Field Deployable Welding Technologies for In-Situ Repair of Thermoplastic Composites Components on Naval Aviation Platforms

The DON26TZ01-NV011 STTR topic seeks proposals for a portable induction welding system for in-situ repair of thermoplastic composite components on naval aviation platforms. The objective is to enable rapid, field-ready maintenance for next-generation naval aircraft. Current welding systems are large and limited to depots, leading to long downtimes. The proposed system must be lightweight, rugged, electromagnetically safe, capable of welding aerospace-grade thermoplastics up to 400°C, have closed-loop thermal control, repair various aircraft components, and achieve at least 70% weld strength of the parent material. Phase I involves developing preliminary system architecture, building a TRL 3-4 configuration, and conducting initial weld strength tests. Phase II focuses on building and validating a ruggedized TRL 6-7 prototype with smart controls and thermal feedback, demonstrating mechanical integrity and EMC qualification. Phase III supports the transition to Navy use for MQ25 and next-generation platforms, with encouragement for commercial maintenance depot transition.