellant mass fractions. This solicitation is open for Phase II proposals only, and Phase I proposals will not be accepted or reviewed. Phase II will involve designing and evaluating enabling technologies at the system and subsystem level, as well as advancing modeling and simulation tools. Physical hardware proposals should include development, installation, integration, demonstration, and/or test and evaluation of the proposed prototype system. Software or advanced tool development proposals should have a development approach anchored in the physics of the problem and ways to validate the software against existing test data. The Phase II effort consists of a base period of 12 months and an option period of 12 months. Phase III of this project will focus on transition and commercialization of the developed technologies. The proposer is required to obtain funding from private sector or non-SBIR Government sources to develop the prototype software into a viable product or non-R&D service for sale in military or private sector markets. The technologies developed under this topic will have applications in both commercial and military sectors, including commercial transportation, high-speed delivery, and responsiveness to fluidic environments. For more information and to submit proposals, interested parties can visit the DOD SBIR 24.4 Annual topic page on the SBIR website (https://www.sbir.gov/node/2492697). The solicitation is currently open, and the application due date is March 31, 2025.
    DOD SBIR 24.4 Annual - Advanced Enabling High-Speed Technologies
    Active
    Department of Defense
    The Department of Defense (DOD) is seeking proposals for the topic of "Advanced Enabling High-Speed Technologies" as part of the SBIR program. The research focuses on advancements in additive manufacturing techniques, materials, propulsion combined cycles, and hot structures. The objective is to deliver combat power and lethality by achieving responsiveness, intensity, and the ability to deliver munitions at range. The technology sought includes propulsion solutions using high-density, storable, and rapidly loadable propellants, as well as advancements in understanding and characterizing novel fluid dynamics for enhanced propulsion performance. The solicitation is open for Phase II proposals only, and proposers must demonstrate feasibility and potential military or commercial applications. The Phase II effort consists of a base period of 12 months and an option period of 12 months. The ultimate goal is to transition and commercialize the developed technologies for both military and commercial applications, particularly in the areas of manned or unmanned air and space platforms.
    DOD SBIR 24.4 Annual - Advanced Manufacturing for Common Launch Container
    Active
    Department of Defense
    The Department of Defense (DOD) is seeking proposals for the topic of "Advanced Manufacturing for Common Launch Container" as part of the SBIR 24.4 Annual solicitation. The objective of this topic is to develop applied research towards an innovative capability to use advanced manufacturing and iterative design to enable a Common Launch Container to meet military specification requirements for storage, transportation, and munition launch. The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), and offerors must disclose any proposed use of foreign nationals and their country of origin. The research should address the development of an iterative design process and advanced manufacturing to design and validate a munition container for transportation, storage, and launch. The system should be designed to launch the munition at 12-18 feet per second from the pallet on the cargo ramp or pallet in free flight after cargo drop. The feasibility study in Phase I should investigate all options that meet or exceed the minimum performance parameters specified and recommend the option that best achieves the objective. Phase II involves developing, installing, and demonstrating a prototype system on a SOCOM aircraft. The system could have broad military applications where rapid iteration and production are needed, and it may be selected for production or follow-on iterations for future applications. The project duration is not specified, but the solicitation is open until March 31, 2025. More details and the application process can be found on the DOD SBIR 24.4 topic page.
    DOD SBIR 24.4 Annual - Advanced Manufacturing for Common Launch Container
    Active
    Department of Defense
    The Department of Defense (DOD) is seeking proposals for the topic of "Advanced Manufacturing for Common Launch Container" as part of their SBIR 24.4 Annual solicitation. The objective of this topic is to develop applied research towards an innovative capability to use advanced manufacturing and iterative design to enable a Common Launch Container to meet military specification requirements for storage, transportation, and munition launch. The technology within this topic is restricted under the International Traffic in Arms Regulation (ITAR), and offerors must disclose any proposed use of foreign nationals and their country of origin. The research should address the development of an iterative design process and advanced manufacturing to design and validate a munition container for transportation, storage, and launch. The system should be designed to launch the munition at 12-18 feet per second from the pallet on the cargo ramp or pallet in free flight after cargo drop. The feasibility study in Phase I should investigate all options that meet or exceed the minimum performance parameters specified and recommend the option that best achieves the objective. Phase II involves developing, installing, and demonstrating a prototype system on a SOCOM aircraft. The potential impacts of this research include enabling rapid and iterative manufacturing processes for a broad range of military applications. The advanced manufacturing and modular design will be critical to all services where rapid iteration and production are needed. The system could be selected for production or follow-on iterations for future applications. The project duration is not specified, but the solicitation is open until March 31, 2025. More details and the application process can be found on the DOD SBIR 24.4 topic page on the Defense SBIR/STTR website.
