The Department of the Air Force (DAF) is seeking innovative solutions for affordable Thermal Protection Solutions (TPS) aimed at enhancing Rocket Cargo materiel transport missions, particularly for payloads in the 1 to 10 metric ton range. The objective is to develop low-cost, expendable external TPS or internal thermal management systems that ensure payload survivability during atmospheric reentry, avoiding the complexities and high costs associated with human-rated systems. This initiative is crucial for reshaping the industrial base towards cost-effective thermal protection technologies, facilitating rapid and efficient transport of materials for military and commercial applications. Interested parties can find more information and submit proposals through the DOD SBIR website, with the solicitation set to open on July 23, 2025, and applications due by August 20, 2025.

## Description

Technology advancements have created an emerging opportunity with significant potential for the Department of the Air Force (DAF) for Rocket Cargo materiel transport missions by enabling the ability to operate after atmospheric reentry. A key objective of this effort is to help advance and reshape the commercial external thermal protection solution and/or internal thermal management solution industrial base(s) from one focused on high performance and expensive thermal protection solutions that deliver small mass to one focused on good performance and lower costs that still enables survivability of the payload in the 1 to 10 metric ton range. This might require novel new approaches to the design, fabrication, and/or testing of the external thermal protection solution or multiple Thermal Protection Solutions. The DAF is seeking to avoid the cost and inflexibility created by developing specialty solutions for this regime. External protections can be expendable as long as the contents inside the containers survive.The Department of the Air Force (DAF) is pursuing new opportunities for Rocket Cargo materiel transport that require payload survivability following atmospheric reentry&mdash;without the cost or complexity of human-rated Thermal Protection Systems (TPS). Current TPS technologies are often over-engineered and cost-prohibitive for cargo-class missions, particularly in the 1 to 10 metric ton payload range. This topic seeks innovative, low-cost, expendable external TPS or internal thermal management solutions for non-human-rated atmospheric reentry containers. Solutions may include new passive materials, active cooling systems, or modified commercial off-the-shelf technologies such as Phenolic Impregnated Carbon Ablator (PICA) or Reinforced Carbon-Carbon (RCC) adapted for affordability.The objective is to reshape the industrial base from one centered on exquisite performance to one optimized for cost-effective survivability of critical payloads. Proposed approaches should emphasize manufacturability, repeatability, and integration potential for materiel transport missions. Expendability is acceptable so long as the payload remains intact and functional post-reentry. Novel design, fabrication, and testing strategies are encouraged, especially those that reduce thermal protection cost without compromising safety or performance in realistic reentry environments.

## Objective

This topic seeks to investigate novel innovative concepts of low-cost expendable exterior Thermal Protection Solutions or internal thermal management solutions for atmospheric reentry containers. The concepts should focus on low-cost solutions whether it be developing a new passive solution (or material) or taking existing products (like Phenolic Impregnated Carbon Ablator (PICA) or Reinforced carbon-carbon (RCC)) and lowering the cost. The proposed concepts can include either passive systems, active cooling, or non-traditional options.The intent is to investigate and demonstrate the feasibility of low-cost, expendable Thermal Protection Solutions (TPS) or internal thermal management concepts for non-human-rated atmospheric reentry containers. The focus is on identifying and characterizing materials, configurations, or cooling methods&mdash;either novel or modified from existing systems (e.g., PICA, RCC)&mdash;that provide adequate thermal protection at significantly reduced cost. Phase I aims to validate the thermal performance-to-cost trade space through modeling, small-scale testing, or analytical studies. Proposed solutions should emphasize manufacturability, scalability, and suitability for protecting payloads in the 1&ndash;10 metric ton class. Passive, active, or hybrid approaches are welcome, provided they show a clear path to Low-Rate Initial Production (LRIP) and system integration potential in Phase II.

