DON26BZ01-NV029 TITLE: Low Cost Malleable Metastructure Adherents for Maritime Environments

OUSW (R&E) CRITICAL TECHNOLOGY AREA(S): Scaled Directed Energy (SCADE)

COMPONENT TECHNOLOGY PRIORITY AREA(S): Advanced Materials;Microelectronics;Sustainment

PROJECTED CMMC LEVEL REQUIREMENT: Level 2 (Self)

OBJECTIVE: Develop a material with the ability to rapidly and cost effectively produce metastructures or frequency selective surfaces which can be adhered to naval assets or similar systems (e.g., apertures, super-structures substructures, deployable, etc.).

DESCRIPTION: Several industries and Department of War (DOW) systems rely on Frequency Selective Surfaces (FSS), metastructures, or comparable materials to protect critical assets, including communications, radar, and Electromagnetic Warfare (EW) systems. Similar materials are also used as protective coatings for Electro-Optical/Infrared (EO/IR) systems—particularly in airborne and maritime applications—where they are consistently challenged by harsh maritime environments. These coatings, covers, and materials are susceptible to degradation from salt, ultraviolet (UV) radiation, and water intrusion due to their attachment to substructures, structures, or apertures.

Furthermore, the manufacturing and application of these materials are often considered expensive, time-consuming, and technically demanding due to platform-specific requirements. Recent constraints within the industrial base—such as the reduced availability of certain materials like CFC resins and polymers—have further exacerbated production challenges. These limitations have driven up costs, which have not benefited from economies of scale or broader adoption.

This SBIR topic seeks to develop alternative solutions that offer frequency selectivity, moldability (to conform to existing superstructures, substructures, or complex geometries), and resilience to maritime environments. In theory, such advancements would enable optimal dynamic performance across RF, microwave, or EO/IR domains, while maintaining durability in challenging conditions.

FSS remains the incumbent solution of choice, given its broadband frequency response, manufacturability, and superior durability in maritime conditions—advantages not matched by commercially available polymer-based fiberglass radomes, which typically lack frequency selectivity or the directive enhancements required by DOW systems. The reduction in availability and manufacturability of certain composites—due to regulatory restrictions or hazardous byproducts—has created an urgent need to pursue viable alternatives. Operating apertures across multiple frequency octaves remains a significant challenge for manufacturers and original equipment manufacturers (OEMs). Addressing the outlined challenges while achieving required performance objectives will likely demand innovation across multiple technical disciplines, including:

• Frequency Response – such as L, S, C, X and Ku Band and/or EOIR: Optical, midwave, longwave, others

• Advanced high-performance materials (ceramics, polymers or superalloys)

• Novel manufacturing or machining techniques

• Advanced 3 D optimized material additive manufacturing

• 3D optimized structures, magnetics or similar (inductor/capacitive/parasitic imbedded circuits)

• Highly resilient coatings, or new coating application techniques to existing materials

• Highly flexible embedded thin film materials

While existing materials with modifications will be considered, alternative solutions are also welcomed. However, the potential impact of these alternative designs—relative to existing materials or coatings—will be a factor during the selection process. Proposers should clearly identify any necessary mitigation considerations (e.g., storage, handling, disposal, etc.) required to support a credible path to qualification and approval for shipboard or airborne use.

The primary objective of this SBIR effort is to develop a material capable of broadband performance—defined here as the ability to provide frequency response across multiple octaves compared to existing materials. However, the proposed material must also be operationally viable and capable of meeting several critical performance objectives. Specifically, the solution should:

1. demonstrate through-performance (S21) in a near-field environment across multiple frequency octaves.

2. operate effectively across multiple bands of the EO/IR spectrum.

3. adhere to materials with sharp angles and varied geometries.

4. be capable of long-term storage without degradation after manufacturing or adherence to a structure.

5. withstand at least five years in a maritime environment without significant performance degradation (defined as <0.5 dB variance).

6. be rapidly applied to a surface with minimal preparation, achieving adherence in less than 24 hours.

7. demonstrate a reduction in abatement of signal return in multiple bands within the microwave and or the EO/IR energy regime radio frequency/midwave (RF/MW).

8. demonstrate that at scale the production cost can be lower than production of existing materials.

Acceptable solutions must also align with intended deployment scenarios, including shipboard/surface, Unmanned Aerial Systems (UAS), and land-based applications. For demonstration purposes, a commercial broadband antenna or a commercially available EO/IR camera may serve as the interface to evaluate proposed materials as radomes, covers, or adapters under defined boundary conditions. Demonstrations must show functional performance across at least two frequency bands—within the L-band to Ku-band range (e.g., S-band and C-band).