    DOD SBIR 24.4 Annual - Multisystem Mobile Corrosion Unit
    Active
    Department of Defense
    The Department of Defense (DOD) is seeking proposals for a research topic titled "Multisystem Mobile Corrosion Unit" as part of their SBIR program. The objective of this topic is to develop a deployable solution for the Army's major corrosion issue, allowing for repairs in austere environments while in the field. The solution should include capabilities such as laser ablation, corrosion preventative coating application, cold spray, plasma blast, welding, and more. The project will consist of two phases, with Phase I accepting proposals for up to $250,000 for a 6-month period to develop a proof-of-concept prototype. Phase II will involve developing a deployment-ready multisystem corrosion unit. The technology has potential applications in industries such as automotive, aircraft, construction, agriculture, and power and energy. The project duration is not specified, and interested parties can find more information and submit proposals on the DOD SBIR website.
    DOD SBIR 24.4 Annual - Thermal Barrier Minimal Deflection Handguard
    Active
    Department of Defense
    The Department of Defense (DOD) is seeking proposals for a research topic titled "Thermal Barrier Minimal Deflection Handguard" under the SBIR program. The research aims to investigate the thermodynamics involved in designing an over-the-suppressor handguard and developing a toolless mounting system. The handguard should have a high thermal conductivity to allow rapid fire while maintaining a surface temperature below discomfort levels. The research should also focus on heat dissipation, insulation, materials, weight, and ergonomics of the handguard. The objective is to develop a handguard that can withstand high temperatures without decomposing or releasing toxic chemicals. Additionally, a toolless mounting system is required for easy removal and maintenance of the piston system. The handguard should remain rigid and return to within ≤ 0.5 milliradians of mounting center when force is applied and removed by the shooter. The proposed handguard should be between 9 and 11 inches in length. The Phase I of the project involves conducting a feasibility study to assess the possibilities that meet the specified requirements. The Phase II focuses on developing, installing, and demonstrating a prototype system. The technology developed through this research can have applications in various military small arms weapons where user interface of a handguard and heat mitigation is a concern. The project has a funding duration until March 31, 2025. For more details and to submit proposals, visit the solicitation agency's website at [solicitationagencyurl].
    DOD SBIR 24.4 Annual - Helicopter Expedited Refueling Operations (HERO)
    Active
    Department of Defense
    The Department of Defense (DOD) is seeking proposals for the topic "Helicopter Expedited Refueling Operations (HERO)" as part of the SBIR program. The objective of this solicitation is to develop solutions that increase the efficiency of setup, refueling operations, and disassembly of forward arming and refueling points (FARP) for rotary-winged assets. The goal is to reduce the amount of time these assets are unavailable for ground combat operations and decrease the likelihood of enemy detection and attack on the FARP. Currently, FARPs are vulnerable to enemy attack and require a significant number of personnel and equipment. Refueling times can take hours, and the FARP's limited defensive capabilities make mobility essential. The Army is looking for solutions that expedite the aggregation/setup/breakdown of FARP vehicles, decrease refueling times, improve pumping systems and equipment, and decrease aircraft wait times. The solicitation is open for proposals until March 31, 2025. The Phase I of the project requires Direct to Phase II (DP2) proposals that demonstrate scientific and technical merit, feasibility, and potential commercial applications. Phase II involves refining the design and creating a Technology Readiness Level (TRL) 6 prototype/model/system. Phase III focuses on commercialization objectives and may involve low-rate production and testing. The SBIR program provides funding for small businesses to develop innovative solutions that address specific research topics. In this case, the focus is on improving the efficiency and safety of helicopter refueling operations in military settings.
    DOD SBIR 24.4 Annual - Helicopter Expedited Refueling Operations (HERO)
    Active
    Department of Defense
    The Department of Defense (DOD) is seeking proposals for the topic "Helicopter Expedited Refueling Operations (HERO)" as part of its SBIR program. The objective of this solicitation is to develop solutions that increase the efficiency of setup, refueling operations, and disassembly of forward arming and refueling points (FARP) for rotary-winged assets. The goal is to reduce the amount of time these assets are unavailable for ground combat operations and decrease the likelihood of enemy detection and attack on the FARP. Currently, FARPs are vulnerable to enemy attack and require a significant number of personnel and equipment. The Army is looking for solutions that expedite the aggregation, assembly, setup, and breakdown of FARP vehicles, hoses, and equipment. Additionally, they are interested in solutions that decrease aircraft refueling times, improve pumping systems, valves, hoses, and other FARP equipment, and decrease aircraft wait/loiter times. The solicitation is open for proposals until March 31, 2025. The Phase I of the project requires Direct to Phase II (DP2) proposals that demonstrate scientific and technical merit, feasibility, and potential commercial applications. Phase II involves refining the design and creating a Technology Readiness Level (TRL) 6 prototype/model/system. Phase III focuses on commercialization objectives and may involve developing a manufacturing-ready product design and engaging in laboratory or operational testing. The Army is particularly interested in solutions that integrate designated Army open standards, consider cost, and adapt to individual Soldiers' needs or scenarios. The funding specifics and performance goals will be provided in the solicitation document available on the DOD SBIR website.