## Phase I

This Phase I effort will demonstrate a concept for a low-cost Thermal Protection Solution idea or conduct a feasibility study that is capable of showing the thermal protection properties in relation to the cost. Awardee(s) should also identify a viable route to manufacture or fabricate their proposed solution and/or identify challenges to get to Low-Rate Initial Production (LRIP) processes in Phase II. The objective of Phase I is to develop and demonstrate the feasibility of a low-cost, expendable Thermal Protection Solution (TPS) or internal thermal management system designed for atmospheric reentry of space cargo containers. The focus should be on proving the thermal performance of the concept relative to its cost, particularly for non-human rated, 1&ndash;10 metric ton payloads used in Rocket Cargo materiel transport missions.Offerors should:- Explore novel materials, passive or active thermal mitigation strategies, or cost-effective adaptations of existing technologies such as PICA, RCC, ablative composites, or non-traditional materials.- Demonstrate feasibility through modeling, material testing, or small-scale prototyping that shows survivability in high-heat flux environments typical of atmospheric reentry.- Compare thermal performance against manufacturing and lifecycle cost considerations to support decision-making around affordability and scalability.- Outline a pathway to Low-Rate Initial Production (LRIP) by identifying manufacturing routes, potential supply chain constraints, and design-for-manufacture considerations.Deliverables may include:- A concept feasibility report with supporting thermal and cost analysis- Identification of candidate materials or designs for development- Initial manufacturability assessment and LRIP transition strategy- Recommendations for Phase II prototyping and validation testing

## Phase II

The Phase II effort will focus on advancing the research and the development effort initiated in Phase I. The Phase II project aims at maturing the design and/or concept from the Phase I-like effort and possibly a prototype to conduct research and testing in lab and realistic environments to provide essential data to address any technical challenges, safety concerns, regulatory requirements, and/or other concerns. Awardee(s) should also identify any challenges for Full-Rate Production (FRP). The objective of Phase II is to mature and validate the low-cost thermal protection solution or internal thermal management concept developed in Phase I. This phase should focus on refining the design, fabricating a functional prototype, and conducting rigorous testing to evaluate performance in both laboratory and simulated reentry conditions.Key goals of Phase II include:<ol><li> Engineering Development: Advance the design to a manufacturable and scalable prototype, incorporating insights from Phase I analysis and material characterization.</li><li> Testing and Evaluation: Perform high-fidelity thermal, structural, and environmental testing&mdash;such as arc-jet, plasma torch, or suborbital trajectory simulations&mdash;to validate thermal protection capabilities.</li><li> Integration Considerations: Evaluate the solution&rsquo;s compatibility with atmospheric reentry containers and payload systems, including form factor, mass efficiency, and mounting techniques.</li><li> Cost and Production Analysis: Refine cost models, assess material sourcing and manufacturing techniques, and identify challenges for Full-Rate Production (FRP).</li><li> Risk Assessment: Address technical, safety, and regulatory considerations for transition to operational deployment.</li></ol>Deliverables could include:- A validated prototype of the TPS or thermal management system- Test reports detailing thermal performance, survivability, and compliance with mission requirements- A production readiness assessment, including updated cost analysis and supply chain risks- A Phase III transition plan outlining commercialization paths and integration into space materiel transport missions

## Phase III: Dual Use Applications

The Phase III effort aims to demonstrate the thermal protection solution in an operational-like environment and achieve technology maturation and commercialization. The Phase III effort aims to transition the thermal protection solution (TPS) into operational use through demonstration in relevant or operational-like environments, including suborbital or orbital reentry test flights. The primary goal is to achieve technology maturation, certification readiness, and commercial scalability.Military Applications:- Rocket Cargo materiel transport: Enable rapid, survivable transport of materiel through atmospheric reentry for Space Force and Air Force missions.- Responsive Launch &amp; Recovery Systems: Support reusable or single-use TPS for cargo return vehicles, drop pods, or reentry platforms.Commercial Applications:- Reusable Space materiel transport: Enable lower-cost thermal shielding for commercial reentry capsules transporting cargo from low Earth orbit (LEO), lunar, or cislunar domains.- Rocket Cargo materiel transport: Advance solutions for materiel transport and express cargo sectors interested in rapid global delivery via suborbital reentry platforms.- Space Tourism and In-Space Manufacturing: Provide cost-effective thermal solutions for non-crew critical missions in emerging space economy applications.Transition Goals:- Conduct one or more operational flight demonstrations using integrated TPS solution.- Finalize qualification data to support DoD or commercial certification standards.- Develop manufacturing and sustainment plans to scale for production and fleet deployment.- Establish commercial partnerships with space materiel transport providers, defense primes, or space capsule manufacturers for integration.This effort supports the broader objectives of the Rocket Cargo portfolio and contributes to building a resilient industrial base for affordable, non-human-rated thermal protection technologies.

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