Domestic Production of Plant-based Carbon Fiber Precursors in Support of Hypersonic Applications

This Navy SBIR solicitation (Topic DON26BZ04-NV066) seeks to develop an environmentally friendly, domestic processing method to produce plant-based carbon fiber precursors (such as cellulose or lignin) for hypersonic thermal protection systems. Currently, the Department of Defense, NASA, and commercial space sectors rely heavily on rayon-based carbon fibers due to their superior thermal performance. However, domestic production of rayon ceased in 1997 due to environmental concerns, leaving the U.S. dependent on volatile foreign textile markets. To address this supply chain vulnerability, the project is structured in three phases: - Phase I focuses on establishing a proof of concept for processing plant-based precursors that meet EPA effluent standards, ensuring the resulting fibers can be carbonized and characterized. - Phase II involves weaving and carbonizing the precursor into a fabric prototype, followed by comprehensive material and structural characterization. - Phase III aims to scale production, integrate the fiber into polymer matrix composites, and transition the technology to the Navy following arc jet testing. Due to the critical nature of this technology, the project requires a projected CMMC Level 2 (Self) certification. It is subject to ITAR/EAR export controls, and work in Phase II is likely to become classified, requiring the contractor to be U.S. owned and operated with the ability to secure and maintain a Secret-level facility and personnel security clearance.