PHASE I:

1. Material Concept Evaluation

Investigate and identify novel materials or coatings capable of providing broadband frequency selectivity across RF, microwave, and EO/IR domains, with an emphasis on alternatives to restricted or environmentally hazardous substances (e.g., CFC resins, specific polymers).

2. Environmental Compatibility Assessment

Assess the proposed material’s theoretical or lab-based resistance to maritime environmental stressors, including saltwater exposure, UV radiation, and water ingress.

3. Geometric and Structural Adaptability

Demonstrate initial feasibility for adherence or conformability of materials to complex substructures and geometries relevant to DOW platforms (i.e., airborne, shipboard, and ground-based).

4. Initial Performance Modeling

Develop simulation-based predictions or benchtop validations of frequency performance across multiple octaves in the RF and EO/IR spectrum (e.g., S21 transmission characteristics, optical transmission in multiple EO/IR bands).

5. Risk and Mitigation Planning

Identify potential risks (e.g., storage, degradation, application time) and propose mitigation strategies for eventual shipboard or airborne qualification.

 

 

PHASE II:

1. Prototype Fabrication

Design, manufacture, and deliver functional prototype(s) of the developed material or coating, tailored for maritime-relevant conditions and representative platform geometries.

2. Performance Validation Across Frequency Bands

Validate the prototype’s frequency-selective behavior through laboratory and controlled-environment testing. Demonstrate multi-band performance (minimum two distinct bands, e.g., S- and C-band) from L-band to Ku-band.

3. EO/IR Performance Characterization

Conduct EO/IR transmission testing to confirm broadband optical performance through multiple EO/IR spectral bands, suitable for integration with commercial EO/IR sensors.

4. Environmental Endurance Testing

Evaluate long-term durability under simulated maritime conditions, including extended salt spray, UV exposure, and temperature/humidity cycling to validate 5+ year service life with minimal (<0.5 dB) performance degradation.

5. Rapid Application Demonstration

Demonstrate field-level application procedures confirming surface adherence with minimal preparation and application time under 24 hours.

6. Platform Integration Assessment

Assess integration potential with at least one DOW-relevant application (e.g., UAS radome, shipboard sensor cover), including initial qualification planning and boundary condition analysis.

PHASE III DUAL USE APPLICATIONS:

1. Qualification for Operational Platforms

Complete the qualification and certification process for use of the material on military platforms (i.e., shipboard, airborne, and land-based), including necessary safety, handling, and environmental compliance documentation.

2. Transition to DOW Programs of Record (PoRs)

Integrate the developed material into one or more PoRs or acquisition pathways (e.g., Navy UxS platforms, EW pods, surface combatant radar housings) through partnerships with prime contractors or system integrators.

3. Production Scale-Up and Cost Reduction

Establish a scalable manufacturing process that ensures material consistency, repeatability, and cost-efficiency, including options for low-rate initial production (LRIP) and full-rate production (FRP).

4. Commercial Dual-Use Expansion

Explore and initiate commercial applications of the developed material or coating, including broadband antennas, protective camera housings, or telecom equipment enclosures, leveraging interest from non-defense markets.

5. Sustainment and Lifecycle Support Plan

Develop a comprehensive sustainment strategy including repair, refurbishment, and replacement options, tailored for DOW logistics pipelines and long-term deployment in austere environments.

REFERENCES:

1. West, P.R.; Stewart, J.L.; Kildishev, A.V.; Shalaev, V.M.; Shkunov, V.V.; Strohkendl, F.; Zakharenkov, Y.A.; Dodds, R.K. and Byren, R. "All-dielectric subwavelength metasurface focusing lens." Opt Express, 2014 Oct 20, 22(21), pp. 26212-21. doi: 10.1364/OE.22.026212 PMID: 25401653
2. Guler et al. "Method of Making a Metamaterial Device." Patent No. 11,726,233 B2. August 15, 2023. https://patents.google.com/patent/US11726233B2/en
3. Mahmoud, A., Davoyan, A. and Engheta, N. "All-passive nonreciprocal metastructure." Nat Commun 6, 8359, 2015. https://doi.org/10.1038/ncomms9359
4. Capolino, Filippo; Khajavikhan, Mercedeh and Alù, Andrea. "Metastructures: From physics to application." Applied Physics Letters, Volume 120, Issue 6, 7 February 2022. https://pubs.aip.org/aip/apl/article/120/6/060401/2832964/Metastructures-From-physics-to-application

KEYWORDS: Frequency Selective Surfaces, Metastrucutures, Engineered Materials, Coatings, Metamaterials, Phase Changing Materials

TPOC 1
Will Crespo
william.f.crespo-miranda.civ@us.navy.mil

TPOC 2
James Stewart
James.L.Stewart7.civ@us.navy.mil