    DOD SBIR 24.4 Annual - Lightweight Longwave Bolometer Sensor Components
    Active
    Department of Defense
    The Department of Defense (DOD) is seeking proposals for the topic "Lightweight Longwave Bolometer Sensor Components" as part of the SBIR program. The objective of this topic is to develop components that enable low size, weight, and power (SWAP) thermal bolometer-type longwave thermal sensor payloads. These components should have equal or better performance than current commercial offerings while driving down SWAP. The components of interest include lens, focal plane, and readout and processing embedded hardware. The components should be ready for integration into a camera module by the end of Phase II. Thermal longwave infrared (LWIR) capabilities are crucial for many Army applications, especially for small Unmanned Aircraft Systems (UAS). However, the size, power, and weight constraints often limit the performance of these sensors. This topic aims to develop components that reduce the weight of thermal payloads while increasing their capabilities and keeping unit costs low. The project will have a Phase I and Phase II, with Phase I proposals accepting a cost of up to $250,000 for a 6-month period of performance. During Phase I, firms should design a proposed component with stakeholder input, analyze the SWAP-C impact of the component, and discuss how it will support the objective sensor payload. Phase II will involve completing the component design, fabricating, testing, and characterizing the component for integration into a lightweight sensor payload. Firms will also refine the design, define relevant interfaces, and lay out a high-level plan for integration. The potential applications of this research include smartphone camera augmentation, UAV camera augmentation, home security systems, and climate tech development. The project references academic research on bolometer manufacturing methods and the efficacy of leveraging colloidal quantum dots (QDs) for IR light sensing. Military contractors have also contributed to the research in the LWIR sensor and bolometer manufacturing spaces. For more information and to submit proposals, visit the DOD SBIR 24.4 Annual solicitation notice on grants.gov or the DOD SBIR/STTR Opportunities page. The open date for proposals is October 3, 2023, and the close date is March 31, 2025.
    DOD SBIR 24.4 Annual - Low-cost Longwave Bolometer Camera Fabrication Techniques
    Active
    Department of Defense
    The Department of Defense (DOD) is seeking proposals for the topic "Low-cost Longwave Bolometer Camera Fabrication Techniques" as part of their SBIR 24.4 Annual solicitation. The objective of this topic is to develop novel technologies and fabrication techniques to reduce the cost of sensor payloads based on resistive microbolometer technology. The focus is on reducing the unit cost of the focal plane array and supporting a low-cost sensor. The solutions should be ready to transition into a camera module development effort by the end of Phase II. The solicitation emphasizes the importance of thermal longwave infrared (LWIR) capabilities in various Army applications and the need for a thermal sensor payload with high-definition array and dramatically reduced unit price. The solutions can involve novel manufacturing techniques, new materials systems, innovative component or module designs, or other approaches. Direct to Phase II contracts will focus on demonstrating enabling developments, and Phase II sequential efforts will deliver a prototype payload meeting the specified requirements for evaluation by Army Unmanned Aircraft Systems (UAS) or other programs. Phase I of the solicitation is only accepting Direct to Phase II (DP2) proposals with a cost of up to $2,000,000 for an 18-month period of performance. DP2 proposals are highly encouraged if they meet the requirements. Proposals should demonstrate the estimated cost reduction compared to products made with current fabrication techniques and discuss the impact on size, weight, and power of a complete camera module. Initial ideas on potential paths for integration into a production camera module should also be discussed. Phase II involves designing and fabricating a prototype device that demonstrates the proposed solution to reduce thermal sensor payload unit cost. The impact of the solution on the unit price of a final sensor payload and its incorporation into such a payload should be discussed. Relevant interfaces should be defined and documented, and potential partnerships with integrators or other companies for follow-on efforts should be considered. In Phase III, the solicitation highlights the potential dual-use applications of leveraging bolometer manufacturing methods for low-cost long wave infrared (LWIR) sensors. These applications include smartphone camera augmentation, UAV camera augmentation (specifically via the Office of Naval Research), home security systems, and climate tech via quantum dot (QD) development. Overall, this solicitation seeks innovative solutions to reduce the cost of thermal sensor payloads based on resistive microbolometer technology, with potential applications in various military and commercial sectors.