High Precision Specialized Waveguides for Extreme Temperatures

This U.S. Navy SBIR solicitation (DON26BZ04-NV067) seeks proposals for high-precision, specialized waveguides capable of low-loss, high-power radio frequency (RF) transmission within hypersonic vehicles. Traditional RF cables fail under extreme hypersonic environments, where surface temperatures can exceed 1,000°C. To address this, the Navy requires ruggedized, custom-shaped waveguides targeting the X, Ku, K, and Ka frequency bands using low-loss dielectric mediums like air. Due to the defense-related nature of the technology, the project is restricted under ITAR and EAR regulations. Additionally, Phase II work is expected to be classified, requiring the selected contractor to be U.S. owned and operated with the ability to obtain and maintain a Secret-level facility and Personnel Security Clearance. Phase I focuses on demonstrating the feasibility of manufacturing robust waveguides and producing a prototype in any target band. Phase II involves producing custom parts, performing extensive machining, and testing the prototype's tolerance, bending limits, and connection capabilities under simulated extreme conditions. Phase III will focus on transitioning the technology to support hypersonic, space, and other military air, land, and sea-based systems.