DON26TZ01-NV011 TITLE: Field Deployable Welding Technologies for In-Situ Repair of Thermoplastic Composites Components on Naval Aviation Platforms
COMPONENT TECHNOLOGY PRIORITY AREA(S): Advanced Materials;Sustainment
PROJECTED CMMC LEVEL REQUIREMENT: Level 2 (Self)
OBJECTIVE: Develop and transition a portable induction welding system capable of in-situ repair of thermoplastic composite components on naval aviation platforms enabling rapid, field-ready maintenance capabilities for next-generation naval aircraft.
DESCRIPTION: Modern aviation platforms are increasingly using high-performance thermoplastic composites such as PAEK, PEEK, PPS, or PEI reinforced with Carbon Fiber for structural and semi-structural components. Their attractiveness is due to their superior damage tolerance, impact, and ability to be reworked for repair. Unlike traditional thermoset composites, which can only be repaired by bonded patches or bolted panels, thermoplastic composites can also be repaired by welding, which restores strength without the need to remove additional material. However, currently available welding systems have a large footprint and are available mostly with OEM and only suited for deployment at the Depots. Thus, without field deployable technofixes, repairs will result in long downtime for repair and likely higher scrap rates.
This STTR topic seeks to leverage the research expertise of academic or government labs in thermoplastic processing and electromagnetic heating to partner with a small business in designing a rugged, portable induction welding system that can be deployed shipboard and/or in Aircraft Intermediate Maintenance Detachments.
The proposed system should: (1) be capable of welding aerospace-grade thermoplastics (at temperatures up to 400°C); (2) be lightweight and field operable, including on aircraft carriers; (3) be electromechanically ruggedized and safe to operate near avionics and flight-critical systems; (4) have a closed-loop thermal control for temperature; (5) be able to repair skins, fairings, panels, and access doors; and (6) have a weld strength of at least 70% of the parent material.
PHASE I: Identify key thermoplastic components and repair scenarios relevant to Navy and Marine Corp Aircraft; develop preliminary induction welding system architecture; build and integrate a TRL 3-4 configuration in collaboration with the research institution; and conduct an initial weld strength test. The weld strength should be at least 70% of parent material. Additionally, the awardee should assess the electromagnetic compatibility and ergonomics of the system.
While this is not an allowable developments program, the awardee may propose a limited amount of testing for calibration and validation of the prototype. The awardee should note that the Phase II down select is based on the performance and final deliverables of the Phase I Base period – so plan accordingly.
The Phase I deliverables should include at a minimum: (a) a Weld Feasibility report which should include results of weld trials meeting the key parameters stated above. It should also include assessment of the thermal profile, fusion quality, and repeatability; and (b) a preliminary system concept and architecture that will meet the topic’s goals.
PHASE II: Build and validate a ruggedized TRL 6-7 prototype system. Integrate smart controls and thermal feedback into the prototype. Adapt tools and fixtures for real world geometry and repair location. Validate the tool on a sub-element level aircraft part. Demonstrate mechanical integrity of repairs by mechanical testing and nondestructive inspection (NDI). Demonstrate that it meets full EMC qualification per appropriate MIL STD [Ref 3].
Ensure that the prototype meets the Phase II goal (stated in the Description).
Provide a test report summarizing all tests done in Phase II, and an electronic user instruction manual for the prototype and a maintainability and support plan for the delivered prototype.
PHASE III DUAL USE APPLICATIONS: Support the transition to Navy use. Expected transition within government is to fleet resource centers servicing MQ25 and next gen platforms including Maritime Strike.
Additionally, the awardee will be encouraged to transition to commercial maintenance depots.
REFERENCES:
KEYWORDS: induction welding; field deployable system; automated process control; forward deployed repair; shipboard repair; structural repair
TPOC 1
Neil Graf
neil.a.graf.civ@us.navy.milTPOC 2
Anisur Rahman
anisur.rahman.civ@us.navy.mil
** TOPIC NOTICE ** |
The Navy Topic above is an "unofficial" copy from the Navy Topics in the DoW FY-26 Release 1 SBIR BAA. Please see the official DoW Topic website at www.dodsbirsttr.mil/submissions/solicitation-documents/active-solicitations for any updates. The DoW issued its Navy FY-26 Release 1 SBIR Topics pre-release on April 13, 2026 which opens to receive proposals on May 6, 2026, and closes June 3, 2026 (12:00pm ET). Direct Contact with Topic Authors: During the pre-release period (April 13, through May 5, 2026) proposing firms have an opportunity to directly contact the Technical Point of Contact (TPOC) to ask technical questions about the specific BAA topic. The TPOC contact information is listed in each topic description. Once DoW begins accepting proposals on May 6, 2026 no further direct contact between proposers and topic authors is allowed unless the Topic Author is responding to a question submitted during the Pre-release period. DoD On-line Q&A System: After the pre-release period, until May 20, 2026, at 12:00 PM ET, proposers may submit written questions through the DoW On-line Topic Q&A at https://www.dodsbirsttr.mil/submissions/login/ by logging in and following instructions. In the Topic Q&A system, the questioner and respondent remain anonymous but all questions and answers are posted for general viewing. DoW Topics Search Tool: Visit the DoW Topic Search Tool at www.dodsbirsttr.mil/topics-app/ to find topics by keyword across all DoW Components participating in this BAA.
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